Documente Academic
Documente Profesional
Documente Cultură
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Maintenance
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
Golf Variant 2010 ➤
rm
ab
pe
ility
Jetta 2005 ➤
ot
wit
, is n
h re
hole
Edition 09.2009
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
Heading by
Volksw not
gu
d ara
e
1. Engine list horis nte
eo
aut ra
2. Service work ss c
ce
e
nl
3. General
pt
du
an
itte
y li
4. Descriptions of work
erm
ab
ility
ot p
wit
, is n
h re
6. Glossary
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . ..V.ol.ks. w. a.g.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
gen AG n AG d
2 Service work . . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o. e.s.no. t .g. . . . . . . . . . . . . . . . . . . . 6
by ua
2.1 Service tables for “Rest of World” ed markets . . . . . . . . . . . . . . . . . . . .
ra . .
nte . . . . . . . . . . . . . . . . 6
ris
2.2 Service scope for North American utho and Canadian markets . . . . . . . . . e. o.r a. . . . . . . . . . . . . 11
sa
2.3 Service scope for “Rest of World” markets up to model year 2007 . . . . . .c . . . . . . . . . . . . 17
s
ce
e
nl
2.4 Service scope for “Rest of World” markets from model year 2008 . . . . . . . . . . . . . . . . . . . . 25
pt
du
an
itte
2.5 Service intervals for “Rest of World” markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
y li
erm
ab
2.6 Service intervals for North American and Canadian markets . . . . . . . . . . . . . . . . . . . . . . . . 35
ility
ot p
wit
, is n
h re
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
hole
spec
3.1 Tow starting/towing for North American and Canadian markets . . . . . . . . . . . . . . . . . . . . 37
es, in part or in w
t to the co
3.2 Raising vehicle with lifting platform and trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
rrectness of i
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
l purpos
nform
ercia
at
om
i
3.10 Engine oils for North American and Canadian markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
on
c
in t
r
his
ate
do
priv
c
3.13 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
um
for
en
ng
t.
yi
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Co
Cop py
4.1 Removable towing bracket: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
t. rig
gh ht
yri by
4.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
cop Vo
by lksw
cted agen
4.3 Driving light assist and cornering light: Check function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Prote AG.
Contents i
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
4.28 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.29 Engine cover -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.30 Removing and installing engine compartment cover -bottom- (noise insulation) . . . . . . . . 116
4.31 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.32 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 117
4.33 Checking breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.34 Panorama sliding roof: Check function, clean guide rails if necessary and grease with special
grease, clean wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.35 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 135
4.36 Wheel securing bolts: Tighten to prescribed torque setting . . . . . . . . . . . . . . . . . . . . . . . . 136
4.37 Reading radio code with fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.38 Radio/navigation system: Activate anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.39 Tyre pressure monitoring: Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.40 Renewing tyre pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.41 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 146
4.42 Headlight adjustment: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.43 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
AG. Volkswagen AG d
4.44 Service interval display:lksw Recode (for “Rest of
agen oesWorld” markets) . . . . . . . . . . . . . . . . . . . . . .
not
154
o
4.45 Service interval ed bydisplay:
V
Recode at delivery inspection
gu
ara (for North American and Canadian
markets) ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ris 156
4.46 ut
Services ainterval display: Recode at first oil change servicer a(for
o
North American and Canadian
c
markets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s ce 158
e
nl
pt
4.47 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
du
an
itte
y li
4.48 Window wash/wipe system and headlight washer system: Check function . . . . . . . . . . . . 160
erm
ab
wit
h re
4.51 Track rod ends: Check play, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
hole
spec
t to the co
4.56 Underbody sealant: Perform visual check for damage to underbody sealant, underbody
l purpos
or
4.59 Toothed belt and toothed belt tensioning roller: Renew (TDI engines) . . . . . . . . . . . . . . . . 174
m
m
atio
m
4.60 Camshaft drive toothed belt: Renew (2.0 l FSI and TFSI) . . . . . . . . . . . . . . . . . . . . . . . . . . 175
o
n in
c
4.61 Camshaft drive toothed belt: Check (4-cylinder petrol engines 1.4 l and 1.6 l) . . . . . . . . . . 175
or
thi
te
o
r
rp
cu
m
f
en
ng
5.1 Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
t.
yi Co
op py
5.2 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
. C rig
ht ht
rig by
py
6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
co Vo
by lksw
cted agen
Prote AG.
ii Contents
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
an
♦ Diesel engines ⇒ page 4
itte
y li
erm
ab
Petrol engines
ility
ot p
wit
, is n
h re
⇒ page 48
hole
spec
Capacity 2.0 2.5 2.5
es, in part or in w
t to the co
in litres
Number of cylinders
4 5 5
rrectness of i
Valves per cylinder
4 4 4
Output/kW at rpm
147/5700 110/5200 110/5200
l purpos
Torque/Nm at rpm
280/2000 228/4000 228 / 4000
nf
ercia
Compression ratio
10.5 9.5 9.5
orm
m
Injection/ignition
MPI Bosch Motronic MPI Bosch Motronic MPI Bosch Motronic
atio
m
n in
or c
thi
RON unleaded, at least 95 91 91
te
sd
a
also 91 RON, but with also 87 RON, but with re‐ also 87 RON, but with re‐
iv
o
r
rp
cu
reduced output duced output duced output
o
m
f
en
ng
t.
Camshaft drive Toothed belt Timing chain Timing chain
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Petrol engines Prote AG.
Petrol engines
Engine codes BMY BLY BSE
⇒ page 48
Capacity 1.4 2.0 1.6
in litres
Number of cylinders 4 4 4
Valves per cylinder 4 4 2
1. Engine list 1
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
also 91 RON, but with also 91 RON, but with re‐ also 91 RON, but with re‐
an
d
itte
y li
rm
ab
pe
ility
Camshaft drive Timing chain Toothed belt Toothed belt
ot
wit
, is n
h re
hole
spec
Petrol engines
es, in part or in w
t to the co
Engine codes BSF BPY BTK
⇒ page 48
rrectness of i
Capacity 1.6 2.0 2.5
in litres
l purpos
Number of cylinders
4 4 5
nform
ercia
Output/kW at rpm
75/5600 147/5700 110/5200
a
com
Torque/Nm at rpm
148/3800 280/2000 228/4000 tion in
r
te o
thi
Compression ratio
10.5 10.5 9.5
s
iva
do
r
rp
Injection/ignition
SIMOS 7.1 MPI Bosch Motronic MPI Bosch Motronic
um
fo
t.
yi Co
op
RON unleaded, at least 95 95 91
C py
t. rig
also 91 RON, but with also 91 RON, but with also 87 RON, but with re‐
gh ht
pyri by
reduced output reduced output duced output
o Vo
by c lksw
cted agen
Prote
Camshaft drive Toothed belt Toothed belt Timing chain
AG.
Petrol engines
Engine codes BUD BVY BVZ
⇒ page 48
Capacity 1.4 2.0 2.0
in litres
Number of cylinders
4 4 4
Valves per cylinder
4 4 4
Output/kW at rpm
59/5000 110/6000 110/6000
Torque/Nm at rpm
130/4200 200/3500 200/3500
Compression ratio
10.5 11.5 10.5
Injection/ignition
4VH MPI Bosch-Motronic MPI Bosch-Motronic
SRE FSI FSI
RON unleaded, at least 95 95 95
also 91 RON, but with also 91 RON, but with also 91 RON, but with re‐
reduced output reduced output duced output
Camshaft drive Toothed belt Toothed belt Toothed belt
2 1. Engine list
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Petrol engines
Engine codes BWA CAXA CAVD
⇒ page 48
Capacity 2.0 1.4 1.4
in litres
Number of cylinders 4 4 4
Valves per cylinder 4 4 4
Output/kW at rpm 147/5700 90/5600 118/5800
Torque/Nm at rpm 280/2000 210/1750...4500 240/1500...4000
Compression ratio 10.5 10 10
Injection/ignition
MPI Bosch Motronic Motronic MED 17.5.20 Motronic MED 17.5.10
TFSI TSI twincharger TSI twincharger
RON unleaded, at least 95 95 95
also 91 RON, but with also 91 RON, but with also 91 RON, but with
reduced output reduced output reduced output
Camshaft drive Toothed belt Timing chain Timing chain
Petrol engines
Engine codes CAWB CBFA CBTA
⇒ page 48
Capacity 2.0 2.0 2.5
in litres
Number of cylinders 4 4 5
Valves per cylinder 4 4 4
. Volkswagen AG
gen AG
Output/kW at rpm 147/5100...6000 147/5100...6000
ksw a d
125/5700
oes no
Vol t gu
by
Torque/Nm at rpm 280/1700...5000 ir se 280/1700...5000
d 240/4250 ara
nte
ho eo
Compression ratio 10.3 aut
10.3 9.5 ra
c
ss
Injection/ignition
Motronic MED 17.1 Motronic MED 17.1 MPI Bosch Motronic
ce
e
nl
pt
TSI turbocharger TSI turbocharger SRE
du
an
itte
y li
RON unleaded, at least 95 95 91
erm
ab
also 91 RON, but with also 91 RON, but with also 87 RON, but with
ility
ot p
wit
, is n
h re
Camshaft drive Timing chain Timing chain Timing chain
hole
spec
es, in part or in w
Number of cylinders 5 4 4
m
at
om
in t
or
do
riv
cum
or
en
ng
t.
yi Co
op
Injection/ignition MPI Bosch Motronic MPI Simos Motronic MED 17.5 C py
t. rig
SRE “flex fuel” TSI turbocharger gh ht
pyri by
Vo
co
RON unleaded, at least 91 95 95
by lksw
cted agen
Prote
also 87 RON, but with re‐ also 91 RON, but with re‐ also 91 RON, but with
AG.
1. Engine list 3
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Diesel engines
Engine codes AZV BKC BKD
⇒ page 48
Capacity 2.0 1.9 2.0
in litres
Number of cylinders 4 4 4
Valves per cylinder 4 2 4
Output/kW at rpm 100/4000 77/4000 103/4000
Torque/Nm at rpm 320/1750...2500 250/1900 320/1750...2500
Compression ratio 18.5 19.0 18.5
Injection/ignition TDI unit injector TDI unit injector TDI unit injector
Fuel conforming to DIN EN 590 DIN EN 590 DIN EN 590
Diesel particulate filter no no no
Camshaft drive Toothed belt Toothed belt Toothed belt
Diesel engines
Engine codes BLS BMN BMM1)
⇒ page 48
Capacity 1.9 2.0 2.0
in litres
Number of cylinders 4 4 4
AG. Volkswagen AG d
agen
Valves per cylinder Volk sw 2 oes
not 4 4
y gu
Output/kW at rpm edb 77/4000
ara
125/4200 103/4000
ris nte
ho eo
Torque/Nms aatut rpm 250/1900 350/1800 ra
c 320/1750...2500
s
Compression ratio 19.0 18.5 18.5
ce
e
nl
pt
du
an
Injection/ignition TDI unit injector TDI unit injector TDI unit injector
itte
y li
erm
ab
h re
spec
es, in part or in w
with elevated sulphur content the service life of the diesel partic‐
ulate filter may be reduced.
rrectness of i
l purpos
Diesel engines
Engine codes BRM3) BXE3) CBDA3)
nf
ercia
⇒ page 48
rm
m
atio
m
n in
c
in litres
or
thi
te
sd
Number of cylinders 4 4 4
iva
o
r
rp
cu
m
f
en
ng
t.
yi
Output/kW at rpm 74 / 4000 77/4000 100/4200
Co
Cop py
t. rig
gh ht
yri by
4
op Vo
by c lksw
1. Engine list Prote
cted AG.
agen
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
with elevated sulphur content the service life of the diesel partic‐
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
Vehicles with retrofitted diesel particulate filter are allocated in the
es, in part or in w
t to the co
with diesel particulate filter (fitted at the factory) can be identified
by PR No. 7GG on the vehicle data sticker.
rrectness of i
l purpos
nf
ercia
or
Capacity 2.0 2.0
m
m
atio
in litres
om
n in
c
Number of cylinders 4 4
or
thi
te
sd
a
o
r
rp
cu
Output/kW at rpm 103/4200 103/4000
o
m
f
en
ng
t.
yi
Torque/Nm at rpm 320/1750...2500 320/1750...2500
Co
Cop py
ht. rig
Compression ratio 18.5 18.5
rig ht
py by
co Vo
lksw
Injection/ignition TDI common rail TDI common rail
by
cted agen
Prote AG.
Fuel conforming to DIN EN 590 DIN EN 590
Diesel particulate filter yes4 yes4
Camshaft drive Toothed belt Toothed belt
4) RME fuel (biodiesel) must not be used! 4) When using fuels
with elevated sulphur content the service life of the diesel partic‐
ulate filter may be reduced.
Note
1. Engine list 5
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
2 Service work
In this chapter you will obtain information on the following sub‐
jects:
♦ Service tables for “Rest of World” markets ⇒ page 6
en AG . Volkswagen AG
♦ Service scope for North American and Canadian wagmarkets does
⇒ page 11 Volks not
gu
by d ara
ise nte
♦ Service scope for “Rest of World” markets
ut
ho
r
up to model year eo
2007 ⇒ page 17 ss
a ra
c
ce
le
pt
an
d
2008 ⇒ page 25
itte
y li
rm
ab
♦ Service intervals for North American and Canadian markets
pe
ility
⇒ page 35
ot
wit
, is n
h re
♦ Service intervals for “Rest of World” markets up to model year
hole
spec
2007 ⇒ page 6
es, in part or in w
t to the co
♦ Service intervals for “Rest of World” markets from model year
2008 ⇒ page 6
♦ Information on LongLife service or time or distance dependent
rrectness of i
service ⇒ page 36
l purpos
nform
mercia
a
VW engine oil standards ⇒ page 7
com
tion in
r
te o
thi
Filter change intervals ⇒ page 8
s
iva
do
r
rp
cum
fo
t.
yi Co
Cop py
Service intervals ⇒ page 10 ht. rig
rig ht
py by
co Vo
by lksw
cted
Spark plugs ⇒ page 9
agen
Prote AG.
Note
ENGINE Engine code Period Toothed belt change inter‐ Tensioning roller change
TYPE vals intervals
TDI-PD AZV, BKC, Since introduc‐ Every 120,000 km Up to model year 2006
BKD, BLS, tion every 240,000 km
BMN, BMM, up to model
BRM, BXE year 2006
TDI-PD AZV, BKC, From model Every 150,000 km From model year 2007
BKD, BLS, year 2007 every 300,000 km
BMN, BMM,
BRM, BXE
6 2. Service work
AG. Volkswagen AG d
agen oes
ksw n t
Golf Variantb2007yV
ol
➤ , Golf Variant 2010 ➤ ,oJetta gu 2005 ➤
ara
d
orise Maintenance - Edition 09.2009
nte
eo
th
au ra
s s c
Jetta 2005▸, Bora 2006▸, Golf Variant 2007▸
ce
e
nl
pt
du
Toothed belt change intervals, tensioning roller change intervals
an
itte
y li
erm
ab
TDI CR CBDA, CBDB, Since introduc‐ every 180,000 km ---
ility
ot p
CBEA tion
wit
, is n
h re
hole
spec
es, in part or in w
Jetta 2005▸, Bora 2006▸, Golf Variant 2007▸
t to the co
Toothed belt change intervals
♦ PETROL ENGINES
rrectness of i
Engine type Engine code l purpos Period Toothed belt change intervals
1.4 l BUD --- No prescribed change interval,
nform
toothed belt drive with test interval
ercia
at
om
ion
c
in t
or
his
te
do
riv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
2.1.2 VW engine oil standards
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
Note
Engine type Engine oil standards Engine type Engine oil standards
4-cylinder 504 001 alternative 4-cylinder engines 501 01/502 00
incl. FSI 2) incl. FSI ▸2007
503 00
4-cylinder engines 502 00
incl. FSI 2008▸
4-cylinder 504 001 4-cylinder 502 00
TSI TSI
2. Service work 7
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
an
• “With LongLife service QG1” • “Without LongLife service QG0, QG2”
itte
y li
erm
ab
ility
ot p
Engine type Engine oil standards Engine type Engine oil standards
wit
, is n
4-cylinder 507 001) alternative 4-cylinder 505 01
h re
hole
TDI-PD 3) TDI-PD
spec
506 01
es, in part or in w
t to the co
♦ DIESEL ENGINES with factory-fitted diesel particulate filter
rrectness of i
Engine type Engine oil standards Engine type Engine oil standards
l purpos
nform
ercia
TDI-CR TDI-CR
at
om
ion
c
in t
r
his
ate
do
riv
cum
for
en
g
3)Combination
n
♦ AIR FILTER
8 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
♦ AIR FILTER
EVERY 90,000 km
♦ Vehicles driving > than 90,000 km in 6 years
whichever occurs first
♦ FUEL FILTER
pt
y li
erm
ab
wit
is n
spec
urposes, in part or in wh
t to the co
1.4 SRI, FSI,TSI BLG, BMY, BUD, CAVD, CAXA EVERY 60,000 km
o
n
c
i
or
1.6 SRI, FSI BLF, BSE, BSF, CCSA ♦ Vehicles driving > than 60,000 km in 4
thi
e
sd
iva
o
pr
cum
r
fo
EVERY 4 years
en
ng
t.
yi
♦ Vehicles driving < than 60,000 km in 4
Co
op py
years
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Service work 9
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
n AG. Volkswagen AG do
Maintenance - Edition 09.2009 lkswage es n
o o t gu
yV
db ara
ir se nte
Jetta 2005▸, Bora 2006▸, uGolf
tho Variant 2007▸ eo
ra
a
Spark plug change
ss intervals c
ce
e
nl
pt
2.0 TSI AXX, BPY, BWA, CAWB, CBFA, EVERY 90,000 km
du
an
itte
2.0 TFSI, 147 kW CCTA ♦ Vehicles driving > than 90,000 km in 6
y li
erm
ab
years
ility
ot p
wit
, is n
EVERY 6 years
h re
♦ Vehicles driving < than 90,000 km in 6
hole
spec
years
es, in part or in w
t to the co
rrectness of i
2.1.5 Service intervals l purpos
nf
ercia
o
♦ Service intervals: Jetta 2008▸, Bora 2008▸, Golf Variant
rm
m
2008▸ ⇒ page 10
atio
om
n in
or c
thi
te
sd
a
o
r
rp
cu
o
m
From - to Service type Service Intervals
f
en
ng
t.
Engine codes/PR No/
yi Co
op py
Remarks t. C rig
gh ht
yri by
Since Diesel engines with elevated Oil change service Every 7,500 km /1 year:
cop Vo
by lksw
introduc‐ sulphur content in fuel
cted agen
Prote AG.
tion • Countries with elevated
sulphur content in fuel
⇒ page 47
10 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
QG1 play
an
itte
y li
erm
ab
km / 2 years
ility
ot p
Time or distance dependent Inspection service ♦ First interval after 3 years or 60,000 km
wit
, is n
h re
flexible/LongLife
hole
QG0/QG2/QG1 ♦ then
spec
es, in part or in w
♦ Every 2 years
t to the co
rrectness of i
Note
l purpos
nform
mercia
at
om
ion
c
in t
or
do
riv
Canadian markets
p
cum
for
en
ng
Caution
2. Service work 11
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
Inform the customer if faults are found during service and repair
measures are necessary.
pt
American and Canadian markets an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
urposes, in part or in wh
Inform the customer if faults are found during service and repair
measures are necessary.
t to the co
rrectne
Caution
s
f in
atio
om
n
c
n thi
te
sd
a
o
pr
cum
r
fo
t.
freeze.
yi Co
Cop py
t. rig
– Removing and installing engine compartment cover -bottom-
gh ht
yri by
(noise insulation tray) ⇒ page 116
op Vo
by c lksw
cted agen
Prote AG.
12 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
The sequence of the individual service tasks has been tested and
optimised. Therefore, it should be followed to avoid unnecessary
interruptions in the work.
Work to be completed Page
– Engine oil: Drain or extract, renew oil filter ⇒ page 117
AG. Volkswagen AG d
– Engine oil: Replenish, observe oil specifications lksw ⇒ page 48
agen oes
not ⇒ page 117
o
yV gu
– Service interval display: Reset ised b ara
nte ⇒ page 153
or
– Window wash/wipe system: Replenish aut
h with Windscreen Clear -G 052 164- eo
ra
s c
– Window wash/wipe system ands headlight washer system: Check function and settings ⇒ page 160
ce
le
un
pt
– Automatic shift lock: Check function including park/neutral position and illumination
an
d
itte
y li
– Brake fluid level (dependent upon brake pad/lining wear): Check
erm
⇒ page 71
ab
ility
ot p
wit
is n
h re
– Brake system: Perform visual check for leaks and damage ⇒ page 72
ole,
spec
– Tyres: Change front tyres and rear tyres
urposes, in part or in wh
t to the co
– Airbag system: Visual check every 12 months independent of mileage
– Check battery using battery tester with printer -VAS 5097A- , always see workshop man‐ ⇒ page 58
ual.
rrectne
– Check tread depth and tyre inflation pressure ⇒ page 59
s
– Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar) - ⇒ page 41
s o
service intervals ⇒ page 41
cial p
f inform
mer
atio
om
n
2.2.3 Inspection service at 20,000 miles/
c
i
or
n thi
e
sd
iva
o
pr
c
60,000 miles/90,000 km etc. for North
um
r
fo
en
ng
Inform the customer if faults are found during service and repair
measures are necessary.
Caution
2. Service work 13
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
– Window wash/wipe system and headlight washer system: Check function and settings ⇒ page 160
nl
pt
du
an
itte
– Wiper blades: Check for damage and park position ⇒ page 165
y li
erm
ab
♦ Every 40,000 miles (60,000 km)
ility
ot p
wit
, is n
– Automatic shift lock: Check function including park/neutral position and illumination
h re
hole
– Automatic gearbox: Check ATF level, replenish if necessary, 09G gearbox ⇒ page 56
spec
♦ Every 40,000 miles (60,000 km)
es, in part or in w
t to the co
– Automatic gearbox: Check for leaks
– Manual gearbox: Check for leaks, check oil level, replenish if necessary
rrectness of i
– Tyres: Change front tyres and rear tyres
l purpos
nform
ercia
at
om
io
– Brake system: Perform visual check for leaks and damage ⇒ page 72
n
c
in t
or
his
ate
do
priv
cum
for
en
g
t.
yi Co
♦ Only 4-cylinder TDI unit injector engines Cop py
ht. rig
rig ht
♦ At 60,000 miles (90,000 km), then every 20,000 miles (30,000 km) py by
co Vo
by lksw
cted agen
Prote AG.
– Camshaft drive toothed belt: Renew ⇒ page 174
♦ Only 4-cylinder TDI unit injector engines up to model year 2006
♦ Every 80,000 miles (120,000 km)
14 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Track rod ends: Check play, security and boots ⇒ page 169
– Performing vehicle system test ⇒ page 75
– Panorama sliding roof: Check function, clean guide rails if necessary and grease with ⇒ page 134
special grease, clean wind deflector, Golf Variant
– Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 160
– 6-speed direct shift gearbox “DSG” 02E: Change oil and filter ⇒ page 74
♦ Every 40,000 miles (60,000 km)
– Final drive and protective bellows: Perform visual check for leaks and damage ⇒ page 76
– Underbody sealant: Visual check for damage to underbody sealant, underbody panels, ⇒ page 172
routing of lines and plugs
♦ Every 40,000 miles (60,000 km)
pt
y li
erm
ab
wit
is n
– Dust and pollen filter: Clean housing and renew filter element ⇒ page 146
t to the co
♦ Only 4-cylinder TDI unit injector engines from model year 2007
inform
mer
n
c
n thi
e
sd
iva
o
pr
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Service work 15
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
an
d
– All switches, electrical consumers, gauges and other controls: Check function
itte
y li
rm
ab
– Transportation mode: Switch off ⇒ page 170
pe
ility
ot
wit
, is n
h re
– Electric windows: Check positioning (open and close functions) ⇒ page 75
hole
spec
– Compass: Set compass zone and calibrate compass ⇒ page 84
es, in part or in w
t to the co
– Service interval display: Recode for first oil change service at 5,000 miles/8,000 km ⇒ page 156
rrectness of i
3VWSG81K86M732351
l purpos
nform
ercia
a
com
ti
– Clock: Set to correct time ⇒ page 173
on in
r
te o
– Radio card, part of radio operating instructions: Stick radio serial number and fixed code
thi
s
iva
en
ng
t.
yi
– Check vehicle interior for cleanliness: Front and rear seats, interior trim, carpets/mats,
Co
Cop py
windows
t. rig
gh ht
pyri by
– Seat and carpet protective coverings: Remove
co Vo
by lksw
cted agen
Prote
Vehicle exterior
AG.
– Install all equipment (if any) which has been packed inside vehicle: mats, wheel trims or
hub caps.
– Edge protection -plastic foil- on doors: Remove
– Check vehicle exterior for cleanliness: Paintwork, decorative parts, windows, wiper blades,
surfaces
– Wheel securing bolts: Tighten to prescribed torque setting ⇒ page 136
Tyres
– Tyre inflation pressure of all 4 wheels and spare wheel: Set to correct pressures (in the ⇒ page 59
factory the tyres are inflated to 3.5 bar).
– Optional equipment “Spare wheel package”: Check condition and inflation pressure. ⇒ page 59
Vehicle from below
– Vehicle from below: Perform visual check for leaks and damage without removing engine ⇒ page 172
noise insulation: Engine, steering, protective bellows, hoses and fluid reservoirs.
– Transport devices, vehicles with sports running gear: Remove blocking pieces from front ⇒ page 172
axle springs
– Underbody sealant: Visual check for damage to underbody sealant, underbody panels, ⇒ page 172
routing of lines and plugs
Engine compartment
– Battery: Check battery terminals by hand for tightness ⇒ page 56
– Window wash/wipe system and headlight washer system: Check function and settings; ⇒ page 160
replenish with Windscreen Clear -G 052 164- to maximum
16 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
– Service schedule: Enter delivery inspection
du
an
itte
y li
– Check number and functions of keys, if necessary remove grease
erm
ab
ility
– Check literature for vehicle is complete and prepare literature for delivery to customer
ot p
wit
, is n
– Performing road test (driving behaviour, noises, air conditioner etc.) ⇒ page 135
h re
hole
spec
es, in part or in w
t to the co
2.3 Service scope for “Rest of World” mar‐
kets up to model year 2007
rrectness of i
♦ Service intervals ⇒ page 6 .
l purpos
nf
ercia
orm
♦ Interval service for “Rest of World” markets up to model year
m
atio
m
2007 ⇒ page 18
o
n in
or c
thi
♦ Interval service inspection for “Rest of World” markets up to
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi
markets, up to model year 2007 ⇒ page 22
Co
Cop py
t. rig
gh
♦ Information on LongLife service or time or distance dependent
ht
pyri by
service ⇒ page 36
co Vo
by lksw
cted agen
Prote AG.
2.3.1 Oil change service for “Rest of World”
markets up to model year 2007
Note
Inform the customer if faults are found during service and repair
measures are necessary.
Caution
Caution
2. Service work 17
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
pt
y li
rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
spec
♦ Inform the customer if faults are found during service and re‐
es, in part or in w
Caution
nform
ercia
a
com
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Caution opyri
gh by
Vo
ht
c by lksw
cted
♦ In countries with elevated sulphur content in diesel fuel,
agen
Prote AG.
change oil every 7,500 km. Affected countries with eleva‐
ted sulphur content ⇒ page 47 .
18 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
page 144
an
d
itte
• If fitted
y li
rm
ab
pe
ility
– Tyre repair set: Check and enter expiry date of tyre filler bottle: _______ ⇒
ot
wit
, is n
page 133
h re
• If fitted
hole
spec
es, in part or in w
t to the co
page 72
– Engine oil: Replenish, observe oil specifications ⇒ page 48 rrectness of i ⇒
page 117
l purpos
a
com
tion in
r
te o
thi
do
r
rp
cum
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
♦ Inform the customer if faults are found during service and re‐
pair measures are necessary.
♦ If service work has been performed for the interval service at
least 10,000 km before the 60,000 km inspection, it is not nec‐
essary to carry out this work again at the 60,000 km inspection.
♦ The service work for “Interval service” is marked with a foot‐
note
2. Service work 19
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Caution
Caution
1)
nl
pt
du
an
itte
y li
– Front lights - check function: Side lights, dipped beam, main beam, fog lights, turn signals,
erm
ab
– Rear lights - check function: Brake lights (including 3rd brake light), tail lights, reversing
wit
, is n
h re
lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load
hole
compartment lights
spec
es, in part or in w
– Interior and glove compartment lights, cigarette lighter, warning lamps and horn: Check
t to the co
function
– Static cornering light (cornering light) and driving light assist: Check function ⇒ page 55
rrectness of i
• If fitted
l purpos
atio
m
1)
o
n in
or c
Vehicle exterior
thi
te
sd
iva
cu
o
m
f
– Panorama sliding roof: Check function, clean guide rails if necessary and grease with ⇒ page 134
en
ng
t.
yi
special grease, clean wind deflector (Golf Variant)
Co
Cop py
t. rig
– Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 160
gh ht
pyri by
Vo
co
– Window wash/wipe system and headlight washer system: Check function, adjustment and ⇒ page 160
by lksw
cted agen
Prote
for damage
AG.
20 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒ page 59
1)
– Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ ⇒ page 59
mm
1)
– Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒ page 59
1)
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒ page 59
1)
– Engine and components in engine compartment (from below): Visual check for leaks and ⇒ page 105
damage
– Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage ⇒ page 76
– Brake system: Perform visual check for leaks and damage ⇒ page 72
– Front and rear brake pads/linings: Check thickness ⇒ page 72
1)
pt
Engine compartment
du
an
itte
y li
ab
ility
– Engine and components in engine compartment (from above): Perform visual check for ⇒ page 105
ot p
wit
h re
hole
at
om
io
in t
or
his
e
Final checks
at
do
riv
– Tyre inflation pressure of all 4 wheels and spare wheel: Correct 1) ⇒ page 59
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
21
cted agen
Prote
2. Service work
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Tyre repair set: Check and enter expiry date of tyre filler bottle: _______ ⇒ page 133
• If fitted agen
AG. Volkswagen AG d
oes
o lksw not
y V gu
– Headlights: Check adjustment rise
d b
⇒ page
ara
nte 147
o e
– “Your next service” sticker: Enter next due date andauattach
th
sticker to driver side B-pillar - ⇒ page o41 ra
service intervals ⇒ page 6 ss c
ce
le
un
pt
– Performing road test (driving behaviour, noises, air conditioner etc.) ⇒ page 135
an
d
itte
y li
1)If these procedures have been already performed during the interval service, they do not need to be per‐
erm
ab
formed again for the 60,000 km inspection.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
work for “Rest of World” markets, up to
model year 2007
rrectne
Depending on conditions under which the vehicle is used
⇒ page 47 and vehicle equipment, extra service work must be
ss
performed in addition to the interval service or interval service
o
cial p
f i
inspection.
nform
mer
atio
m
n
c
i
or
n thi
te
sd
a
Every 30,000 km
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Fuel filter: “RENEW” - when using diesel: ⇒ page 91
t. C rig
gh ht
pyri by
Vo
o
• “NOT” conforming to EN 590
c by lksw
cted agen
Prote AG.
• When using RME (biodiesel) conforming to “EN 14214”
• For models up to 05.2006
Every 60,000 km
Additional work Page
– 6-speed dual clutch gearbox (DSG) 02E: Change oil and filter ⇒ page 74
– Haldex coupling (Jetta 4motion): Change oil ⇒ page 78
– Renew dust and pollen filter (cabin filter) ⇒ page 146
♦ Vehicles driving more than 60,000 km in 2 years
22 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Every 90,000 km
Additional work Page
– Air filter element: Renew and clean housing ⇒ page 95
♦ Vehicles driving more than 90,000 km in 6 years
• Conforming to EN 590
Every 120,000 km
AG. Volkswagen AG d
agen oes
Additional work Volksw not
gu
Page
d by ara
– Camshaft driveorise toothed belt: Renew nte
eo
⇒ page 174
h
aut ra
• Valid for
s 4-cylinder TDI unit injector engines up to ▸2006 c
s
ce
e
nl
pt
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Every 150,000 km
hole
spec
t to the co
atio
om
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Every 180,000 km opyri
gh by
Vo
ht
by c lksw
Additional work cted Page
agen
Prote AG.
2. Service work 23
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ AG. Volkswagen AG d
agen oes
Maintenance - Edition 09.2009 Volksw not
g y ua
db ran
rise tee
Every 240,000 km tho or
s au ac
s
Additional work Page
ce
e
nl
pt
du
an
– Camshaft drive toothed belt tensioning roller: Renew ⇒ page 174
itte
y li
erm
ab
• Valid for 4-cylinder TDI unit injector engines up to ▸2006
ility
ot p
wit
, is n
• It is not necessary to renew before the current interval
h re
hole
spec
es, in part or in w
t to the co
Every 300,000 km
rrectness of i
Additional work Page
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
Every 12 months (only valid for Germany)
iva
o
r
rp
cu
o
m
Additional work Page
f
en
ng
t.
yi Co
op
– Exhaust emissions test: Perform test ⇒ page 191
C py
t. rig
gh ht
yri by
• For vehicles with commercial passenger transport, e.g. taxis
cop Vo
by lksw
cted agen
Prote AG.
• Additional work as a separate charge!
Every 2 years
Additional work Page
– Brake and clutch system: Change brake fluid ⇒ page 67
3 years after initial registration and then every 2 years / only valid
for Germany
Additional work Page
– Exhaust emissions test (EET): Perform test ⇒ page 191
Every 4 years
Additional work Page
– Spark plugs: Renew ⇒ page 175
♦ Vehicles driving less than 60,000 km in 4 years
♦ Not valid for 2.0 l TFSI 147 kW engine
♦ Spark plug designation: “Power unit” ⇒ Rep. Gr. 28 “Test data, spark plugs”
24 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
an
d
Every 6 years
itte
y li
erm
ab
Additional work Page
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
♦ Vehicles driving less than 90,000 km in 6 years
♦ Only 2.0 l, TFSI 147 kW engine
rrectne
♦ Spark plug designation: “Power unit” ⇒ Rep. Gr. 28 “Test data, spark plugs”
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
op
• Interval service 2008▸ ⇒ page 27 . C py
t. rig
gh ht
yri by
• Inspection service 2008▸ ⇒ page 28 . cop Vo
by lksw
cted agen
Prote
• Time or distance dependent additional work for “Rest of World”
AG.
Caution
2. Service work 25
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Caution
♦ The vehicle is not suitable for use with biodiesel and must
not be filled up or driven with biodiesel.
AG. Volkswagen AG d
♦ If you use biodiesel fuel, the engine and fuel system could olkswagen oes
not
be damaged. db
yV gu
ara
e nte
ris
♦ Some diesel manufacturers blend biodiesel with diesel tho eo
fuel in compliance with European Standard 590. This s au die‐ ra
c
s
sel is suitable for use in your vehicle and will not damage
ce
le
un
pt
the engine and fuel system.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Inform the customer if faults are found during service and repair
t to the co
measures are necessary.
rrectness of i
• New wiper blades
l purpos
nform
ercia
– Check if storage life date of first aid box has been exceeded
m
a
com
ti
and if warning triangle is fitted.
on in
r
te o
thi
– Removing and installing engine compartment cover -bottom-
s
iva
do
(noise insulation tray) ⇒ page 116
r
rp
cum
fo
The sequence of the individual service tasks has been tested and
en
ng
t.
yi
optimised. Therefore, it should be followed to avoid unnecessary
Co
Cop py
interruptions in the work. ht. rig
rig ht
py by
co Vo
Work to be completed Page
by lksw
cted agen
Prote AG.
– Engine oil: Drain or extract, renew oil filter ⇒
page 117
– Front and rear brake pads/linings: Check thickness ⇒
page 72
– Engine oil: Replenish, observe oil specifications ⇒ page 48 ⇒
page 117
– Service interval display: Recode to non-flexible intervals ⇒
♦ Vehicles with PR No. QG1 page 154
26 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
♦ The service life of the diesel particulate filter could be re‐
un
pt
an
d
duced considerably if diesel fuels with a high sulphur
itte
y li
content are used.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
♦ The vehicle is not suitable for use with biodiesel and must
not be filled up or driven with biodiesel.
rrectness of i
♦ If you use biodiesel fuel, the engine and fuel system could
be damaged.
l purpos
nform
ercia
sel is suitable for use in your vehicle and will not damage
the engine and fuel system.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
Note
um
fo
en
ng
t.
yi Co
op
Inform the customer if faults are found during service and repair C py
t. rig
measures are necessary.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
– Ask the customer if he requires:
AG.
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____
– Tyre inflation pressure of all 4 wheels and spare wheel: Check ⇒
page 59
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒
page 59
– Tyre repair set: Check and enter expiry date of tyre filler bottle: ____ ⇒
page 133
• If fitted
2. Service work 27
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
– Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒
an
d
itte
y li
page 59
rm
ab
pe
ility
– Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒
ot
page 59
wit
, is n
h re
– Engine oil: Drain or extract, renew oil filter ⇒
hole
spec
page 117
es, in part or in w
t to the co
– Front and rear brake pads/linings: Check thickness ⇒
page 72
– Brake system: Perform visual check for leaks and damage ⇒
rrectness of i
page 72
l purpos
nform
ercia
a
com
tio
– Service interval display: Reset ⇒
n in
page 153
r
te o
thi
s
iva
– Enter date of next service on sticker and attach sticker to driver side door pillar (B-pillar) - ⇒
do
r
rp
c
service intervals ⇒ page 6 page 41
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
2.4.3 Inspection service 2008▸
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Inform the customer if faults are found during service and repair
measures are necessary.
Caution
28 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Caution
♦ The vehicle is not suitable for use with biodiesel and must
not be filled up or driven with biodiesel.
♦ If you use biodiesel fuel, the engine and fuel system could
be damaged. AG. Volkswagen n AG do
wage e
♦ Some diesel Vomanufacturers
lks blend biodiesel
s no
t gwith diesel
by ua
fuel inricompliance
se
d with European Standard 590.
ran This die‐
sel uisthosuitable for use in your vehicle and will not edamage
t e
or
the
ss
a engine and fuel system. ac
ce
e
nl
pt
du
an
itte
y li
– Ask the customer if he requires:
erm
ab
ility
ot p
wit
, is n
h re
• Replenish Windscreen Clear G 052 164 (cleanser and anti-
hole
freeze).
spec
es, in part or in w
– Check if storage life date of first aid box has been exceeded
t to the co
and if warning triangle is fitted.
– Removing and installing engine compartment cover -bottom-
rrectness of i
(noise insulation tray) ⇒ page 116
l purpos
The sequence of the individual service tasks has been tested and
optimised. Therefore, it should be followed to avoid unnecessary
interruptions in the work. nf
ercia
orm
m
n in
c
Electrics
or
thi
te
– Front lights - check function: Side lights, dipped beam, main beam, fog lights, turn signals,
sd
iva
o
r
cu
o
m
f
en
ng
– Static cornering light (cornering light) and driving light assist: Check function ⇒ page 55
t.
yi Co
Cop py
. rig
• If fitted
t
gh ht
pyri by
Vo
co lksw
by
cted
– Rear lights - check function: Brake lights (including 3rd brake light), tail lights, reversing
agen
Prote AG.
lights, rear fog light, number plate light, turn signals, hazard warning lights, luggage/load
compartment lights
– Interior and glove compartment lights, cigarette lighter, warning lamps and horn: Check
function
Vehicle exterior
– Window wash/wipe system and headlight washer system: Check function and settings ⇒ page 160
– Door arrester: Grease ⇒ page 170
– Panorama sliding roof: Check function, clean guide rails if necessary and grease with ⇒ page 134
special grease, clean wind deflector (Golf Variant)
– Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 160
Tyres
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____
– Tyre inflation pressure of all 4 wheels and spare wheel: Correct ⇒ page 59
– Tyre repair set: Check and enter expiry date of tyre filler bottle: _______ ⇒ page 133
• If fitted
• If fitted
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒ page 59
– Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm ⇒ page 59
2. Service work 29
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage ⇒ page 76
– Swivel joints: Visual check of swivel joint boots for leaks and damage ⇒ page 55
– Track rod ends: Check play, security and boots ⇒ page 169
olkswagen AG
– Exhaust system: Visual check for leaks, security and damage wage
n AG. V
does
olks not
– Underbody: Visual check for damage to underbody ed by Vsealant, underbody panels, routing gu of ⇒ page 172
ara
lines, plugs horis nte
eo
ut ra
Engine compartment ss
a c
ce
le
– Engine and components in engine compartment (from above): Perform visual check for ⇒ page 105
un
pt
an
leaks and damage
d
itte
y li
erm
ab
– Windscreen wash/wipe system: Check fluid level and frost protection, replenish (only if
ility
ot p
customer requires)
wit
is n
h re
• Use Windscreen Clear -G 052 164-
ole,
spec
urposes, in part or in wh
t to the co
♦ Frost protection specification -25 °C. In countries with arctic climate -35 °C
♦ Enter actual value (measured value) _______°C
rrectne
Final checks
ss
– Headlights: Check adjustment ⇒ page 147
o
cial p
f in
– “Your next service” sticker: Enter next due date and attach sticker to driver side B-pillar - ⇒ page 41
form
mer
– Performing road test (driving behaviour, noises, air conditioner etc.) ⇒ page 135
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
en
ng
t.
yi
work for “Rest of World” markets 2008▸
Co
Cop py
t. rig
gh ht
yri by
Depending on conditions under which the vehicle is used cop Vo
by lksw
⇒ page 47 and vehicle equipment, extra service work must be cted agen
Prote AG.
performed in addition to the interval service, inspection service or
interval service inspection.
It is also possible, to perform additional work outside the service
intervals with regard to the entries in the service schedule (or
sticker: next service).
Every 7,500 km
Additional work Page
– Fuel filter: Renew ⇒ page 91
• Only valid when using diesel with sulphur content ≥2000 ppm.
30 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Every 30,000 km
Additional work Page
– Fuel filter: Renew ⇒ page 91
Every 60,000 km
Additional work Page
– Dual clutch gearbox (DSG) 02E: Renew gear oil and filter ⇒ page 74
– Renew dust and pollen filter (cabin filter) ⇒ page 146
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Every 90,000 km rised b ara
nte
ho eo
ut
Additional work
ss a ra
c Page
ce
le
pt
an
d
y li
rm
ab
pe
ility
wit
, is n
h re
spec
es, in part or in w
♦ Spark plug designation: “Power unit” ⇒ Rep. Gr. 28 “Test data, spark plugs”
nform
mercia
a
com
tio
thi
do
r
rp
en
ng
t.
yi Co
• Valid for 4-cylinder petrol engines (1.4 l and 1.6 l) Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Service work 31
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Every 150,000 km
Additional work Page
– Camshaft drive toothed belt: Renew ⇒ page 174
♦ Only 4-cylinder unit injector engines
• Generally it is not necessary to renew the toothed belt before the actual change
interval is reached. Especially cracks on the belt side are not relevant for service
life
ce
• Vehicles with diesel particulate filter ⇒ page 4
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Every 180,000 km
h re
hole
spec
Additional work Page
es, in part or in w
t to the co
– Camshaft drive toothed belt: Renew ⇒ page 175
rrectness of i
• It is not necessary to renew before the current interval
l purpos
nform
ercia
Every 300,000 km
m
a
com
tio
thi
do
r
rp
cum
en
ng
t.
yi Co
• It is not necessary to renew before the current interval ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Every 2 years
Additional work Page
– Renew dust and pollen filter (cabin filter) ⇒ page 146
♦ Vehicles driving less than 60,000 km in 2 years
32 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
n AG. Volkswagen AG do Maintenance - Edition 09.2009
lkswage es n
Vo ot g
3 years after initial registration by ua
ed and then every 2 years ran
oris tee
th or
Additional work ss
au ac Page
ce
le
– Brake and clutch system: Change brake fluid ⇒ page 67
un
pt
an
d
itte
– Exhaust emissions test (EET): Perform test ⇒ page 191
y li
rm
ab
pe
ility
• Only valid for Germany
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Every 4 years
Additional work Page
rrectness of i
– Spark plugs: Renew ⇒ page 175
• Vehicles driving less than 60,000 km in 4 years
l purpos
nform
ercia
a
com
t
♦ Spark plug designation: “Power unit” ⇒ Rep. Gr. 28 “Test data, spark plugs”
ion in
r
te o
thi
– Breakdown set: Renew tyre sealant ⇒ page 133
s
iva
do
♦ If fitted
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Every 6 years
p by
co Vo
by lksw
cted agen
Prote AG.
Additional work Page
– Tyre pressure sensors: Change ⇒ page 146
• If fitted
2. Service work 33
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– All switches, electrical consumers, gauges and other controls: Check function
– Clock and date: Set to correct time ⇒ page 173
– Front passenger front airbag: Check activation / deactivation ⇒ page 58
• If fitted
– Check vehicle interior for cleanliness: Front and rear seats, interior trim, carpets/mats,
windows
– Seat and carpet protective coverings: Remove
Vehicle exterior
– Install all equipment (if any) which has been packed inside vehicle: mats, wheel trims or
hub caps.
– Edge protection on doors (plastic foil): Remove
– Check vehicle exterior for cleanliness: Paintwork,wage
n Adecorative
G. Volkswageparts,
n AG d windows, wiper blades,
oes
surfaces y Volks not
gu
d b ara
– Wiper blade protection: Removeorise nte
eo ⇒ page 166
th
u
– Wheel securing bolts: Tighten ss to prescribed torque setting
a ra
c ⇒ page 136
ce
le
Tyres
un
pt
an
d
– Tyre inflation pressure of all 4 wheels and spare wheel: Set to correct pressures (in the ⇒ page 59
itte
y li
rm
ility
wit
, is n
h re
hole
• If fitted
spec
es, in part or in w
t to the co
– Optional equipment “Spare wheel package”: Check condition and inflation pressure. ⇒ page 59
Vehicle from below
rrectness of i
– Vehicle from below, visual check for leaks and damage (without removing engine noise ⇒ page 172
insulation cover): Engine, steering, protective bellows/boots, hoses and fluid reservoirs.
l purpos
– Transport devices (vehicles with sports running gear): Remove blocking pieces from front ⇒ page 172
axle springs.
nform
ercia
– Underbody sealant: Visual check for damage to underbody sealant, underbody panels, ⇒ page 172
routing of lines and plugs
m
a
com
tio
Engine compartment
n in
r
te o
thi
– Window wash/wipe system and headlight washer system: Check function and settings; ⇒ page 160
s
iva
do
cum
fo
– Engine oil level: Check, top-up with engine oil if necessary; observe oil specifications! ⇒ page 117
en
ng
t.
yi Co
op
– Engine and components in engine compartment (from above): Perform visual check for ⇒ page 105
C py
t. rig
leaks and damage
gh ht
pyri by
Vo
co
– Coolant level: Check that it is at maximum ⇒ page 88
by lksw
cted agen
Prote AG.
– Brake fluid: Check that it is at maximum ⇒ page 71
Documentation/final checks
34 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
pt
du
an
itte
– Check literature for vehicle is complete and prepare literature for delivery to customer
y li
erm
ab
– Performing road test (driving behaviour, noises, air conditioner etc.) ⇒ page 135
ility
ot p
wit
, is n
h re
hole
spec
1) In countries with elevated sulphur content in diesel fuel, change oil every 7,500
es, in part or in w
t to the co
km.
rrectness of i
markets
l purpos
nf
ercia
o
2.6 Service intervals for North American
rm
m
atio
m
n in
or c
thi
te
sd
iva
Caution
o
r
rp
cu
o
m
f
en
ng
t.
yi
♦ In countries with elevated sulphur content in diesel fuel,
Co
op py
change oil every 7,500 km. Affected countries with eleva‐
. C rig
ht ht
rig
ted sulphur content ⇒ page 47 . py by
co Vo
by lksw
cted
♦ For vehicles from model year 2009 the oil change service
agen
Prote AG.
is no longer valid at 5,000 miles (8,000 km).
2. Service work 35
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Golf Variant 2007 ➤ , uGolf
tho Variant 2010 ➤ , Jetta 2005 ➤ eo
ra
a
Maintenance - Edition
s 09.2009
s c
ce
le
un
pt
an
d
Inspection service (oil change service & inspection service) every 10,000 miles or after 1 Page
itte
y li
year
erm
ab
ility
♦ whichever occurs first
ot p
wit
♦ according to service sticker is n
h re
ole,
spec
urposes, in part or in wh
– 10,000 miles (15,000 km) oil change service & inspection service ⇒ page 11
t to the co
– 20,000 miles (30,000 Km) oil change service & inspection service
rrectne
– 30,000 miles (45,000 Km) oil change service & inspection service
– 40,000 miles (60,000 Km) oil change service & inspection service
ss o
cial p
f i
– 50,000 miles (75,000 Km) oil change service & inspection service
nform
mer
– 60,000 miles (90,000 Km) oil change service & inspection service
atio
om
n
c
i
or
n
– 70,000 miles (105,000 Km) oil change service & inspection service
thi
te
sd
iva
o
– 80,000 miles (120,000 Km) oil change service & inspection service
pr
cum
r
fo
en
ng
t.
– 90,000 miles (135,000 Km) oil change service & inspection service
yi Co
Cop py
ht. rig
ht
– 100,000 miles (150,000 Km) oil change service & inspection service
rig by
copy Vo
by lksw
cted agen
– 110,000 miles (165,000 Km) oil change service & inspection service
Prote AG.
– 120,000 miles (180,000 Km) oil change service & inspection service
36 2. Service work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
3 General
In this chapter you will obtain information on the following sub‐
jects:
♦ Tow starting/towing for North American and Canadian markets
⇒ page 37
♦ Raising vehicle with lifting platform and trolley jack
⇒ page 41
♦ Sticker ⇒ page 41
♦ Connecting vehicle diagnostic tester ⇒ page 43
♦ Vehicle identification number ⇒ page 46
♦ Vehicle data sticker ⇒ page 46 AG. Volkswagen AG d
agen oes
ksw
♦ Countries with elevated sulphur content in diesel
by V fuel
ol not
gu
ara
⇒ page 47 rised
nte
ho eo
ut
♦ Severe operating conditions ⇒ pagess47
a ra
c
ce
le
pt
an
d
itte
y li
♦ Engine oils for North American market ⇒ page 48
rm
ab
pe
ility
♦ Engine oils (for “Rest of World” markets) ⇒ page 48
ot
wit
, is n
h re
♦ RME fuel (biodiesel) for vehicles up to 05.2006 ⇒ page 49
hole
spec
♦ Type plate ⇒ page 49
es, in part or in w
t to the co
3.1 Tow starting/towing for North American
and Canadian markets
rrectness of i
To tow the vehicle a towing eye must be screwed in first.
l purpos
nform
ercia
a
– Remove bolt -arrow 1- from air intake grille -A- using screw‐
com
tio
driver.
n in
r
te o
thi
– Grasp into both openings of air intake grille -arrows 2- with
s
iva
do
both hands.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. General 37
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Ensure that lugs on air intake grille do not break off when remov‐
ing air intake grille -1- from openings of bumper -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Screw towing eye to stop in direction of arrow (left-hand
rm
ab
thread) and tighten with wheel bolt wrench.
pe
ility
ot
wit
– Unscrew towing eye after use and place in vehicle tool kit.
, is n
h re
Reinstall cover.
hole
spec
Rear towing eye:
es, in part or in w
t to the co
– The threaded hole for towing eye is located at rear right of
bumper -bottom-.
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
38 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
ce
le
un
pt
an
♦ Regulations concerning towing must be observed.
d
itte
y li
erm
ab
♦ Both drivers must be familiar with special considerations when
ility
ot p
wit
is n
or tow.
h re
ole,
spec
♦ When using a tow rope, the driver of the towing vehicle must
urposes, in part or in wh
engage the clutch very gently when driving off or changing t to the co
gear.
♦ The driver of the vehicle being towed must ensure that the tow
rrectne
f in
free and the turn signals, horn and windscreen wiper and
atio
n
c
i
or
o
r
cum
r
fo
en
ng
3. General 39
Golf Variant 2007 ➤ , Golf agVariant
en AG. V 2010 ➤ , Jetta
olkswagen AG
does 2005 ➤
ksw not
Maintenance - Edition
by V 09.2009
ol
gu
a
ed ran
oris tee
– As soon as engine au starts, depress clutch and move gear
th
stick or
ac
into neutral to avoid
ss running into the towing vehicle.
ce
le
un
pt
Notes on vehicles with automatic gearbox:
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
urposes, in part or in wh
an automatic gearbox.
t to the co
♦ Selector lever at “N”.
rrectne
♦ Do not tow vehicle faster than 50 km/h.
♦ Do not tow further than 50 km.
ss o
♦ If towed over greater distances, the vehicle must be suspen‐
cial p
f in
ded at the front.
form
mer
Reason: When the engine is not turning, the gearbox oil pump it
atio
m
n
c
i
or
n
high speeds or long distances.
thi
te
sd
va
o
pr
cum
r
en
ng
t.
yi Co
Reason: If vehicle is towed with rear suspended, the drive shafts t. Cop py
turn backwards. The planetary gears in the automatic gearbox
rig
gh ht
yri by
then turn at such high speeds that the gearbox will be severely cop Vo
by lksw
damaged in a short time. cted agen
Prote AG.
40 3. General
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho Golf Variant 2007 ➤ , Golf tee
or Variant 2010 ➤ , Jetta 2005 ➤
u
ss
a
Maintenance - Edition 09.2009
ac
ce
le
un
pt
3.2 Raising vehicle with lifting platform and
an
d
itte
y li
erm
trolley jack
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
WARNING
rrectne
♦ Before driving onto a lifting platform, ensure that there is
sufficient clearance between low-lying vehicle compo‐
s
nents and lifting platform.
s o
cial p
f
♦ Before driving a vehicle onto a lifting platform it must be
inform
ensured that the vehicle weight does not exceed the per‐
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
♦ Never start engine and engage a gear with vehicle lifted
um
r
fo
en
ng
t.
yi Co
floor! Disregarding these warnings risks the danger of an Cop py
accident!
t. rig
gh ht
pyri by
Vo
o
♦ If work is to be performed under vehicle, it must be sup‐
c by lksw
cted agen
ported by suitable stands.
Prote AG.
WARNING
WARNING
3.3 Sticker
♦ Attaching “Your first service” sticker at delivery inspection
⇒ page 42 .
♦ Attaching “LongLife engine oil” sticker ⇒ page 42
♦ Attach “Your next service” sticker ⇒ page 42
3. General 41
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
an
d
itte
y li
Attach “Your next service” sticker ⇒ page 41
rm
ab
pe
ility
“Your first service” sticker
ot
wit
, is n
h re
– Attach sticker on driver door pillar (B-pillar); the sticker is found
hole
spec
Destroy the instruction after attaching the sticker!
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
3.3.2 Attaching “LongLife engine oil” sticker:
r
rp
cum
fo
en
g
t.
yi Co
op
sticker must be attached as shown below. C py
t. rig
gh ht
yri by
– Apply sticker Art. No.: -K 69.5121.50.00- -arrow- on left side
cop Vo
by lksw
of lock carrier (in direction of travel) as illustrated. cted agen
Prote AG.
42 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
3.3.4 Attaching “data sticker” in customer
hole
spec
service schedule
es, in part or in w
t to the co
– Attach the upper of the two data stickers -arrow-.
1 - Production week
rrectness of i
2 - PR number
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. General 43
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
or subsequent units
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
44 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
♦ Diagnostic system -VAS 5053- olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Diagnostic cable -VAS 5052/3-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Ensure that the fault reader is only used with the respective di‐
agnosis cable.
WARNING
3. General 45
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
3.5 Vehicle identification number
es, in part or in w
t to the co
Location engine compartment
The vehicle identification number is located on the extension of
rrectness of i
longitudinal member -arrow-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
3.5.1 Interpretation of vehicle identification number: C py
t. rig
gh ht
pyri by
Vo
o
3VW DG7 1K2 / 1K5 X 5 M 600015
c by lksw
cted agen
Prote AG.
Manufactur‐ Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
er's code ters ters 2005 cation
46 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Caution
an
itte
y li
ab
ility
wit
, is n
spec
at
om
ion
c
in t
r
his
ate
do
riv
cum
or
en
ng
t.
yi
service intervals.
Co
Cop py
ht. rig
Severe operating conditions rig ht
py by
co Vo
by lksw
• Regular short trips or stop and go operation in urban trafficcted agen
Prote AG.
3. General 47
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
Note
le
un
pt
an
d
itte
y li
♦ As of model year 2008 4-digit engine codes will be introduced.
erm
ab
ility
♦ The first 3 digits show the design of engine and are stamped ot p
wit
is n
on the engine as previously.
h re
ole,
spec
♦ The fourth digit shows the engine output and varies according
urposes, in part or in wh
t to the co
♦ The four-digit engine code can be found on the type plate, the
vehicle data sticker and on the engine control unit.
rrectne
♦ Petrol engines: “Power unit” ⇒ Rep. Gr. 00 ; Technical data,
s
engine number “Technical data/engine number”
s o
cial p
f i
♦ Diesel engines: “Power unit” ⇒ Rep. Gr. 00 ; Technical data,
nform
engine number “Technical data/engine number”
mer
atio
m
n
c
i
or
n thi
3.10 Engine oils for North American and
te
sd
iva
o
r
Canadian markets
p
cum
r
fo
en
ng
t.
yi
Engine oils for “Rest of World” markets ⇒ page 48 .
Co
Cop py
t. rig
gh ht
3.10.1 Approved engine oil standards pyri by
Vo
co lksw
by
cted agen
Prote
Petrol engines
AG.
Diesel engines
PR No. QG0, QG2, QG3
VW standards
With unit injector 505 01 ACEA B3/B4
Common rail with diesel particulate 507 001) ACEA B4/C3
filter
1)Combination product: 504 00/ 507 00
48 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
ce
e
nl
pt
du
an
itte
y li
♦ When RME fuel is used and your vehicle is not suitable for
erm
ab
this, the fuel system can be damaged.
ility
ot p
wit
, is n
♦ When filling the tank with biodiesel, only use RME fuel
h re
conforming to EN 14214 (FAME)!
hole
spec
es, in part or in w
t to the co
quired standard, the fuel filter can become blocked.
rrectness of i
RME fuel must conform to EN 14214 (FAME).
l purpos
nf
ercia
or
♦ FAME means “Fatty Acid Methyl Ester”.
m
m
atio
om
sd
iva
cu
o
m
f
en
ng
Note
Note
3. General 49
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
The type plate -A- is visible at the lower door pillar when the left
front door is opened.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
50 3. General
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
4 Descriptions of work
In this chapter you will obtain information on the following sub‐
jects:
♦ Removable towing bracket: Check ⇒ page 53
♦ Swivel joints: Visual check ⇒ page 55
♦ Driving light assist and cornering light: Check function
⇒ page 55
♦ Automatic gearbox: Check ATF level, 09G gearbox
⇒ page 56
♦ Battery: Check battery terminal clamps for secure seating
⇒ page 56
♦ Battery: Check using battery tester with printer -VAS 5097A-
⇒ page 58
♦ Front passenger front airbag: Check activation / deactivation
⇒ page 58
♦ Checking tyres: Condition, wear pattern, inflation pressure,
tread depth ⇒ page 59
♦ Changing brake fluid ⇒ page 67
♦ Brake fluid level: Check ⇒ page 71
♦ Brake system: Perform visual check for leaks and damage
⇒ page 72
♦ Checking diesel particulate filter ⇒ page 74
♦ 6-speed dual clutch gearbox (DSG) 02E: Change oil and filter
⇒ page 74
♦ Electric windows: Check positioning (open and close func‐ AG. Volkswagen AG d
tions) ⇒ page 75 agen oes
olksw not
V gu
by ara
♦ Vehicle system test: Perform test ⇒ page 75 ris
ed
nte
tho eo
♦ Protective bellows: Visual check ⇒ page 76 s au ra
c
s
ce
le
pt
an
d
itte
y li
♦ Poly V-belt: Adjust tension on engines without automatic ten‐
erm
ab
sioning roller ⇒ page 81
ility
ot p
wit
is n
⇒ page 83
t to the co
f inform
⇒ page 95
atio
om
n
c
n thi
te
sd
a
o
pr
⇒ page 105
en
ng
t.
yi Co
op
♦ Engine cover -top-: Removing and installing ⇒ page 105
C py
t. rig
gh ht
yri by
♦ Removing and installing engine compartment cover -bottom-
op Vo
by c lksw
cted
(noise insulation) ⇒ page 116
agen
Prote AG.
4. Descriptions of work 51
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
pt
y li
erm
ab
wit
♦ Track rod ends: Check play, security and boots ⇒ page 169
is n
h re
ole,
⇒ page 172
o
cial p
f inform
atio
⇒ page 174
c
i
or
n thi
te
o
r
cum
r
fo
en
ng
52 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
Check procedure
an
itte
y li
erm
ab
– Remove cover -1-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Pull off protective cap -1- from ball head mounting -2-.
om
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
After ball head has been inserted, green mark on hand wheel
must be aligned with white mark on ball head. Hand wheel must
be entirely in contact. Afterwards, it must be possible to close the
towing bracket lock by removing the key. If this is not possible,
the following repair procedure must be performed.
Note
Repair procedure:
4. Descriptions of work 53
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
o lksw not
– Check contact surfaces -arrows- of ball head d by V for corrosion. gu
ara
ise nte
r
– If contact surfaces are corroded, eliminate
ut
ho corrosion with a tri‐ eo
ra
angular scraper and clean the treated
ss a areas with silicone c
remover.
ce
e
nl
pt
du
an
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
itte
y li
erm
on cleaned surfaces.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– After checking, fit protective cap -1- into ball head mounting
rrectness of i
-2-.
l purpos
Note
nform
mercia
io
cap must be fitted to protect ball head mounting against corrosion n
c
in t
r
⇒ ETKA .
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
54 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
4.3 Driving light assist and cornering light:
erm
ab
ility
ot p
Check function
wit
, is n
h re
♦ Checking driving light assist ⇒ page 55
hole
spec
es, in part or in w
t to the co
4.3.1 Checking driving light assist
rrectness of i
l purpos
Note
nf
ercia
(AHC).
orm
m
atio
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
– Switch on ignition.
o
m
f
en
ng
t.
yi Co
– Turn light switch -4- to position -2- for driving light assist. t. Cop py
rig
gh ht
The headlights may not light in brightness. yri
p by
o Vo
by c lksw
cted
Checking at night or in darkness
agen
Prote AG.
The rain and light sensor -G397- is secured on the interior mirror
retainer.
The rain and light sensor -G397- is located centrally at top of
windscreen -arrow-.
– Cover the securing area for interior mirror from outside of
windscreen by hand or with a suitable object -arrow-.
This measures the light incidence and the headlights are switched
on.
4. Descriptions of work 55
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Turn light switch -4- to position O -1- and switch off ignition.
Note
n AG. Volkswagen AG do
wage es n
♦ Vehicles with cornering light (static
y V cornering light) can be
olks ot g
ua
identified by an additional reflector
ris
ed b
-arrow- between turn signal ran
-1- and dipped beam module -3-.
o tee
th or
au ac
s
♦ The static cornering light only functions in conjunction with the
s
ce
le
dipped beam.
un
pt
an
d
itte
y li
rm
ility
ot
wit
– Turn steering wheel from straight-ahead position one turn to
, is n
h re
the right and check if the cornering light bulb lights up in the
hole
spec
right headlight.
es, in part or in w
t to the co
09G gearbox
m
a
com
tion in
thi
do
topping up”
r
rp
cum
fo
t.
yi Co
op
for secure seating
C py
t. rig
gh ht
pyri by
Vo
o
Special tools and workshop equipment required
by c lksw
cted agen
Prote AG.
56 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Check whether battery clamps are secure on battery terminals
rrectness of i
by moving battery negative cable -1- and battery positive cable
-2- back and forth.
l purpos
WARNING nform
mercia
at
ion
in t
or
do
priv
cum
for
en
g
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Disconnect battery terminal clamp -1- from battery negative op Vo
by c lksw
terminal first. cted agen
Prote AG.
4. Descriptions of work 57
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
pt
an
itte
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Turn key switch -2- with the vehicle key -3- in position “AIR‐
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
58 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
Front passenger front airbag activated
pt
du
an
itte
y li
– Switch off ignition.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Turn key switch -2- with ignition key -3- to position “ON” The
nf
ercia
o
key slot must show to “ON”.
rm
m
atio
m
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Descriptions of work 59
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009 wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
by ara
♦ Tyre inflator -VAS 5216- ris
ed
nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.8.1 Checking condition of tyre
l purpos
nform
ercia
WARNING
m
a
If damage is determined, always check to see if a new tyre
com
tion in
should be fitted.
r
te o
thi
s
iva
do
r
rp
cum
Tests at delivery inspection
fo
en
ng
t.
yi Co
– Check tyre treads and side walls for damage and remove for‐ Cop py
eign bodies such as, for example, nails or glass splinters.
t. rig
gh ht
pyri by
Vo
co
Tests at inspection service
by lksw
cted agen
Prote AG.
– Check tyre treads and side walls for damage and remove for‐
eign bodies such as, for example, nails or glass splinters.
– Check tyres for cupping, one-sided wear, porous side walls,
cuts and punctures.
Note
60 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
WARNING
♦ For safety reasons, only tyres of same type and tread pat‐
tern should be fitted on a vehicle!
♦ On four-wheel drive vehicles, tyres of the same type and
tread pattern must be used. Otherwise the centre differ‐
ential may be damaged.
Note
♦ The tyre pressure table is valid for standard tyres for all tyre
sizes fitted at the factory.
♦ The pressures in the table apply to cold tyres. Do not reduce
increased pressures of warm tyres.
♦ Tyre inflation pressures for the relevant model are on a sticker
attached to the inside of fuel tank flap or on the driver side B-
pillar.
♦ Adjust the tyre pressure to suit the vehicle load.
♦ The spare wheel should have the highest tyre pressure deter‐
mined for the vehicle.
wage
n AG. Volkswagen AG do
e
ks s no
Vol t
♦ Please note
ed
bthat
y basic setting should be performed
gu on vehicles
ara
with tyre
tho
ripressure
s monitoring after every pressurenchange
tee
⇒ page
s au 144 . or
ac
s
ce
e
nl
pt
Winter tyres
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ For winter tyres the tyre pressures for standard tyres are valid.
rrectness of i
markets
m
at
om
ion
c
Petrol engines
in t
or
his
ate
2.0 l / 85 kW ⇒ page 62
do
priv
cum
or
en
ng
t.
yi Co
op
2.0 l / 147 kW FSI ⇒ page 62 . C py
t. rig
gh ht
yri
Diesel engines
p by
co Vo
by lksw
cted agen
1.9 l / 77 kW TDI ⇒ page 63
Prote AG.
4. Descriptions of work 61
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Petrol engine
Capacity / output
2.0 l/85 kW
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
195/65 R 15 2.2 2.2 2.4 2.9
205/55 R 16 2.2 2.2 2.4 2.9
225/45 R 17 2.2 2.2 2.4 2.9
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
Capacity / output
2.5 l/110 kW
Tyre sizes Half load Full load
front rear front rear
(bar / kpa / psi) (bar / kpa / psi) (bar / kpa / psi) (bar / kpa / psi)
195/65 R 15 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33
205/55 R 16 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33
225/45 R 17 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33 2.3 / 230 / 33
225/40 R 18 2.4 2.4 2.6 3.0
Temporary spare
wheel (collapsible agen
AG. Volkswagen AG d
oes
spare wheel) Volksw not
gu
by ara
rise
d
4.2 4.2 nte 4.2 4.2
tho eo
au r ac
ss
ce
e
nl
pt
du
Petrol engine
an
itte
y li
erm
ab
Capacity / output
ility
ot p
2.0l/147 kW
wit
, is n
h re
spec
t to the co
Temporary spare
wheel (collapsible
spare wheel)
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
62 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Diesel engine
Capacity / output
1.9 l / 74 kW TDI
Tyre sizes Half load Full load
front rear front rear
(bar / kpa / psi) (bar / kpa / psi) (bar / kpa / psi) (bar / kpa / psi)
195/65 R 15 2.2 / 220 / 32 2.0 / 200 / 29 2.4 / 240 / 34 2.9 / 290 / 42
205/55 R 16 2.2 / 220 / 32 2.0 / 200 / 29 2.4 / 240 / 34 2.9 / 290 / 42
225/45 R 17 2.2 / 220 / 32 2.0 / 200 / 29 2.4 / 240 / 34 2.9 / 290 / 42
Temporary spare
wheel (collapsible
spare wheel)
n AG. Volkswagen AG do
olk4.2
swage 4.2 es no 4.2 4.2
yV t gu
d b ara
ir se nte
tho eo
au ra
4.8.6 Checking inflation pressure and adjust if
ss c
ce
e
nl
pt
necessary, Jetta 2006 ▸, Golf Variant
du
an
itte
y li
2007 ▸
erm
ab
ility
ot p
Petrol engines
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4 l / 118, 125 kW ⇒ page 64
1.6 l / 75 kW ⇒ page 64 rrectness of i
1.6 l / 85 kW ⇒ page 64
l purpos
atio
m
Diesel engines
o
n in
or c
sd
iva
cu
o
m
f
en
ng
Capacity / output
1.4 l / 88 kW / 90 kW
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 2.0 2.0 2.3 2.8
225/45 R 17 2.0 2.0 2.3 2.8
225/40 R 18 2.0 2.0 2.3 2.8
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
4. Descriptions of work 63
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Petrol engine
Capacity / output
1.4 l / 103 kW
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 2.2 2.2 2.4 2.9
225/45 R 17 2.2 2.2 2.4 2.9
225/40 R 18 2.2 2.2 2.4 2.9
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
AG. Volkswagen AG d
Petrol engine l ksw
agen oes
not
o
byV gu
ara
ed Capacity / output
ris nte
ho eo
aut 1.4 l / 118, 125 kW ra
ss c
Tyre sizes Half load Full load
ce
e
nl
pt
du
an
front (bar) rear (bar) front (bar) rear (bar)
itte
y li
erm
ab
205/55 R 16 2.3 2.3 2.5 3.0
ility
ot p
wit
, is n
h re
225/40 R 18 2.3 2.3 2.5 3.0
hole
spec
Temporary spare
es, in part or in w
t to the co
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
rrectness of i
l purpos
Petrol engine
nf
ercia
or
Capacity / output
m
m
atio
m
1.6l/75 kW
o
n in
or c
sd
iva
cu
o
m
f
t.
yi Co
op
205/55 R 16 2.0 2.0 2.3 2.8
C py
ht. rig
rig ht
225/45 R 17 2.0 2.0 2.3 2.8
py by
co Vo
by lksw
cted
225/40 R 18 2.0 2.0
agen
Prote AG.
2.3 2.8
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
Petrol engine
Capacity / output
1.6l/85 kW
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
195/65 R 15 2.0 2.0 2.3 2.8
64 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
agen
AG. Volkswagen AG d
oes
Maintenance
- Edition 09.2009
olksw not
V g
by ua
oris
ed Capacity / output rante
th eo
s au 1.6l/85 kW ra
c
s
Tyre sizes Half load Full load
ce
le
un
pt
an
d front (bar) rear (bar) front (bar) rear (bar)
itte
y li
erm
ab
205/55 R 16 2.0 2.0 2.3 2.8
ility
ot p
wit
225/45 R 17 2.0 2.0 2.3 2.8
is n
h re
ole,
spec
urposes, in part or in wh
Temporary spare
t to the co
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
rrectness o
Petrol engine
cial p
f inform
mer
Capacity / output
atio
m
2.0l/110 kW
o
n
c
i
or
n
Tyre sizes Half load Full load
thi
te
sd
va
o
pr
cum
r
fo
en
ng
Petrol engine
Capacity / output
2.0l/147 kW
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 2.4 2.4 2.6 3.0
225/45 R 17 2.4 2.4 2.6 3.0
225/40 R 18 2.4 2.4 2.6 3.0
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
Diesel engine
Capacity / output
1.9l / 77 kW TDI
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
195/65 R 15 2.2 2.2 2.4 2.9
205/55 R 16 2.2 2.2 2.4 2.9
225/45 R 17 2.2 2.2 2.4 2.9
4. Descriptions of work 65
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Capacity / output
1.9l / 77 kW TDI
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
225/40 R 18 2.2 2.2 2.4 2.9
Temporary spare
wheel (collapsible
spare wheel)
4.2 4.2 4.2 4.2
Diesel engine
Capacity / output
2.0 l / 100 + 103 kW
TDI
Tyre sizes Half load Full load
AG. Volkswagen AG d
front (bar) rear (bar) front
lksw(bar)
agen rear (bar)
oes
n
o ot g
yV ua
195/65 R 15 2.2 2.2 sedb 2.4 2.9 ran
ri tee
ho
205/55 R 16 2.2 2.2 aut 2.4 2.9 or
ac
ss
225/45 R 17 2.2 2.2 2.4 2.9
ce
e
nl
pt
du
an
itte
y li
erm
Temporary spare
ab
ility
wheel (collapsible
ot p
wit
spare wheel)
, is n
h re
hole
spec
es, in part or in w
t to the co
Diesel engine
rrectness of i
Capacity / output
l purpos
nf
ercia
o
front (bar) rear (bar) front (bar) rear (bar)
rm
m
atio
m
n in
or c
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
Temporary spare Cop py
t. rig
wheel (collapsible yri
gh by
ht
spare wheel) cop Vo
by lksw
cted agen
4.2 4.2 4.2
Prote
4.2
AG.
Diesel engine
Capacity / output
1.9 l / 77 kW TDI four-
wheel drive
Tyre sizes Half load Full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 2.2 2.2 2.4 2.9
225/45 R 17 2.2 2.2 2.4 2.9
66 4. Descriptions of work
Golf Variant 2007 A➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
n G. Volkswagen AG do
lkswage Maintenance
es n - Edition 09.2009
o o t gu
yV
db ara
ir se nte
hCapacity
o / output eo
aut ra
ss 1.9 l / 77 kW TDI four- c
ce
le
wheel drive
un
pt
an
d
itte
Tyre sizes Half load Full load
y li
erm
ab
front (bar) rear (bar) front (bar) rear (bar)
ility
ot p
wit
is n
225/40 R 18 2.2 2.2 2.4 2.9
h re
ole,
Temporary spare
spec
urposes, in part or in wh
wheel (collapsible
t to the co
spare wheel)
4.2 4.2 4.2 4.2
rrectnes
4.9 Brake and clutch system: Change brake
s o
cial p
f
fluid
inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
♦ From model year 2006 a new brake fluid will be introduced.
♦ The new brake fluid can also be used for older vehicles.
♦ For this purpose it can be mixed with the previous brake fluid.
WARNING
4. Descriptions of work 67
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Brake pedal depressor -V.A.G 1869/2-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Unscrew cover cap -1- from brake fluid reservoir. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
68 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
WARNING
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility
Use an appropriate bleed hose. It must seat tightly on bleeder
ot p
wit
screw so that no air can enter the brake system.
is n
h re
ole,
spec
urposes, in part or in wh
– Push collector bottle bleed hose -1- onto front left bleeder
t to the co
screw, open bleeder screw and let appropriate quantity of
brake fluid run out (see table). Close bleeder screw, specified
torque: ⇒ Running gear; Rep. Gr. 47 ; Servicing front brake
rrectne
calipers “Servicing front brake calipers”.
Repeat procedure on right-hand side of vehicle at front.
ss o
cial p
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Descriptions of work 69
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Volkswagen AG
– Push collector bottle bleed hose -1- onto rear left bleeder agen
AG. does
ksw
screw. by
Vol not
gu
ara
d
se nte
– Open bleeder screw and let appropriate quantity ho of brake fluid
ri eo
ut
run out (see table). Close bleeder screw, sspecified
s a torque: ⇒ ra
c
Running gear; Rep. Gr. 47 ; Servicing rear brake caliper
ce
e
nl
“Servicing rear brake caliper”
pt
du
an
itte
y li
Repeat procedure on right-hand side of vehicle at rear.
erm
ab
ility
ot p
For vehicles with manual gearbox
wit
, is n
h re
– Remove air filter housing. “Mixture preparation, diesel injec‐ hole
spec
tion system” ⇒ Mixture preparation, diesel injection system;
es, in part or in w
t to the co
jection” ⇒ Mixture preparation, injection; Rep. Gr. 24 ; Air filter
“Air filter”
rrectness of i
– Push bleed hose onto bleeder valve of clutch slave cylinder.
l purpos
– Open valve and allow approx. 100 ml of brake fluid to flow out.
– Close valve and depress clutch pedal 10 to 15 times quickly
nf
ercia
in succession.
orm
m
atio
m
out.
o
n in
or c
thi
e
sd
iva
several times.
o
r
rp
cu
o
m
f
en
ng
Brake caliper
Front left 0.25 litre (250 ml)
Front right 0.25 litre (250 ml)
Wheel brake cylinder/
brake caliper
Rear left 0.25 litre (250 ml)
Rear right 0.25 litre (250 ml)
Clutch slave cylinder 0.15 litre (150 ml)
Total quantity: approx. 1.15 litre
– Fit caps on bleeder screws of brake calipers.
– Move fill lever of brake filling and bleeding equipment -VAS
5234- to position “B” (see operating instructions).
70 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
WARNING
pt
du
an
itte
y li
To prevent that brake fluid flows out of reservoir, the MAX marking
erm
ab
wit
, is n
h re
spec
t to the co
pad wear.
When vehicle is in use, fluid level tends to drop slightly due to
lining/pad wear and automatic adjustment.
rrectness of i
wear limit:
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Descriptions of work 71
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
WARNING
If the fluid level is below MIN. marking, the brake system must
be checked before fluid is topped up “repair measure”.
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Brake calipers
ility
ot p
wit
– Ensure that brake hoses are not twisted.
, is n
h re
hole
spec
when steering is at full lock.
es, in part or in w
t to the co
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
rrectness of i
– Check brake connections and fastenings for correct seating,
l purpos
WARNING
m
at
om
io
in t
or
his
ate
do
priv
en
g
Check thickness
n
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required
rig ht
py by
co Vo
by lksw
♦ Torque wrench -V.A.G 1332-
cted agen
Prote AG.
72 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
AG. Volkswagen AG d
agen oes
lksw not
When replacing brake pads, always check brake discs V as well for
o gu
by ara
d
wear! Checking and if necessary replacing theoribrake
se discs is a nte
eo
repair measure. auth
ra
ss c
ce
e
nl
pt
du
an
Repairing front brakes “Repairing front brakes”
itte
y li
erm
ab
– Install wheel in marked position.
ility
ot p
wit
, is n
h re
⇒ page 136 .
hole
spec
es, in part or in w
t to the co
– Reinstall wheel bolt covers if necessary.
rrectness of i
4.12.2 Rear brake pads:
l purpos
at
om
io
in t
or
his
e
do
priv
en
ng
t.
yi
Wear limit: 2 mm
Co
Cop py
t. rig
The brake pads have reached their wear limit at a pad thickness
gh ht
pyri by
of 2 mm (without backplate) and must be renewed (repair meas‐
co Vo
by lksw
cted
ure). Inform customer!
agen
Prote AG.
Note
When replacing brake pads, always check brake discs as well for
wear! Checking and if necessary replacing the brake discs is a
repair measure.
4. Descriptions of work 73
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
When checking the diesel particulate filter the ash mass limit val‐
ue is read.
ce
e
nl
pt
du
♦ Model year
an
itte
y li
erm
ab
♦ Engine code
ility
ot p
wit
– Confirm vehicle identification.
, is n
h re
hole
spec
es, in part or in w
t to the co
– Select “Read measured value block”.
rrectness of i
– Confirm with “>” button (press twice).
l purpos
o
– Determine actual value using “Reading button”.
rm
m
atio
m
n in
or c
thi
te
sd
iva
Note
r
rp
cu
o
m
f
en
ng
t.
yi
♦ If the specification “less than 60 grams” is exceeded, the diesel
Co
op py
particulate filter must be renewed, ⇒ 4-cylinder diesel engine;
t. C rig
gh ht
Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - pyri by
Vo
co
front exhaust pipe with particulate filter .
by lksw
cted agen
Prote AG.
♦ Renewing the diesel particulate filter is a repair measure.
– End test.
– Switch off ignition and separate diagnostic connections.
74 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
The automatic opening and closing features for the electric win‐
dows do not function after disconnecting and reconnecting the
battery. Therefore, with immediate effect, before a new vehicle is
delivered, the window adjusters must be reactivated. Once the
windows have been reactivated, the battery must not be discon‐
nected again.
WARNING
ce
e
nl
pt
automatic functions:
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
regulator. Reactivate the other window automatic functions in the
es, in part or in w
t to the co
same manner by operating the respective switch in the driver
door.
rrectness of i
– Switch on ignition.
l purpos
atio
– Pull switch again for 1 second. The side window must now go
om
n in
thi
te
o
r
rp
cu
m
f
en
ng
t.
yi Co
op
– Connect vehicle diagnostic tester ⇒ page 43 .
C py
t. rig
gh ht
yri by
– Switch on ignition. cop Vo
by lksw
cted agen
Prote AG.
– Select operating mode “Guided fault finding” on display.
– Then perform vehicle identification on tester.
The programme now automatically performs a vehicle system test
and reads all control units available for this vehicle type.
– Press > button.
Now all faults are listed.
4. Descriptions of work 75
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
Caution
pt
ommend in agreement with the customer to rectify these faults
an
d
itte
ab
ility
Sporadic faults
ot p
wit
is n
If only sporadic faults or notes are stored in the fault memory and
h re
ole,
End.
All fault memories are read again.
ss o
cial p
cleared.
mer
atio
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
76 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Check outer bellows and inner bellows -arrows- for leaks and
damage.
Note
The rubber buffers for engine cover are renewed every 60,000
km in conjunction with air filter change for the Jetta GTI Edition
30.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Descriptions of work 77
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
♦ Used oil collection and extraction unit -V.A.G 1782-
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
78 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
AG. Volkswagen AG d Maintenance - Edition 09.2009
agen oes
olksw not
♦ Charging device for Haldex yV gu
d b coupling 2 -VAS 6291- ara
rise nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Vehicle diagnostic, testing and information system -VAS
5051B-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
♦ Diagnostic cable -VAS 5051/6A-
AG.
Procedure
– Raise vehicle with lifting platform and place used oil collection
and extraction unit -V.A.G 1782- below Haldex coupling.
– Unscrew oil drain plug -A- and fully drain high performance oil.
– Screw in new drain plug ⇒ Parts catalogue with new seal. The
drain plug is fitted with a secure seal.
Specified torque: 30 Nm
– Remove oil filler plug -B-.
4. Descriptions of work 79
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Separate angled piece -B- from adapter -A- and screw adapter
fully in oil filler hole.
– Reconnect angled piece and route hose above drive shaft to
prevent sagging.
– The vehicle can be lowered as soon as the hose above the
rear left wheel leads away from the vehicle.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Open valve -arrow- and hold oil container as shown in the il‐
lustration.
rrectne
Oil capacity according to maintenance: 0.65 l high performance
oil for Haldex coupling -G 055 175- ⇒ Parts catalogue
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
80 4. Descriptions of work
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Golf Variant
au 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
th or
ac
ss Maintenance - Edition 09.2009
ce
le
un
pt
an
d
– Check for correct filling by raising the vehicle again, and check
itte
y li
if oil has flown out of adapter -A-.
erm
ab
ility
ot p
– If no oil has flown out, lower the vehicle again and continue
wit
is n
with filling.
h re
ole,
spec
– As soon as oil has run out, hold the oil container below the
urposes, in part or in wh
height of the Haldex coupling, so that excessive oil can flow
t to the co
back from the line into the container.
– Remove charging device for Haldex coupling 2 -VAS 6291-
rrectne
and screw in oil filler plug.
Specified torque: 15 Nm
ss o
cial p
– Now check the correct oil level at prescribed temperature
f in
range.
form
mer
atio
– For this, connect vehicle diagnostic tester ⇒ page 43 .
om
n
c
i
or
n
– Select one after the other:
thi
te
sd
va
♦ Vehicle self-diagnosis
i
o
pr
cum
r
fo
♦ Running gear
en
ng
t.
yi Co
op py
♦ Four-wheel drive with Haldex coupling t. C rig
gh ht
pyri by
♦ 01 - Systems capable of self-diagnosis
co Vo
by lksw
cted agen
Prote AG.
♦ Four-wheel drive Haldex
♦ Electrical components
♦ Oil temperature
The oil temperature must be 20...40 °C and can be reached by
carrying out a road test.
4. Descriptions of work 81
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– Fit tensioning lever, secure
ss a
with pin -arrow- and swing alter‐ c
nator downwards (use torque wrench as drive for 3297).
ce
le
un
pt
an
d
y li
rm
ility
ot
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
82 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
pt
an
d
itte
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
urposes, in part or in wh
– Switch on ignition.
rrectne
f inform
– To return to the main menu, press rocker switch -B- and hold
mer
n
c
n thi
te
sd
o
pr
cum
r
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Descriptions of work 83
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
The marked menu point can be found between the two horizontal
lines; there is also a triangle on the right-hand side.
– Mark menu point “Settings”.
– Press button -A- in windscreen wiper lever.
The menu “Settings” is selected.
The setting menu will display the following:
1- Setting time
2- Speed warning for winter tyres
3- Units
4- Language
5- Auxiliary heater
6- Light & View and Convenience
3. Select menu “language”
Select menu point “language” and confirm with -button A-.
In the menu the language can be chosen.
Select language and confirm with -button A-.
y li
ab
ility
ot p
h re
spec
urposes, in part or in wh
t to the co
f in
General ⇒ page 84 .
form
mer
n
c
n thi
te
sd
a
4.23.1 General
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
Only valid for vehicles with Highline dash panel insert. Prote
cted AG.
agen
84 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Your geographic zone can be read off the zone map, e.g. zone
8 for Germany, zone 6 for Mexico.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Select compass zone and calibrate compass with button -A- and
AG.
4. Descriptions of work 85
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
The marked menu point can be found between the two horizontal
lines; there is also a triangle on the right-hand side.
– Mark menu point “Settings”.
– Press button -A- in windscreen wiper lever.
The menu “Settings” is selected.
3. Select menu “Convenience”
– Mark the menu point “Convenience” with rocker switch -B-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
wit
h re
ole,
1- Direction
rrectne
2- Zone
3- Calibration
ss o
4- Back
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
86 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
an
3- (+1 zone) the possibility to select the next zone in each case
itte
y li
erm
ab
4- (-1 zone) the possibility to select the previous zone in each
ility
ot p
case
wit
, is n
h re
5- Back
hole
spec
– Mark the menu point “+ 1 zone” or “- 1 zone” with rocker switch
es, in part or in w
t to the co
and press button to select the compass zone in the display.
6. Exit menu
rrectness of i
– Mark the menu point “Back” with rocker switch -B-.
l purpos
nform
ercia
The menu point “Compass” is exited and the last shown menu is
called up.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
4.23.3 Calibrating compass
co Vo
by lksw
cted agen
Prote AG.
1. Select main menu
– Switch on ignition.
A vehicle symbol is displayed.
– Press button -A- in windscreen wiper lever once.
– To return to the main menu, press rocker switch -B- and hold
for two seconds.
Repeat this procedure until the main menu appears.
2. Select menu “Settings”
– Press upper or lower rocker switch to mark a menu point.
The marked menu point can be found between the two horizontal
lines; there is also a triangle on the right-hand side.
– Mark menu point “Settings”.
– Press button -A- in windscreen wiper lever.
The menu “Settings” is selected.
3. Select menu “Convenience”
– Mark the menu point “Convenience” with rocker switch -B-.
4. Descriptions of work 87
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
e
nl
pt
du
1- Direction
an
itte
y li
erm
ab
2- Zone
ility
ot p
wit
3- Calibration
, is n
h re
hole
4- Back
spec
es, in part or in w
t to the co
5. Select menu “Calibration”
Select menu point “Calibration” and confirm with -button A-.
rrectness of i
The compass menu will display the following:
l purpos
nf
ercia
orm
3- Back
m
atio
om
n in
6. Select menu “Calibrate”
or c
thi
te
sd
iva
o
r
rp
m
f
en
ng
t.
yi Co
1- Drive a complete circle t. Cop py
rig
gh ht
yri
Press -button A-. p by
co Vo
by lksw
cted agen
– Drive a complete circle with a speed of less than 10 mph (20 Prote AG.
Km/h).
The direction appears on the upper display next to the arrow
“CAL”.
Having finished the calibration the display “CAL” is replaced by
the actual direction (e.g. “N” for north).
88 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
♦ For vehicles from model year 2008 only use coolant additive
-G 12 plus-plus- in accordance with TL VW 774 G.
♦ For vehicles up to and including model year 2007 use coolant
additive G12 plus in accordance with TL VW 774 F and G 12
plus-plus in accordance with TL VW 774 G.
♦ Coolant additive -G 12 plus-plus- may only be mixed with -G
12 plus- . Both can be identified by their purple colour.
♦ Coolant additives marked “in accordance with TL VW 774 G”
or “in accordance with TL VW 774 F” prevent frost and corro‐
sion damage, scaling and also raise boiling point of coolant.
For these reasons, the cooling system must be filled all-year-
round with a frost and corrosion protection additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection must be assured to about -25 °C (in arctic
climatic countries to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive ratio must be at least 40 %.
♦ If for climatic reasons greater frost protection is required, the
amount of -G 12 plus-plus- can be increased, but only up to
60 % (frost protection to about -40°C), as otherwise frost pro‐ AG. Volkswagen AG d
tection is reduced again and cooling effectiveness is also olkswagen oes
not
reduced. d byV gu
ar
e an
ris tee
♦ The refractometer -T10007- is recommended to determine
ut
ho the or
current frost protection density. ss
a ac
ce
le
pt
an
d
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Refractometer -T10007-
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
Read precise value for the following tests at bright/dark boundary.
t. rig
gh ht
yri
Using a pipette, place a drop of water on the glass to improve the
p by
co Vo
by lksw
readability of the bright/dark boundary. The bright/dark boundary Prote
cted AG.
agen
can be clearly recognised on the “WATERLINE”.
4. Descriptions of work 89
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
Note
Caution
Only tap water may be used for mixing. Well water does not
have the required quality to ensure the effectiveness of cool‐
n AG. Volkswagen AG do
ant. olks
wage es n
o
yV t gu
db ara
rise nte
ho eo
– Check coolants aadditive
ut concentration after road test again. ra
c
s
ce
le
un
pt
y li
ab
pe
ility
ot
h re
hole
-arrow-.
es, in part or in w
t to the co
nform
ercia
Note
m
a
com
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
90 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Caution
Only tap water may be used for mixing. Well water does not
have the required quality to ensure the effectiveness of cool‐
ant.
Note
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tion in
thi
s
iva
cum
fo
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Descriptions of work 91
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
– Remove easy change filter -1- and seal -2- from fuel filter lower
part -4-.
– Renew seal -3-.
– Insert new easy change filter into fuel filter lower part.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– Position new seal -1- on fuel filter upper part. s aut ra
c
s
– Fit fuel filter upper part with seal to fuel filter lower part.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
92
AG.
4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
♦ Angled
ss a screwdriver -VAS 6543- c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing:
m
at
om
io
Caution
n
c
in t
or
his
ate
♦ Do NOT pull fuel hoses off fuel filter cover and do NOT
do
priv
en
t.
yi Co
op py
♦ Ensure that no diesel fuel contacts other components in
t. C rig
gh ht
yri
the engine compartment. Clean immediately, if necessa‐
p by
o Vo
by c
ry.
lksw
cted agen
Prote AG.
4. Descriptions of work 93
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
ksw
Note by
Vol not
gu
ara
ed
ris nte
o eo
Observe disposal regulations! aut
h
ra
ss c
ce
e
nl
Carry out the following procedure:
pt
du
an
itte
y li
– Unscrew all bolts -arrows- from fuel filter upper part and re‐
erm
ab
move fuel filter upper part.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
If the fuel filter upper part is stuck, loosen as follows:
rrectness of i
l purpos
nform
ercia
at
om
i
-arrow A- using angled screwdriver -VAS 6543- .
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
assembly groove -arrow A- and turn angled screwdriver -VAS
Co
op py
6543- .
t. C rig
gh ht
pyri by
Vo
o
Then the fuel filter upper part is raised. by c lksw
cted agen
Prote AG.
94 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Remove old seal -2- from fuel filter upper part -1- by levering
seal out of respective groove -2-.
AG. Volkswagen AG d
Caution agen oes
o lksw not
V gu
d by ara
ise nte
Remove all diesel, dirt and water residuesh or
from fuel filter lower eo
ut
part using diesel extractor -VAS 5226-
ss a . ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
Note
ility
ot
wit
, is n
h re
Observe disposal regulations!
hole
spec
es, in part or in w
Installing:
t to the co
– Insert new filter into fuel filter lower part.
rrectness of i
l purpos
– Moisten new seal -1- lightly with diesel fuel and insert fuel filter
upper part -arrows-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Place fuel filter upper part with seal properly onto fuel filter
lower part, press on firmly and evenly until the fuel filter upper
part is correctly seated.
Caution
– Screw all bolts into fuel filter lower part and tighten hand-tight.
– Then tighten bolts to 5 Nm according to sequence shown in
illustration.
This procedure prevents the seal from being damaged.
4. Descriptions of work 95
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
ce
le
un
pt
⇒ page 103 .
an
d
itte
y li
erm
4.26.1 Removing and installing air filter ele‐
ab
ility
ot p
ment, 1.4 l SRE engine
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
⇒ page 96
♦ Air filter version 2: Separate air filter housing on engine
rrectne
⇒ page 97
Air filter version 1
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove air filter housing lower part -1- and air filter element
-2-.
Note
96 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Insert new filter element -1- into air filter housing lower part
-2-.
Note
♦ To secure the air filter housing upper part to air filter housing
lower part and intake connection, self-tapping bolts are used
as standard. If these bolts are loosened and tightened using
a cordless screwdriver, the thread in the air filter housing upper
part can be damaged.
♦ For this reason it is only permitted to use a cordless screw‐
driver, if the following prerequisites are fulfilled:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
– Carefully pull off hose -1-.
ot p
wit
is n
– Loosen bolts of air filter housing upper part -2- and fold up‐ h re
ole,
t to the co
Note
rrectne
f in
atio
om
i
or
n thi
e
sd
iva
o
pr
cum
r
fo
Removing
en
ng
t.
yi Co
– Remove engine cover ⇒ page 105 . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Descriptions of work 97
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Place engine cover with upper side on a soft surface and pre‐
vent damage to the housing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Unscrew bolts -arrows- from engine cover lower side.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
– Lift air filter housing lower part -1- upwards in direction of arrow
om
n
and remove.
c
i
or
n thi
te
sd
– Remove air filter element -1- from air filter housing lower part
iva
o
r
-2-.
p
cum
r
fo
en
ng
Note
Note
♦ For attaching the air filter housing upper part onto air filter
housing lower part and intake connection, self-tapping bolts
must be used as standard. When loosening or tightening these
bolts using a power screwdriver, the thread in air filter housing
upper part could be damaged.
♦ For this reason it is only permitted to use a power screwdriver,
if the following prerequisites are fulfilled:
♦ The speed of power screwdriver must be max. 200 rpm.
♦ Setting torque of max. 2 Nm must be adjustable.
98 4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance
olksw
- Edition 09.2009
AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Hook air filter lower part -1- on retaining lugs -arrows- of air
rrectness of i
filter upper part -2- and swing in direction of arrow, then press
on lightly. l purpos
Check if parts of housing -1- and -2- are flush (rear part)
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Both parts of housing must be flush -arrows-.
op Vo
by c lksw
cted agen
Prote
Check if parts of housing -1- and -2- are flush (front part)
AG.
Note
4. Descriptions of work 99
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
– Remove air filter housing lower part -1- and air filter element
-2-.
Note
– Insert new filter element -3- into air filter housing lower part
-2-.
Note
olkswagen AG
en AG. V
♦ For attaching the air filter housing
olks upper part onto air filter
wag does
not
housing lower part and intake
ed
by
V
connection, self-tapping boltsguara
must be used as standard.
oris When loosening or tightening these ntee
th
bolts using a power
sa
uscrewdriver, the thread in air filter housing or
ac
upper part could be damaged.
s
ce
e
nl
pt
du
y li
ab
ility
ot p
h re
spec
es, in part or in w
– Fit air filter housing lower part to filter housing upper part.
t to the co
rrectness of i
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
– Pull off retainer -2-.
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Note
rrectne
– Clean filter housing and install new filter element. ss o
– Tighten bolt -1- of retainer to 2 Nm and bolts of cover to 3 Nm.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
4.26.5 Removing and installing air filter ele‐
co lksw
by
cted agen
Prote AG.
ment, 2.0 l TFSI engines
Removing
– Remove engine cover ⇒ page 105 .
– Place engine cover with upper side on a soft surface, prevent
damage to chrome applications.
– Unscrew bolts -arrows- from engine cover lower side.
– Separate air filter housing lower part -1- from air filter housing
upper part -3-.
– Remove air filter element -2- from air filter housing lower part
-1-.
Installing
Note
♦ For attaching the air filter housing upper part onto air filter
housing lower part and intake connection, self-tapping bolts
must be used as standard. When loosening or tightening these
bolts using a power screwdriver, the thread in air filter housing
upper part could be damaged.
♦ For this reason it is only permitted to use a power screwdriver,
if the following prerequisites are fulfilled:
♦ The speed of power screwdriver must be max. 200 rpm.
♦ Setting torque of max. 3 Nm must be adjustable.
For the GTI Edition 30 the rubber buffers for engine cover must
be renewed ⇒ page 77 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o
– Both parts of housing must be flush
aut -arrows-.
h eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
102
Prote AG.
4. Descriptions of work
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ment, 1.4 l TSI engines (103 kW, 118
ility
ot p
wit
, is n
h re
hole
spec
– Remove bolts -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
en
ng
t.
yi Co
op py
Caution
. C rig
ht ht
rig by
copy Vo
by lksw
To prevent damage to the connection and to vacuum hose, do cted agen
Prote AG.
not use sharp-edged tools when pulling hose off.
– Remove air filter housing upper part and air filter element -1-.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.26.7 Removing and installing air filter ele‐
nform
ercia
at
om
io
– Remove the 4 screws -arrows- and remove cover -A-.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
du
4.28 Engine and components in engine com‐
an
itte
y li
erm
ab
partment (from above and below): Per‐
ility
ot p
form visual check for leaks and damage
wit
, is n
h re
hole
Perform visual check as follows:
spec
es, in part or in w
– Check engine and components in engine compartment for
t to the co
leaks and damage.
– Check lines, hoses and connections of
rrectness of i
♦ Fuel system
l purpos
nform
ercia
at
for leaks, abrasions, porosity and brittleness.
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
t.
yi Co
op py
♦ If fluid loss is greater than can be expected through normal
. C rig
ht ht
rig
use, determine source and rectify (repair measure). py by
co Vo
by lksw
cted agen
Prote AG.
Caution
♦ Do not push with the fist or a tool on the engine cover when
it is installed or engaged at securing points, it could be
damaged.
ce
e
nl
pt
du
an
1.4 l petrol injection engines
itte
y li
erm
ab
ility
• There are two different versions of engine covers:
ot p
wit
, is n
♦ Engine cover version 1: air filter housing integrated in engine
h re
hole
cover ⇒ page 106
spec
es, in part or in w
t to the co
Engine cover version 1
rrectness of i
Removing:
l purpos
– Pull hose off oil separator or non-return valve off air filter hous‐
ing upper part.
nform
ercia
at
om
io
Installing:
n
c
in t
or
his
e
do
riv
cum
for
en
ng
t.
yi Co
housing upper part. t. Cop py
rig
gh ht
Engine cover version 2 yri
p by
o Vo
by c lksw
cted agen
Prote AG.
– Carefully pull off hose -2-.
– Unscrew the four bolts -1- and remove cover.
– Install in reverse order.
Bolt torque setting 10 Nm
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
raise.
es, in part or in w
t to the co
– Then pull out of bracket -arrow C-.
Installing:
rrectness of i
– Push engine cover -1- with lug -arrow A- at securing point
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Then fit engine cover at the other securing points -arrows B-
and press on, until they noticeably engage.
– Fit hose on connection -arrow A -.
AG. Volkswagen AG d
agen
4.29.5 Removing and installing engine cover,
oes
olksw not
V gu
by ara
1.6 l FSI engines ed
ris nte
ho eo
aut ra
Removing: ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Fit engine cover at securing points -2- and press on, so that it
y li
erm
ab
engages.
ility
ot p
wit
– Fit connector -C- and hose connection -B-.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Connect hose and tighten clip -A-.
m
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Removing:
s
upwards.
cial p
f inform
Installing:
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
4.29.9 Removing and installing engine cover,
agen
Prote AG.
Installing:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
4.29.10 Removing and installing engine cover: aut
ho eo
ra
c
2.5 l petrol injection engines ss
ce
e
nl
pt
du
an
Special tools and workshop equipment required
itte
y li
erm
ab
♦ Spring-type clip pliers -VAS 5024A-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
clip pliers -VAS 5024A- and push them back.
nl
pt
du
an
itte
y li
– Separate air intake hose -1- on air mass meter -2-.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull connector -C- off air mass meter, and place connector to
side.
rrectness of i
– First disengage engine cover at securing points -arrows A- and
l purpos
nform
– Slightly raise engine cover at front.
mercia
at
om
io
and carefully remove from fastenings.
n
c
in t
or
his
ate
do
priv
cum
for
en
g
Note
n
t.
yi Co
Cop py
t. rig
gh
Ensure that the air mass meter is not damaged when removing
ht
pyri by
Vo
o
the engine cover. by c lksw
cted agen
Prote AG.
Installing
– First fit engine cover onto rear securing points -arrows B-, then
onto front securing points -arrows A-.
Carefully press on securing points by hand until the engine cover
noticeably engages.
Note
♦ Ensure that the air mass meter is not damaged when fitting
the engine cover.
♦ The remaining assembly steps are basically a reverse of the
dismantling procedure.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Installing:
m
a
com
tion in
– Fit engine cover onto securing points -arrows- and press on.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.29.12 Removing and installing engine cover,
rrectness of i
2.0 l 103 KW PD diesel engines
l purpos
Removing:
nform
ercia
a
– Disengage engine cover -arrow 2- and lift.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
– Then pull off forwards -upper arrow in illustration-. pyri by
Vo
co lksw
by
cted agen
Installing: Prote AG.
Caution
ce
le
un
pt
an
d
itte
y li
♦ 1. The outer part, darker shading in the illustration
rm
ab
pe
ility
♦ 2. The centre part, lighter shading in the illustration
ot
wit
, is n
h re
– Disengage engine cover carefully at individual securing points
hole
spec
and raise as follows.
es, in part or in w
t to the co
– Remove outer part -1-.
rrectness of i
– Disengage centre part -2- also carefully and remove.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Installing:
– First fit centre part -2- onto securing points and press on.
– Then fit outer part -1- onto securing points -arrows- and press
on.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Removing
h re
hole
spec
1- Panel bolts, Qty. 8, torque setting 2 Nm.
es, in part or in w
t to the co
2- Combi-bolts, Qty. 3, torque setting 6 Nm.
– Remove bolts -arrows-.
rrectness of i
– Remove noise insulation.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
Installing
at
do
priv
en
g
shown.
n
t.
yi Co
Cop py
– The smaller lugs -arrow a- must be pushed in underneath and ht. rig
rig ht
the wider lugs -arrow b- must be pushed in over the edge of py by
co Vo
lock carrier -2-.
by lksw
cted agen
Prote AG.
– The retaining lugs on wider lugs must engage in holes of lock
carrier.
– Tighten bolts -arrows- to the correct torque setting.
ce
e
nl
pt
du
an
itte
y li
erm
ab
A - Oil must not be replenished.
ility
ot p
B - Oil may be replenished. It may happen that the oil level after‐
wit
, is n
h re
wards is in the -A- region.
hole
spec
C - Oil must be replenished. It is sufficient if the oil level is in the
es, in part or in w
t to the co
There is a danger of damaging the catalytic converter if the oil
level is above the -A- marking.
rrectness of i
– If oil level is below -C- marking, replenish oil to -A- marking.
l purpos
nform
ercia
at
om
ion
c
in t
or
Engine oil capacities, “Power unit” ⇒ Rep. Gr. 17 “Engine oil” or his
ate
in “Maintenance table”.
do
priv
cum
or
en
ng
t.
yi Co
op
Renew oil filter ⇒ page 118 . C py
t. rig
gh ht
yri
Engine oil: Replenish ⇒ page 133
p by
co Vo
by lksw
cted agen
Prote
4.32.1 Draining or extracting engine oil
AG.
Caution
♦ For engines with standing oil filter the oil filter must be re‐
newed before changing the engine oil ⇒ page 121 ,
⇒ page 130 . When removing the filter element a valve is
opened, the oil in the filter housing automatically flows into
crankcase.
♦ The oil drain plug is fitted with a secure seal, therefore the
oil drain plug must always be renewed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
♦ Oil spill cloth -VAS 6204/1- auth eo
ra
ss c
Draining or extracting engine oil
ce
le
un
pt
an
d
y li
rm
ab
– Extract engine oil using used oil collection and extraction unit
pe
ility
ot
-V.A.G 1782- .
wit
, is n
h re
Or
hole
spec
es, in part or in w
t to the co
– Let engine oil drain.
– Screw in new oil drain plug with seal hand-tight.
rrectness of i
– Replenish engine oil. Specification ⇒ page 6 .
l purpos
nform
ercia
a
com
thi
♦ Diesel engines: 30 Nm
s
iva
do
r
rp
cum
fo
en
g
WARNING
n
t.
yi Co
Cop py
t. rig
gh
♦ Torque specifications must not be exceeded.
ht
pyri by
Vo
co lksw
by
♦ Excessive torque can cause leaks in the area of the oil
cted agen
Prote AG.
drain plug or even damage.
ce
le
un
pt
an
d
itte
Removing
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
♦ Observe disposal regulations!
es, in part or in w
t to the co
♦ Oil new O-rings before installing.
♦ Prevent engine oil from dripping onto components in engine
rrectness of i
compartment.
l purpos
– Loosen oil filter -arrow- e.g. using combination spanner, AF 30
-VAS 5399- or ring spanner, 30x32mm -VAS 5410- and re‐
nform
ercia
a
– Clean engine sealing surface.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Installing
– Oil rubber seal lightly on new filter.
– Screw in filter and tighten hand-tight.
The remaining assembly steps are basically a reverse of the dis‐
mantling procedure.
Note
Removing
Remove engine cover ⇒ page 105 .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove oil filter cover -1- with oil filter element -4- and valve
-5-.
rrectness of i
Installing
l purpos
– Renew O-ring -2- of oil filter cover and O-ring -3- of valve.
nform
ercia
at
om
ion
c
in t
Note
or
his
ate
do
riv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Removing
Remove engine cover ⇒ page 105 .
– Unscrew oil filter cover -arrow- using e.g.socket insert 36 mm.
– Remove oil filter cover -1- with oil filter element -4- and valve
-5-.
Installing AG. Volkswagen AG d
agen oes
ksw not
– Renew O-ring -2- of oil filter cover and O-ring -3- of valve.byV
ol
gu
ara
e d
is nte
– Renew used oil filter element by new filter element hor
-4-. eo
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
Observe disposal regulations!
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Torque wrench -V.A.G 1331-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Removing
c by lksw
cted agen
Prote AG.
Note
– Loosen oil filter -arrow- first, using a strap or oil filter tool -3417-
before removing oil filter completely.
– Wait a minute, so that engine oil can flow back from filter into
engine.
– Then remove oil filter.
Caution
Installing
Note
n AG. Volkswagen AG do
wage
Observe fitting o instructions on oil filter s not g
e
♦ yV
lks
b ua
ed ran
♦ Observe
thoris disposal regulations! tee
u or
a ac
ss
– Clean oil filter sealing surface on control housing. ce
le
un
pt
an
d
y li
rm
ab
pe
ility
wit
, is n
h re
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
thi
engines
s
iva
do
r
rp
cum
fo
t.
yi Co
op
♦ Oil filter tool -VAS 3417-
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen oil filter -arrow- from below using a strap or oil filter tool
-3417-
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Removing
m
a
com
tio
thi
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
Installing
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Clean thread -3- and lightly moisten with oil.
rrectness of i
l purpos
nform
mercia
tion in
r
thi
mantling procedure.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Note
– Loosen oil filter -arrow- first, using a strap or oil filter tool -3417-
before removing oil filter completely.
– Wait a minute, so that engine
agen
AGoil
. Vocan
lkswaflow
gen Aback
G do from filter into
engine. V olksw es n
ot g
y ua
db ran
– Then remove
ho
risoil filter.
e
tee
t or
au ac
ss
Caution
ce
le
un
pt
an
d
itte
y li
ab
pe
ility
ot
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Note
a
com
tion in
thi
s
iva
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
♦ Oil drain adapter -T40057-
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Note
– Insert oil drain adapter -T40057- into oil filter housing and hold
hose in oil drip tray. gen AG
. Volkswagen AG
d wa oes
olks not
– Drain engine oil. byV gu
ara
ed nte
ris
– Unscrew oil drain adapter -T40057-
tho again. eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
The drain valve -1- should be flush with oil filter housing lower part
-2-.
Removing oil filter element
rrectness of i
– Loosen oil filter housing using oil filter tool -VAS 3417- .
l purpos
– Then unscrew by hand and remove together with oil filter ele‐
ment.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
– Remove oil filter element -2- from centre pipe of oil filter hous‐
yi Co
op
ing -4-.
C py
ht. rig
rig ht
py by
Removing seal co Vo
by lksw
cted agen
Prote AG.
Caution
The seal of oil filter housing -3- must be renewed every time
the oil filter element -2- is changed or the oil filter housing is
loosened.
The seal is fitted with a so-called “service tag” -A-.
♦ Using a suitable tool the seal can be pulled out of sealing
groove at the “service tag” -A-.
– Remove seal -1- from sealing groove of oil filter housing -2- by
pulling seal out at the “service tag” -arrow-, using pointed pliers
-3-.
Installing seal
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Oil seal -3-.
ility
ot p
wit
– Place seal into sealing groove of oil filter housing, so that the
, is n
h re
service tag -A- faces upwards.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Push seal into sealing groove and check by touching with fin‐ py by
co Vo
ger, if the seal in sealing groove contacts evenly -arrows-.
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
– Tighten oil filter housing -2- to 25 Nm.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
– Remove threaded cover -arrow-.
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
gine oil can flow out of filter housing.
es, in part or in w
t to the co
– Clean sealing surfaces on threaded cap and oil filter housing.
rrectness of i
l purpos
nf
ercia
Installing
orm
m
atio
om
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
Removing
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ Observe disposal regulations!
hole
spec
es, in part or in w
t to the co
– Remove threaded cover -arrow-.
rrectness of i
l purpos
Note
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
. rig
Installing
ht ht
rig by
copy Vo
lksw
– Renew filter element -3-.
by
cted agen
Prote AG.
– Renew O-rings -2 and 4-.
Note
ce
le
un
pt
– Pull dipstick out again and read oil level.
an
d
itte
y li
erm
ab
For dipstick as illustrated:
ility
ot p
wit
is n
h re
ole,
B - Oil may be replenished. It may happen that the oil level after‐
spec
urposes, in part or in wh
t to the co
C - Oil must be replenished. It is sufficient if the oil level is in the
-B- region (hatched area) afterwards.
rrectne
There is a danger of damaging the catalytic converter if the oil
level is above the -A- marking.
ss
f inform
mer
atio
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi
The breakdown set is also called “Tyre repair set” or “Tire Mobility
Co
op py
System TMS”. t. C rig
gh ht
pyri by
Vo
o
by c lksw
The tyre repair set is located in the spare wheel well -arrow- cted agen
Prote AG.
The tyre repair set consists of the compressor and a tyre filler
bottle with sealant.
Note
This example shows that the expiry date 05/2003 has been ex‐
ceeded, then the bottle has to be renewed.
– Check the expiry date and enter this in maintenance tables.
– Renew tyre sealant if the expiry date has been reached.
Caution
. Volkswagen AG
gen AG does
♦ The tyre sealant must not be more than 4 years old.
Vol
ksw
a
not
by gu
d ara
♦ If the bottle was opened e.g. at a "flat tyre", itomust
ris
e also be nte
eo
renewed. aut
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ Residual tyre sealant or bottles which are filled and the expiry
h re
date has been exceeded, must be disposed of.
hole
spec
es, in part or in w
t to the co
disposed of with other fluids.
rrectness of i
4.34 Panorama sliding roof: Check function,
l purpos
nform
ercia
deflector
m
at
om
io
Special tools and workshop equipment required
n
c
in t
or
his
e
do
priv
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
♦ PSD means panorama sliding roof. Prote AG.
ce
le
un
pt
an
d
– Apply a thin coat of lithium grease -G 052 147 A2- on all seal‐
itte
y li
ing surfaces of guide rail -arrows-.
erm
ab
ility
ot p
A - Outer seal
wit
is n
h re
ole,
B - Wind deflector
spec
urposes, in part or in wh
C - Inner seal
t to the co
D - Arrow points forwards
rrectne
Note
ss o
Ensure that no other components are soiled.
cial p
f inform
mer
atio
m
Caution
o
n
c
i
or
n thi
e
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Cleaning wind deflector
C py
t. rig
gh ht
yri by
– Check wind deflector -1- for soiling. Thoroughly check lower
op Vo
by c lksw
part of wind deflector for soiling -arrows-.
cted agen
Prote AG.
– Remove soiling e.g. using wet and dry cleaner -VAS 5128- .
– To remove insects and particles from the net and wind deflec‐
tor frame, use a sponge and a soapy solution.
Mixture ratio for soapy solution: 3 drops of washing-up liquid to 1
litre of water
Caution
Caution
– When doing this, ensure that no dirt drops into vehicle interior.
ce
le
un
pt
an
d
y li
rm
ab
♦ Loosening/tightening anti-theft wheel bolts ⇒ page 137
pe
ility
ot
wit
, is n
h re
hole
♦ Installing wheel centre cover, wheel bolt cover caps and wheel
spec
es, in part or in w
t to the co
Pulling off wheel hub trim
rrectness of i
Caution
l purpos
On vehicles with light alloy wheels do not lever wheel hub trim
off with screwdriver, only use the special tool for this purpose
nform
ercia
a
com
tion in
r
The puller hook -1- to remove the cover caps is located with the
te o
thi
do
r
rp
cum
– Hook puller hook into one drilling of wheel hub trim and pull off
fo
en
g
in -direction of arrow-.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
On vehicles with light alloy wheels do not lever wheel bolt caps
off with screwdriver, only use the special tool for this purpose
(puller hook in vehicle tool kit).
Note
The puller hook to remove the cover caps is located with the ve‐
hicle tool kit.
– Place the puller hook through opening in cover cap.
. Volkswage n AG n AG d
wage oes
– Pull off cap using the
yV
olpuller
ks hook. not
gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
t to the co
Note
rrectne
n
c
n thi
te
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Slide adapter -2- into anti-theft wheel bolt -1- onto stop.
rrectne
– Slide the wheel bolt wrench onto adapter -2- onto stop.
Tightening wheel bolts
ss o
f in
♦ 120 Nm
atio
om
n
c
i
or
n thi
e
WARNING
t
sd
iva
o
pr
cum
r
fo
t.
yi Co
Cop py
t. rig
gh ht
yri
Installing wheel centre cover, wheel bolt cover caps and wheel p by
o Vo
by c
cover
lksw
cted agen
Prote AG.
– Push wheel hub trim into opening of wheel hub. Ensure that
-A and B- are accurately fitted on rim.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Fit cover caps on wheel bolts.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Install wheel trim by inserting trim evenly into steel wheel. Ensure
o
n
c
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
yi Co
op py
Place adapter and puller hooks properly in vehicle tool kit after
t. C rig
gh ht
completing work. pyri by
Vo
co lksw
by
cted agen
Prote AG.
Specified torque: 120 Nm
Note
♦ The radio codes can be read in the central database and can
be displayed on fault reader.
♦ For radio activation the codes must be entered via radio but‐
tons, as previously ⇒ page 140 .
Procedure
– Connect fault reader ⇒ page 43 .
– Switch on ignition.
ce
le
un
– Confirm with > button.
pt
an
d
itte
y li
– Select one after the other:
erm
ab
ility
ot p
♦ Brand
wit
is n
h re
♦ Type
ole,
spec
urposes, in part or in wh
♦ Model year
t to the co
♦ Engine code
– Confirm vehicle identification.
rrectne
– Select one after the other:
ss
♦ “Radio system”.
o
cial p
f in
♦ “Reading radio code”
form
mer
atio
– Read code according to the information of “GUIDED FUNC‐
om
TIONS”.
n
c
i
or
n thi
e
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
– Press the “End” button on display. t. Cop py
rig
gh ht
– Press “End” button in End menu. yri
p by
co Vo
by lksw
cted
– Switch off ignition and separate diagnostic connections.
agen
Prote AG.
Note
Note
Activate fixed code on “radio system RCD 300” and “radio system
RCD 500” as follows:
ce
Activate fixed code on "radio-navigation system MFD 2" as fol‐
e
nl
pt
du
lows:
an
itte
y li
erm
ab
– Switch on radio navigation system using press button -1-.
ility
ot p
h re
hole
t to the co
ton briefly.
l purpos
If the correct code has been entered, the actual radio frequency
will appear after a short “learning phase”.
nform
ercia
The LED on the top right of the radio-navigation system must flash
m
ion
c
do
priv
cum
or
en
ng
t.
yi Co
“TravelPilot DX-R4/RN S4” Cop py
ht. rig
rig ht
py by
The radio units and radio-navigation systems are supplied with a
co Vo
by lksw
cted
fixed code. Fixed code means that each unit with an anti-theft
agen
Prote AG.
coding is programmed with its own code number. This fixed code
must be activated after installing.
On the Blaupunkt system “TravelPilot DX-R4/RN S4” activate the
fixed code as follows:
The security coding of the ready to play radio is not activated until
the fixed code is entered. The fixed code is to be activated as
follows:
– Switch on radio navigation system using press button -5-.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
a
com
tion in
thi
do
r
rp
cum
– Move the selection bar using the right rotary/push button -4-.
fo
en
ng
t.
yi Co
op py
– Select the menu option “SECURITY” -arrow-.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
spec
es, in part or in w
t to the co
nform
ercia
at
om
in t
or
If the correct code number has been entered, the actual status
his
ate
cum
or
en
ng
t.
yi Co
op
♦ Basic setting is “ON”, means the code is activated. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
On the radio system "Sound System" for vehicles for USA and
Canada, activate the fixed code as follows:
– Switch radio on.
The unit automatically displays "SAFE" and then "1000". For this
no buttons are used.
– With the help of station buttons 1 to 4 enter code number ap‐
plied on the radio card. Use button 1 to enter the first digit of
the code number, button 2 to enter the 2nd digit and so on.
– Then press arrow button located above FAD button and hold,
until the anti-theft coding is activated. This is indicated by a
brief sound.
If the code number has been entered correctly into the radio unit,
a radio frequency appears on display.
ce
le
pt
plied on the radio card. Use button 1 to enter the first digit of
an
d
itte
y li
the code number, button 2 to enter the 2nd digit and so on.
rm
ab
pe
ility
– Then press the station button, located below "OK" indicated
ot
wit
, is n
on display (usually this is the last station button) and hold until
h re
the anti-theft coding is activated. This is indicated by a brief
hole
spec
sound.
es, in part or in w
If the code number has been entered correctly into the radio unit, t to the co
a radio frequency appears on display. rrectness of i
setting
nform
ercia
a
com
tion in
Note
r
te o
thi
s
iva
do
cum
en
g
t.
yi Co
Cop py
♦ If no pressure loss and tyre damage are found after a tyre ht. rig
rig ht
pressure warning, the incorrect warning can be rectified by a
py by
co Vo
by lksw
basic setting. Prote
cted AG.
agen
– Press button ESP -1- and button SET -2- simultaneously and
for longer than 2 seconds in the centre console.
If ESP is not fitted, press TCS button.
The start of basic setting will be confirmed by an acoustic signal.
When switching on ignition again, no warning is indicated.
Perform basic settings
– Switch on ignition.
– Press button ESP -1- and button SET -2- simultaneously
gen AG
. Volkswageand
n AG d
for longer than 2 seconds in the centre
ol swa
kconsole.
oes
not
yV g b ua
ed ran
If ESP is not fitted, press TCS button.
ho
ris tee
t or
au ac
ss
The tyre pressure monitoring warning lamp -K220- in combi-in‐
ce
le
un
pt
y li
rm
ility
ot
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
NAR
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
en
ng
be removed.
nl
pt
du
an
itte
y li
erm
wit
h re
sensor”
hole
spec
t to the co
Note
l purpos
Before installing the new filter, clean area around the dust and
nform
ercia
at
om
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The clips -A- are available in different versions, e.g. -C- and -D-.
– If necessary remove bolts -A-.
The bolt -A- is not fitted on all vehicles. The bolts secure the cover
-B-, if catches -D- do not hold.
olkswagen AG
ag en AG. V
– Slide cover -B- in direction of arrow -C- and remove the
Vol
ksw cover.
does
not
by gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Take filter element -A- out of duct -B- of air conditioner unit or
ot
wit
, is n
heater.
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
– Clean duct -B- of air conditioner unit or heater e.g. with a vac‐
l purpos
uum cleaner.
nform
– Install in reverse order.
mercia
a
com
tion in
thi
s
iva
do
cum
fo
en
t.
yi Co
⇒ page 150 . ht. Cop py
rig
rig ht
♦ Adjusting headlights ⇒ page 151 py by
co Vo
by lksw
cted agen
♦ Adjusting fog lights and other additional lights ⇒ page 153 . Prote AG.
Note
ce
e
nl
pt
times so that springs settle.
du
an
itte
y li
• Vehicle and headlight adjuster must be on a level surface. ⇒
erm
ab
ility
Operating instructions for headlight adjustment unit -VAS
ot p
wit
, is n
h re
unit -VAS 5047-
hole
spec
• Inclination must be set.
es, in part or in w
t to the co
Note
rrectness of i
For NAR vehicles the side adjustment of headlight is not permit‐
l purpos
nform
ercia
at
om
his
ate
cum
for
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
For certain export markets halogen headlights with manually
cted agen
Prote AG.
regulated headlight range control are not offered.
Note
Note
n AG. Volkswagen AG do
Before adjusting headlights on vehicles with headlights with gasolkswage es n
ot g
discharge bulbs, the fault memory must be read, cleared and bthe
yV ua
ed ran
headlight range control must be set to basic setting usingorvehicle
is tee
diagnostic, testing and information system -VAS 5051-auorth vehicle or
ac
diagnostic and service information system -VAS 5052- ss
ce
le
⇒ page 150 .
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Whether, with the dipped beam switched on, the horizontal
hole
spec
bright/dark boundary contacts the dividing line -1- of the test
es, in part or in w
area and
t to the co
– Whether the breaking point -2- between the horizontal part of
the blight/dark boundary on the left and the rising part on the
right lies on the vertical line of the central point -3-. The bright rrectness of i
core of the light beam must be to the right of the vertical line.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
un
pt
perform basic setting
an
d
itte
y li
rm
ab
pe
Basic setting
ility
ot
wit
, is n
h re
manual adjustment, the basic setting procedure must be per‐
hole
spec
formed to adjust the headlights.
es, in part or in w
t to the co
The adjusting mechanism in the headlight housing will be dam‐
aged if the automatic range control basic settings are not per‐
formed.
rrectness of i
After the headlights have been adjusted, the fault memory must
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ GoTo
ility
ot p
wit
♦ Function/Component Selection
, is n
h re
hole
♦ Body
spec
es, in part or in w
♦ Electrical system
t to the co
♦ 01 - Systems capable of self-diagnosis
rrectness of i
♦ 55 - Dynamic headlight range control
l purpos
nform
ercia
♦ Press → button.
m
at
om
i
– Follow the sequence of tester and confirm entry until the fol‐
on
c
in t
lowing text appears:
or
his
ate
cum
or
♦ Press → button.
f
en
ng
t.
yi Co
op py
– Follow the sequence of tester and confirm entry until the fol‐
t. C rig
gh
lowing text appears:
ht
pyri by
Vo
co lksw
by
cted
J 431 - Control unit for headlight range control, basic setting
agen
Prote AG.
Note
Please check also that both headlights move evenly when the
manually operated headlight range control is operated.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
identified by an additional reflector -arrow- between turn signal
hole
spec
-1- and dipped beam module -3-.
es, in part or in w
t to the co
♦ The static cornering light only functions in conjunction with the
dipped beam.
rrectness of i
AFS means Adaptive Front Lighting System
l purpos
The headlights with gas discharge bulbs and cornering light have
no “additional main beam”.
nform
ercia
a
matically adjusted together with the dipped beam.
com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
t.
yi Co
lights, perform basic setting using vehicle diagnostic tester Cop py
. rig
⇒ page 150 .
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Adjusting left headlight: Prote AG.
Note
The adjustment bolts for the right headlight are a mirror image.
♦ First adjust the height adjustment bolt -2- for dipped beam and
main beam, to bright/dark boundary of test area in display of
tester.
♦ Then adjust the lateral adjustment bolt -1- for dipped beam
and main beam, to bright/dark boundary of test area in display
of tester.
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
♦ Every service
l purpos
– Switch on ignition.
m
at
om
io
in t
r
TIONS”.
o
his
ate
do
riv
cum
en
g
t.
yi Co
op
5052- . C py
t. rig
gh ht
yri
– Confirm with > button.
p by
co Vo
by lksw
cted agen
Prote
– Select one after the other:
AG.
ce
le
un
pt
an
d
♦ Engine code
itte
y li
erm
ab
– Confirm vehicle identification.
ility
ot p
wit
is n
– Select one after the other:
h re
ole,
spec
♦ “Dash panel insert” -ARROW-.
urposes, in part or in wh
t to the co
♦ “Resetting the service interval display”.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
cum
r
fo
FUNCTIONS”.
en
ng
t.
yi Co
op
Ending adaption
C py
t. rig
gh ht
yri by
Indicated on display:
op Vo
by c lksw
cted agen
Prote
– Press “GoTo” button on display -arrow-.
AG.
Indicated on display:
– Press the “End” button on display -arrow-.
– Press “End” button in End menu.
– Switch off ignition and separate diagnostic connections.
– Switch on ignition.
After the ignition is switched on, the type of service is no longer
displayed in the distance display in the dash panel insert.
Note
ce
e
nl
pt
♦ Model year
du
an
itte
y li
erm
♦ Engine code
ab
ility
ot p
wit
, is n
h re
If the vehicle identification has been performed correctly, confirm
hole
spec
with > button.
es, in part or in w
t to the co
– Select one after the other:
♦ “Dash panel insert” -ARROW-.
rrectness of i
♦ “Adapting service interval extension”.
l purpos
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Indicated on display:
ht
pyri by
Vo
co lksw
by
cted
– Press “GoTo” button on display -arrow-.
agen
Prote AG.
Indicated on display:
– Press the “End” button on display -arrow-.
– Press “End” button in End menu.
– Switch off ignition and separate diagnostic connections.
ce
le
pt
an
d
-VAS 5052- .
itte
y li
rm
ab
pe
ility
– Select one after the other:
ot
wit
, is n
h re
♦ Brand
hole
spec
♦ Type
es, in part or in w
t to the co
♦ Model year
♦ Engine code
rrectness of i
– Confirm vehicle identification.
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Body
♦ Electrical system
♦ 01 - Systems capable of self-diagnosis
♦ “Dash panel insert” -ARROW-.
♦ Dash panel insert functions
♦ “Adapt service interval display”.
Note
Note
pt
an
d
itte
y li
Ending adaption
erm
ab
ility
ot p
wit
Indicated on display:
is n
h re
ole,
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Indicated on display:
– Press the “End” button on display -arrow-.
– Switch off ignition and separate diagnostic connections.
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
wit
, is n
h re
VAS 5051- or vehicle diagnostic and service information system
hole
spec
-VAS 5052- .
es, in part or in w
t to the co
– Select one after the other:
♦ Brand
♦ Type rrectness of i
l purpos
♦ Model year
nf
ercia
♦ Engine code
orm
m
atio
n in
or c
sd
o
r
rp
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Indicated on display:
– Press the “End” button on display -arrow-.
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
Carry out the following procedure:
rm
ab
pe
ility
– Check function of sunroof.
ot
wit
, is n
h re
– Clean guide rails -arrows- and lubricate with special grease.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
light washer system: Check function
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
Window wash/wipe system: Check spray jet settings and adjust
yi Co
op
if necessary ⇒ page 162 .
C py
ht. rig
rig ht
py by
Headlight washer system: Check spray jet settings and adjust if co Vo
by lksw
cted
necessary ⇒ page 163 .
agen
Prote AG.
ce
le
cleanser as well as a mixture of commercially available wind‐
un
pt
an
d
screen cleanser and Windscreen Clear -G 052 164- .
itte
y li
erm
ab
Mixture ratio:
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Frost protection Windscreen Clear Water
to G 052 164
ss
In summer 1 part 4 parts
o
cial p
f in
-16 °C 1 part 2 parts
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Replenishing fluid:
en
ng
t.
yi Co
op
The fluid reservoir of the window washer system must be filled C py
t. rig
gh
completely.
ht
pyri by
Vo
co lksw
by
Starting immediately, use only Windscreen Clear -G 052 164- all- cted agen
Prote AG.
year-round when replenishing the window wash/wipe system.
Note
Note
♦ If the spray field is uneven due to soiling in the spray jet, re‐ olkswagen AG
move spray jet “Vehicle electrics/Electrical system” ⇒ Rep. agen
AG. V does
ksw
Gr. 92 “Removing windscreen washer system/Removing by
Vol not
gu
spray jets” and rinse with water opposite to direction of spray.rised ara
nte
tho eo
♦ Then it is permitted to blow out opposite to direction of spray
ss
au ra
c
with compressed air.
ce
le
un
pt
an
d
itte
y li
rm
ab
Caution
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Never use a needle or a similar object to adjust the spray
es, in part or in w
t to the co
damaged!
rrectness of i
Special tools and workshop equipment required
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
– Adjust spray jet using adjusting tool -T10127- so that the water
t to the co
jet sprays onto the upper third of rear window.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
jet settings, adjust if necessary Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.
♦ If the spray field is uneven due to soiling in the spray jet, re‐
move spray jet “Vehicle electrics/Electrical system” ⇒ Rep.
Gr. 92 “Removing headlight washer system/Removing and
installing spray jet retainer” and rinse with water opposite to
direction of spray.
♦ Then it is permitted to blow out opposite to direction of spray
with compressed air.
Caution
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
The spray jets -arrows- are extended.
hole
spec
es, in part or in w
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.49 Wiper blades: Check park position
Windscreen wiper blades: Check park position ⇒ page 165 .
rrectness of i
Rear wiper blades: Check park position, Golf Variant 2007▸:
l purpos
⇒ page 165 .
nf
ercia
or
position
m
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
o
m
♦ Every other time that the wiper motor is switched off, it moves
f
en
ng
t.
yi
to a reverse-park position which ensures that the wiper blade
Co
op py
is flipped over in the other direction.
t. C rig
gh ht
pyri by
Vo
♦ To do this, the wiper motor runs downwards into park position
o
by c lksw
cted agen
and then slightly upwards again. This reverse-park position Prote AG.
must not be used for adjusting or checking the wiper crank.
♦ When checking, use the normal park position, not the reverse-
park position. If necessary, operate touch-wipe function again.
– Switch windscreen wiper off and on and let it move into park
position.
– Switch off ignition.
– Check that the distance of the wiper blade ends to plenum
chamber cover on lower edge of windscreen are as follows:
♦ Dimension -a- = 0...10 mm
♦ Dimension -b- = 10...20 mm
– Adjust wiper arms if necessary:
Adjusting windscreen wiper blades ⇒ Electrical system; Rep. Gr.
92 ; Windscreen wiper blades - park position .
Note
– Check that the distance of wiper blade ends to the lower edge
of window is as follows.
♦ Dimension -a- = 15 + 5 mm
– Adjust wiper arm if necessary: “Vehicle electrics/Electrical
system” ⇒ Electrical system; Rep. Gr. 92 ; Wiper blade park
position “Rear window wiper system/Adjusting rear window
wiper park position”.
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
blade.
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
3. Transport wiper blade
C py
ht. rig
rig ht
py by
♦ Identification, the transport wiper blade is fitted without wind co Vo
by lksw
deflector, it must be replaced by the standard wiper blade.
cted agen
Prote AG.
ce
e
nl
Caution
pt
du
an
itte
y li
erm
ab
When doing this, do not touch the wiper blade to prevent dam‐
ility
ot p
age.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
downwards -arrows-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
– Pull blade protector off wiper blade from bottom to top, as
ng
t.
yi Co
shown in illustration. t. Cop py
rig
gh ht
– Carefully place wiper arm back onto windscreen. pyri by
Vo
co lksw
by
cted agen
– Switch ignition on and briefly operate the wiper lever to move Prote AG.
the wipers back to park position. Switch ignition off again.
Caution
When doing this, do not touch the wiper blade to prevent dam‐
age.
pt
an
d
itte
y li
rm
ab
ility
ot
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
168
cted agen
Prote
4. Descriptions of work
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
pt
– Press button -4- until “Weekday” is shown and select using an
d
itte
y li
button -3-.
erm
ab
ility
ot p
– Now set weekday using buttons -4- and -2- and confirm with
wit
is n
button -3-.
h re
ole,
spec
t to the co
rrectne
f i
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Connect vehicle diagnostic tester ⇒ page 43 .
rrectne
– Switch on ignition.
Indicated on display:
ss o
cial p
f
Selecting operating mode
inform
mer
atio
om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum
r
en
ng
Indicated on display:
– Press the button on display for “Switch off transportation
mode”.
Ending output
Indicated on display:
– Press “GoTo” button on display -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Indicated on display:
h re
hole
spec
t to the co
Note
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
The blocking pieces must be removed without reservation be‐
hole
spec
fore delivering the vehicle. A “Warning” notice, attached to the
es, in part or in w
t to the co
Carry out the following procedure:
rrectness of i
l purpos
Note
nform
ercia
a
com
t
♦ Ensure that the surface of the springs is not damaged.
ion in
r
te o
thi
– Relieve weight on springs by raising vehicle with a hoist.
s
iva
do
r
rp
cum
fo
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Always ensure that all lines are secured in their mountings, all
plugs are available and that there is no visible damage on the
underbody.
Always ensure that there are no cracks, detachments and corro‐
sion of underbody protection on the sealing caps -arrows-.
Note
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Setting clock and date using buttons on windscreen ised wiper lever
b ara
nte
or eo
h
– Switch on ignition. s aut ra
c
s
– Press button -2- for 2 seconds to open the main menu.
ce
le
un
pt
an
d
itte
– Press button -2- to select the menu “Settings” and confirm us‐
y li
erm
ab
ing button -1-.
ility
ot p
– Press button -2- to select the menu “Time” and confirm using
wit
is n
h re
button -1-.
ole,
spec
urposes, in part or in wh
– Now mark the menu option “Hours” by pressing button -1-, set
correct hour using button -2- and confirm with button -1-.
t to the co
– The menu “Settings” can be closed via the menu option “back”.
– Now select “MFI” for actual display and confirm this using but‐
ss
ton -1-.
o
cial p
f in
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
4.58.1 Checking toothed belt condition
ility
ot p
wit
, is n
h re
Removing and installing cylinder head .
hole
spec
es, in part or in w
t to the co
♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
rrectness of i
♦ -C- Fraying of cord strands
l purpos
nf
ercia
orm
m
atio
♦ Surface cracks (synthetic coating)
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
Note
f
en
ng
t.
yi Co
Cop py
If faults are found always renew toothed belt. This will avoid pos‐
t. rig
gh ht
yri by
sible breakdowns or operating problems. The replacement of a cop Vo
by lksw
toothed belt is a repair measure. cted agen
Prote AG.
Note
Note
ce
le
un
pt
♦ -C- Fraying of cord strands
an
d
itte
y li
rm
ab
♦ -D- Cracks (in teeth base)
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
If faults are found always renew toothed belt. This will avoid pos‐
sible breakdowns or operating problems. The replacement of a
toothed belt is a repair measure.
nform
mercia
a
com
tio
thi
do
r
rp
cum
Renewing spark plugs, 1.4 l TSI engines (90 kW) ⇒ page 181 .
fo
en
ng
t.
yi Co
Renewing spark plugs, 1,4 l TSI engines (103 kW, 118 kW, 125 t. Cop py
kW) ⇒ page 179 .
rig
gh ht
pyri by
Vo
o
by c
Renewing spark plugs, 1.6l petrol injection engines
lksw
cted agen
Prote
⇒ page 188 .
AG.
♦ Puller -T40039-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Puller -T10094 A-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Puller -T10095-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
♦ Assembly tool -T10029-
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
♦ Puller -T10112-
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The spark plugs are located under ignition coils with output stages
-arrow-.
Note
– Pull ignition coils with output stages off spark plugs using the
puller -T10094 A- .
– Press connector in direction of ignition coils with output stage,
press onto catch by hand and pull off.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Unscrew spark plugs using spark plug socket
s aut and extension ra
c
-3122 B- . s
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Spark plug designation and torque setting: “Power unit” ⇒
, is n
h re
Rep. Gr. 28 “Repairing ignition system/test data”.
hole
spec
♦ Observe disposal regulations!
es, in part or in w
t to the co
rrectness of i
l purpos
Installing
– Screw in new spark plugs using spark plug socket and exten‐
nform
ercia
sion -3122 B- .
m
at
io
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
hand. They must be felt to engage. Cop py
t. rig
gh ht
yri
– Install engine cover. p by
o Vo
by c lksw
cted agen
Prote AG.
ce
le
un
pt
result, these ignition coils can only be removed and installed with
an
d
itte
y li
erm
ab
used if adapted as described below.
ility
ot p
wit
is n
h re
– Using suitable workshop tools mill marked area -2- to reach
ole,
spec
urposes, in part or in wh
t to the co
Removing:
rrectne
– Remove engine cover ⇒ page 105 .
ss o
cial p
f
Note
inform
mer
atio
To simplify removing and installing spark plugs, loosen some
om
n
c
i
or
n thi
te
sd
iva
o
pr
Caution cum
r
fo
en
ng
t.
yi Co
op
To prevent damage to the connection and to vacuum hose, do C py
t. rig
not use sharp-edged tools when pulling hose off.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ When pulling out the ignition coils with output stages, the ca‐
bles or the ignition coil connectors can remain connected.
♦ Note installation position of ignition coils with output stages.
Caution
Note
ce
le
noticeably engage.
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Engage clamps of cable guide -arrows-.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
tion in
thi
s
iva
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
(90 kW)
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
The ignition coil housings with output stages have changed. As a
hole
spec
result, these ignition coils can only be removed and installed with
es, in part or in w
t to the co
used if adapted as described below.
rrectness of i
– Using suitable workshop tools mill marked area -2- to reach
new nominal dimension -B- of 18 mm.
l purpos
nf
ercia
Removing:
orm
m
atio
om
n in
or c
thi
te
Note
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
components and place them to side. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
– Remove bolt -arrow 1-. cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
ksw
When pulling out the ignition coils with output stages, theguca‐
l not
♦ by Vo
ar
bles or the ignitionorcoil
ise connectors can remain connected. ante
d
th eo
♦ Note installation
ss au position of ignition coils with output stages. ra
c
ce
e
nl
pt
du
an
itte
y li
connected to side.
erm
ab
ility
ot p
wit
, is n
Caution
h re
hole
spec
Ensure that the cables are not kinked or damaged.
es, in part or in w
t to the co
– Seat puller -T10094 A- on ignition coil with output stage.
rrectness of i
– Pull out ignition coil with output stage and carefully place to
l purpos
side.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Unscrew spark plugs using spark plug socket and extension - cop Vo
by lksw
VAS 3122B- . cted agen
Prote AG.
Installing:
– Screw in new spark plugs using spark plug socket and exten‐
sion -VAS 3122B- .
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Fit bolt -arrow 1- and tighten to 10 Nm.
– Connect line -arrow 2-.
– Insert hoses -arrows 3- into brackets. rrectnes
f i
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
4.62.4 Renewing spark plugs, 1.6 l FSI engines Cop py
t. rig
gh ht
yri by
Carry out the following procedure: cop Vo
by lksw
cted agen
Prote AG.
– Remove engine cover ⇒ page 105 .
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
t to the co
Removing:
Carry out the following procedure:
rrectness of i
l purpos
Note
nform
ercia
♦ To pull off spark plugs, fit puller -T40039- on top, thick rib
-arrow- of ignition coils with output stages.
m
a
com
tio
thi
s
iva
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The spark plugs are located below the ignition coils with output
stages -2-.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
– Remove the two bolts -1-.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
direction of arrow using puller -T40039- .
m
m
atio
m
n in
or c
-arrows- off.
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Installing
– Screw in new spark plugs using spark plug socket and exten‐
sion -3122 B- .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
– Press ignition coils with output stages on spark plugs until stop
ility
ot
h re
hole
nform
mercia
a
com
tio
thi
gines
s
iva
do
r
rp
cum
Removing:
fo
en
ng
t.
yi
Carry out the following procedure:
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note cted agen
Prote AG.
♦ To pull off spark plugs, fit puller -T40039- on top, thick rib
-arrow- of ignition coils with output stages.
♦ If the lower ribs are used, they could be damaged.
The spark plugs are located below the ignition coils with output
stages -2-.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Pull all ignition coils out of cylinder head approx. 30 mm in
urposes, in part or in wh
t to the co
– Press connectors in direction of ignition coils with output
stages, press onto catch by hand and pull connectors
rrectne
-arrows- off.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
en
ng
-3122 B- .
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
cop Vo
by lksw
cted agen
Prote AG.
Installing
– Screw in new spark plugs using spark plug socket and exten‐
sion -3122 B- .
n AG. Volkswagen AG do
lks wage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Insert ignition coils with output
ss
au
stages into cylinder head. ac
ce
e
pt
du
an
of cylinder head cover.
itte
y li
erm
ab
– Fit all connectors onto ignition coils -arrows-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press ignition coils with output stages on spark plugs until stop
by hand. They must be felt to engage.
nf
ercia
o
– Secure cable guides with bolts -1-.
rm
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Installing:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Screw in new spark plugs using spark plug socket and exten‐
sion -3122 B- .
rrectness of i
– Fit spark plug connectors using puller -T10112- .
l purpos
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
4.62.8 Renewing spark plugs, 2.5 l petrol injec‐
Co
Cop py
t. rig
tion engines
gh ht
pyri by
Vo
o
by c lksw
cted agen
Removing: Prote AG.
Note
♦ To pull off spark plugs, fit puller -T40039- on top, thick rib
-arrow- of ignition coils with output stages.
♦ If the lower ribs are used, they could be damaged.
The spark plugs are located below the ignition coils with output
stages.
– Remove connector -1- in direction of arrow, using assembly
tool -T10118- .
Note
– Remove all ignition coils with output stages -1- upwards using
puller -T40039- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
u or
a a
♦ When pullingssout the ignition coils with output stages, the ca‐ c
bles or the ignition coil connectors can remain connected.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
connected to side.
h re
hole
spec
es, in part or in w
Caution
t to the co
-3122 B- .
m
Installing
at
om
ion
c
in t
his
e
do
priv
en
g
t.
yi Co
er. t. Cop py
rig
gh ht
yri
– Push ignition coils with output stages onto spark plugs until p by
co Vo
stop, they must be felt to engage.
by lksw
cted agen
Prote AG.
– Connect connector onto exhaust recirculation valve until it no‐
ticeably engages.
Note
Ensure that the cable guide for ignition coils with output stages is
routed correctly.
Note
Caution
pt
du
an
itte
ab
wit
h re
spec
es, in part or in w
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
♦ OBD adapter cable -VAS 5052/16- rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
♦ It is only possible to carry out an exhaust emissions test when
itte
y li
all units of the emissions testing station -VAS 6300- are con‐
erm
ab
ility
nected properly and combined with each other according to
ot p
operating instructions.
wit
, is n
h re
hole
♦ All work to be performed is displayed by the emissions testing
spec
station -VAS 6300- .
es, in part or in w
t to the co
Test prerequisites:
rrectness of i
• All test conditions and data required for exhaust emissions test
are found on EET data sheet for the respective engine.
• For bar code reading of specified data for EET, the EET data l purpos
sheet must be printed out.
nform
ercia
at
om
io
• Manual gearbox: Gear lever in neutral
n
c
in t
or
his
e
• Handbrake pulled on
at
do
priv
c
– Perform exhaust emissions test according to instructions on
um
for
display.
en
ng
t.
yi Co
op py
Initial screen: t. C rig
gh ht
pyri by
– Select button -arrow- “exhaust emissions test”.
co Vo
by lksw
cted agen
Prote AG.
pt
du
an
y li
erm
ab
wit
, is n
spec
t to the co
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ To use the ELSA web service, the VAS 5052 which is used for
the exhaust emissions test, must be integrated in the work‐
shop network.
♦ For the ELSA web service the vehicle specified data are au‐
tomatically transmitted via the network to the respective mask.
AG. Volkswagen AG d
agen oes
ksw
Manual specified data input for EET: by
Vol not
gu
ara
ed
ris nte
ho eo
aut ra
Note ss c
ce
e
nl
pt
du
All test conditions and data required for exhaust emissions test
an
itte
y li
⇒ Data sheets for exhaust emission test for respective engine
erm
ab
ility
ot p
wit
– Perform manual data input according to instructions on dis‐
, is n
h re
play.
hole
spec
es, in part or in w
t to the co
values for exhaust emissions test” on display as follows:
1- Test speed (idling speed)
rrectness of i
2- Warm-up phase for catalytic converter
l purpos
3- Engine temperature
nf
ercia
atio
n in
c
thi
te
sd
iva
7- Idling speed
o
r
rp
cu
o
m
f
t.
yi
“broad-band probe” -item 1-.
Co
Cop py
t. rig
gh
9- Lambda probe value
ht
pyri by
Vo
o
by c lksw
cted
– When all data have been entered properly, press “Continue”
agen
Prote AG.
button -arrow-.
Visual check:
– Follow instructions on display.
– Perform visual check.
– If visual check is OK press “OK” button. -arrow-.
Note
The visual check is displayed with the request to connect the di‐
agnostic connector -arrow A- and to check the MI lamp
-arrow B-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
n thi
te
sd
a
o
pr
cum
r
fo
– Switch on ignition.
en
ng
t.
yi Co
op
– Perform visual check of “MI lamp”.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If the MI lamp does not light up during visual check, the result of
the exhaust emissions test is “Failed”.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
not performed.
spec
es, in part or in w
♦ If not all display values are set to zero, a regulating probe test
t to the co
will be performed later.
rrectness of i
Catalytic converter conditioning:
l purpos
at
om
Measurement starts when the engine speed has reached the re‐
on
c
in t
quired level.
or
his
ate
cum
or
en
ng
t.
yi
- arrow A -.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Warm-up phase:
It is automatically switched to display for measuring engine tem‐
perature.
– Follow instructions on display.
Note
AG. Volkswagen AG d
agen oes
olksw not
This is only indicated on display if engine temperature d by has not
V gu
ara
reached 80 °C. horise nte
eo
aut ra
ss c
– Bring engine to required temperature.
ce
le
un
pt
an
d
itte
y li
Measurement at increased idling speed:
rm
ab
pe
ility
It is automatically switched to display for measuring increased
ot
wit
, is n
idling speed.
h re
hole
spec
es, in part or in w
t to the co
Measurement starts when the engine speed has reached the re‐
quired level.
rrectness of i
Note
l purpos
nform
ercia
♦ Measured values are reset using ← button and the test can be
a
com
tio
repeated.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
-arrow A-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
The regulating probe test is only performed, when “NOT” all dis‐
wit
, is n
play values are set to zero at the test for readiness of operation.
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The regulating probe test is performed for every lambda probe
l purpos
individually.
nform
ercia
Measurement starts when the engine speed has reached the re‐
m
quired level.
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
-arrow A-.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Evaluation:
When the exhaust emissions test has been performed, the log is
shown on display.
The test result is displayed.
Now remarks concerning the exhaust emissions test can be en‐
tered -arrow A-. They will then be included in the test log.
– When the exhaust emissions test is classed as passed, select
-arrow B- “EET sticker issued” in drop-down menu and date.
– Then confirm with “Yes” -arrow C-.
The exhaust emissions test log is shown on display and can be
printed out as often as required in the menu “Print preview” using
“Print” button -arrow A-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
5.2 Exhaust emissions test for diesel en‐
an
d
itte
y li
erm
ab
gines with OBD
ility
ot p
wit
is n
Exhaust emissions test for diesel engines with OBD with exhaust
h re
ole,
spec
urposes, in part or in wh
t to the co
be found in the engine list ⇒ page 1 .
Caution rrectne
f inform
mer
atio
n
c
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Caution Cop py
t. rig
gh ht
pyri by
• Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐
co Vo
by lksw
cted
CAUTIONS” in the operating instructions for VAS 6300.
agen
Prote AG.
ce
e
nl
pt
du
an
board diagnosis”, OBD.
itte
y li
erm
ab
♦ The OBD monitors all components and part systems influenc‐
ility
ot p
wit
, is n
h re
hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Emissions testing station -VAS 6300-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
♦ OBD adapter cable -VAS 5052/16- Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Test prerequisites:
• All test conditions and data required for exhaust emissions test
are found on EET data sheet for the respective engine.
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
• Automatic gearbox: Selector lever in position “P” or “N”.
• Manual gearbox: Gear lever in neutral
• Handbrake pulled on
– Perform exhaust emissions test according to instructions on
display.
Initial screen:
– Select button “Exhaust emissions test” -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
certificate part 1:
pe
ility
ot
wit
♦ Registration number: “e.g. WOB-HH 1234”
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Vehicle identification number “field E”
rrectness of i
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
l purpos
Note
nform
mercia
tion in
r
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ To use the ELSA web service, the VAS 5052 which is used for
the exhaust emissions test, must be integrated in the work‐
shop network. n AG. Volkswagen AG ge does
swa
♦ For the ELSA web service
by
Vol
k
the vehicle specified data
not
are
gu au‐
tomatically transmitted
ris
ed via the network to the respective mask.
a ran
te
ho eo
aut ra
ss data c
Manual specified input for EET:
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
All test conditions and data required for exhaust emissions test
, is n
h re
⇒ Data sheets for exhaust emission test for respective engine
hole
spec
es, in part or in w
t to the co
– Perform manual data input according to instructions on dis‐
play. rrectness of i
– Enter displayed values on EET data sheet in column “Test
values for exhaust emissions test” on display as follows:
l purpos
tion in
thi
s
iva
do
5- Idling speed
r
rp
cum
fo
6- Rev limit
en
ng
t.
yi Co
op
7- Rev limit measuring period (1 second)
C py
t. rig
gh ht
yri by
8- Opacity figure (average)
cop Vo
by lksw
cted agen
Prote AG.
9- Select probe type (No. of probe)
10 - Select measuring mode
11 - Measured period portion
– When all data have been entered properly, press → button
-arrow-.
Specified data input for EET as bar code:
– If specified data for EET are available as bar code, read bar
code of EET data sheet with bar code reader.
Visual check:
– Follow instructions on display.
– Perform visual check.
– If visual check is OK press “OK” button. -arrow-.
Note
ce
le
un
pt
an
d
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Connect diagnostic cable connector to EOBD connection. rrectness
f inform
– Switch on ignition.
mer
atio
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If the MI lamp does not light up during visual check, the result of
the exhaust emissions test is “Failed”.
ce
e
nl
Conditioning:
pt
du
an
itte
y li
In the conditioning phase the engine and, if necessary, the emis‐
erm
ab
sion control systems are brought to operating temperature by
ility
ot p
throttle bursts and are prepared for the exhaust emissions test.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Follow instructions on display.
– Maintain engine speed in required engine speed range.
rrectness of i
If no conditioning is necessary, press → button -arrow- for the next
l purpos
measurement.
nf
ercia
n in
or c
thi
e
sd
iva
cu
o
m
f
t.
yi Co
Cop py
t. rig
– Follow instructions on display.
gh ht
pyri by
Vo
o
by c lksw
Measurement starts when the engine speed has reached the re‐ cted agen
Prote AG.
quired level.
Note
Note
An air quality check is carried out before starting the free accel‐
eration. When doing this, no emission probe must be in the
exhaust tail pipe. Otherwise measuring errors or faulty signals
could occur during further measurements.
– When the air quality check is carried out, insert emission probe
into exhaust tail pipe
Free acceleration:
It is automatically switched to display for “Free acceleration”.
During “Free acceleration” the engine is revved up to rev limit
without load as quickly as possible.
The “Free acceleration” test consists of at least four throttle
bursts.
Free acceleration - phase 1:
AG. Volkswagen AG d
agen oes
olksw not
– Follow instructions d b on display -arrow A- and -arrow C-.
y V gu
ara
rise nte
o
– Maintain idling
aut speed in engine speed range indicated
h eo
ra
-arrow D-.ss c
ce
le
un
pt
-arrow B-.
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
206
AG.
5. Exhaust emissions test
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Note
ce
le
un
pt
tolerance, but can be assessed by the operator.
an
d
itte
y li
erm
ab
Further throttle bursts:
ility
ot p
wit
is n
h re
– Follow instructions on display -arrow B-.
ole,
spec
urposes, in part or in wh
Now the next throttle burst follows, starting with phase 1 of “Free
t to the co
acceleration”.
Many “Free accelerations” can be carried out until:
rrectne
♦ Three “Free accelerations” have been completed in succes‐
sion and the range of acceleration is OK.
ss
♦ All values are OK, with the exception of range of acceleration,
o
cial p
f i
and the test is continued by pressing the → button -arrow C-.
(In this case, the operator assesses if the value is OK.) nform
mer
atio
m
n
c
n thi
te
sd
va
o
pr
cum
r
cession, i.e. all fields are coloured white, the exhaust emissions
fo
en
ng
test is completed.
t.
yi Co
Cop py
t. rig
gh ht
Evaluation: pyri by
Vo
co lksw
by
cted
When the exhaust emissions test has been performed, the log is
agen
Prote AG.
shown on display.
The test result is displayed.
Now remarks concerning the exhaust emissions test can be en‐
tered -arrow A-. They will then be included in the test log.
– When the exhaust emissions test is classed as passed, select
-arrow B- EET sticker issued in drop-down menu and date.
– Then confirm with “Yes” -arrow C-.
The exhaust emissions test log is shown on display and can be
printed out as often as required in the menu “Print preview” using
“Print” button -arrow A-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Glossary
These explanations only apply to “Maintenance Manual”. They
are not necessarily generally valid!
Term Explanation
ABS “Anti-lock brake system”, the ABS is a regulating system in the brake system that pre‐
vents locking when braking.
This helps to maintain directional stability and steerability.
ATF “Automatic Transmission Fluid” gear oil for automatic gearboxes
ATF level “Filling level” of ATF in gearbox.
ACF Activated charcoal filter
CO “Carbon monoxide:” occurs when fuels containing carbon are not combusted com‐
pletely.
Common rail Refers to a common high-pressure injection line “rail”, which supplies all cylinders of
“CR” the relevant cylinder bank with fuel
DIN Deutsches Institut für Normung e.V (German institute for standardization)
DS Direct shift
DSG Dual clutch gearbox
ATA Anti-theft alarm system
Part No. Abbreviation for part number
EN European standard
ETKA Electronic parts catalogue - successor to microfiche
EOBD European onboard diagnosis
FAME Fatty acid methyl ester
AG. Volkswagen AG d
agen
FSI “Fuel Stratified Injection”, Volksw
oes
not
see also TSI ⇒ page 210 , TFSIed⇒ b page 210
y gu
ara
nte
ris
MM Maintenance Manual utho eo
ra
s a c
LongLife service The LongLife service enables
s extremely long inspection or oil change intervals de‐
ce
le
pt
an
d
y li
rm
ab
LED Light emitting diode
pe
ility
ot
MIL “Malfunction indicator light” American designation for exhaust emissions warning lamp
wit
, is n
h re
K83
hole
spec
MPI Multi-point injection
es, in part or in w
t to the co
NAR North american region
OBD Onboard diagnosis, the OBD monitors all components influencing the exhaust emis‐
sions quality.
rrectness of i
tion in
PPM “Parts per million” e.g. for sulphur content in diesel fuel
r
te o
thi
s
iva
QG0 Vehicles are “not” factory-fitted with components for LongLife service.
do
r
For maintenance, the time and distance dependent intervals “non-flexible intervals”
rp
cum
fo
apply.
en
ng
t.
yi Co
op
QG1 Vehicles are factory-fitted with active LongLife service. This means, vehicles have a
C py
t. rig
flexible service interval display and are fitted with the following components:
gh ht
pyri by
♦ Flexible service interval display in dash panel insert
co Vo
by lksw
cted agen
Prote AG.
♦ Engine oil level sensor
♦ Brake pad wear indicator
6. Glossary 209
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
Maintenance - Edition 09.2009
Term Explanation
QG2 The LongLife service is not active at the factory. This means that vehicles have a non-
flexible service interval display “time and distance dependent service intervals” and are
fitted with the following components:
♦ Non-flexible service interval display in dash panel insert
♦ Engine oil level sensor
♦ Brake pad wear indicator
Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐
formed by the engine management.
RON “Research Octane Number” measurement of the knock resistance of petrol
RME Biodiesel
SPF Soot particulate filter
RDK, RKA Tyre pressure monitoring, tyre monitor display
SAE “Society of Automotive Engineers”, society which prepares proposals/guidelines on
how the legal requirements can be implemented, e.g. standards
SD Naturally aspirated diesel engine
SDI Naturally aspirated diesel engine - direct injection
SRE Intake manifold injection system
TFSI Turbo “fuel stratified injection”
TSI From model year 2008 the designation TFSI is replaced by TSI.
Therefore the designation TSI is given to TSI turbocharger and TSI twincharger.
TSI turbocharger: charging only with turbocharger
TSI twincharger: charging with turbocharger and compressor
. Volkswagen AG
gen AG does
TDI Turbo diesel engine - directVinjection
olks
wa
not
by gu
DP Distributor injection pumprised ara
nte
tho eo
ULEV Ultra-low emissions auvehicle ra
c
s
ESI Extended service interval
ce
le
un
pt
an
ASSY Assembly
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
210 6. Glossary