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Passat B2
General information
Introduction to instructions
Preface to the repair manual
Passport data of the car
Car models
Lifting and towing a car
Volkswagen car layout «Passat»
General requirements for car repair
Tightening torques for threaded connections
Specifications of wheels and tires
Body Specifications
User manual
Engine start
Engine lubrication system
Engine cooling system
Supply system
Ignition system
Automatic transmission
Front wheel drive
Steering
Front and rear suspension
Brake system
Control lamp of a charge of the rechargeable battery
Programmable speed controller
Sunroof
Heating and ventilation
Windshield and side windows
Interior heating
Ventilation
Air conditioner
Controls and instrumentation
Fuels and lubricants of domestic production and their foreign analogues
Power unit
Engines 4-cylinder FZ
Design and technical characteristics. General information
Specifications of the cylinder head
Specifications of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the gas distribution mechanism
Specifications of the lubrication system
Specifications of the cooling system
Power System Specifications
Specifications of the ignition system
Tightening torques for main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Fuel pump
Carburetor Pierburg 1B1. Carburetor adjustment
The device and principle of operation of the ignition system
The principle of operation of the ignition system
Setting the ignition timing
Ignition system troubleshooting circuit, voltage test
Removing and installing the camshaft drive belt
Adjusting the tension of the timing belt of the timing mechanism
Removal and installation of a head of cylinders
Dismantling and assembly of a head of cylinders
Removal and installation of the engine
Engine disassembly and assembly
Preparatory stages of engine assembly
Engine Assembly
Removal and installation of the oil pump of the lubrication system
Checking the oil pressure in the lubrication system
Replacing the coolant in the cooling system
Removal and installation of the water pump
Engines 4-cylinder
Design and technical characteristics. General information
Specifications of the cylinder head
Specifications of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the gas distribution mechanism
Specifications of the lubrication system
Specifications of the cooling system
Power System Specifications
Technical characteristics of carburetors
Specifications of the ignition system
Tightening torques of the main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Fuel pump supply system
The principle of operation of the Keihin 26-30 DC carburetor
Keihin 26-30 DC carburetor adjustment
The principle of operation of the Pierburg 1VZ carburetor
Checking and adjusting the Pierburg 1VZ carburetor
The principle of operation of the Pierburg 2B5 carburetor
Checking and adjusting the Pierburg 2B5 carburetor
The principle of operation of the Pierburg 2E2 carburetor
Checking and adjusting the Pierburg 2E2 carburetor
The device and principle of operation of the electronic ignition system
Checking and adjusting the ignition system
Removal and installation of the sensor-distributor ignition
Setting the ignition timing
Removing and installing the camshaft drive belt
Removing the cylinder head
Installing the cylinder head
Disassembly and repair of the cylinder head
Cylinder head assembly
Removal and installation of the engine
Engine disassembly
Engine Assembly
Removal and installation of the oil pump
Dismantling, checking the technical condition and assembling the oil pump
Coolant replacement
Removal and installation of the water pump
Disassembly and assembly of the water pump
Alternator Drive Belt Tension Adjustment
Engines 5-cylinder
Design and technical characteristics. General information
Specifications of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the gas distribution mechanism
Specifications of the lubrication system
Specifications of the cooling system
Power System Specifications
Specifications fuel injection system «K-Jetronic» engine model JS
Specifications of the ignition system
Tightening torques of the main threaded connections, kgf.m
Checking and adjusting clearances in the valve drive mechanism
Design of hydraulic pushers
The principle of operation of hydraulic pushers
Checking the technical condition of hydraulic pushers
WN Engine Fuel Pump
Carburetor Pierburg 2B5
Features of the device and the principle of operation of the system «K-Jetronic»
Checking and adjusting the system «K-Jetronic»
Possible malfunctions of the fuel injection system «K-Jetronic», their causes and methods of elimination
The device and principle of operation of the electronic ignition system
Checking and adjusting the ignition system
Removal and installation of the sensor-distributor ignition
Removing and installing the camshaft drive belt
Cylinder head
Installing the cylinder head
Disassembly and repair of the cylinder head
Cylinder head assembly
Removal and installation of the engine
Engine disassembly
Engine Assembly
Removal and installation of the oil pump
Coolant replacement
Removal and installation of the water pump
Transmission
Clutch
Clutch design and specifications
Tightening torques of the main threaded couplings of the clutch, kgf.m
Removal and installation of clutch
Mechanical clutch drive
Removing and installing hydraulic clutch release bearing
Removal and installation of the working cylinder of a hydraulic drive of coupling
Removing and installing the hydraulic clutch master cylinder
Pumping the clutch hydraulic drive
Hydraulic clutch pedal free travel adjustment
Four-speed gearbox
The design and technical characteristics of the four-speed gearbox
Tightening torques of the main threaded connections, kgf.m
Removal and installation of a transmission
Disassembly and assembly of the gearbox
Disassembly and assembly of the input shaft of the gearbox
Dismantling and assembly of a secondary shaft of a transmission
Gearbox Assembly
Disassembly and assembly of the differential
Adjusting the distance between the end face of the drive gear and the axle of the differential
Shift control mechanism
Five-speed gearbox
Design and specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of a transmission
Disassembly and assembly of the gearbox
Disassembly and assembly of the input shaft
Dismantling and assembly of a secondary shaft
Gearbox Assembly
Adjusting the distance between the end face of the final drive pinion and the axle of the differential
Shift control mechanism
Hydromechanical gearbox
Design and specifications
Gearbox Specifications
Tightening torques for main threaded connections, kgf.m
Removal and installation of an automatic transmission
Torque converter
Torque converter test
Gearbox control mechanism
Front wheel drive
Design and specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of shafts of a drive of forward wheels
Removal and installation of the internal hinge of a shaft of a drive of a forward wheel
Removal and installation of the external hinge of a shaft of a drive of a wheel
Chassis
Front suspension
Specifications of the front suspension
Specifications of the front wheels
Tightening torques of the main threaded connections, kgf.m
Removal and installation of shock absorbers and springs
Removal and installation of the stabilizer bar
Front wheel alignment
Checking and adjusting the toe-in of the front wheels
Checking and adjusting the camber of the front wheels
Checking the longitudinal angle of the rotation axis
Disassembly and assembly of the front wheel hubs
Rear suspension
Rear Suspension Specifications
Rear wheel specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of shock absorber with suspension spring
Removal and installation of a back suspension bracket
Replacing the silent blocks of the rear suspension beam
Removal and installation of naves of back wheels
Replacing wheel bearings
Adjustment of a backlash in bearings of naves of back wheels
Steering
Design and specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of the steering mechanism of a mechanical steering
Adjusting the gap between the stop and the mechanical steering rack
Removal and installation of a shaft of a mechanical steering
Removal and installation of the steering mechanism of a steering with the hydraulic booster
Replacing the stuffing box and sealing gaskets of the spool body
Disassembly and assembly of the steering mechanism
Check of tightness of system of the hydraulic booster of a steering
Checking the discharge pressure of the hydraulic booster pump
Checking the pressure in the hydraulic booster system
Adjusting the tension of the power steering pump drive belt
Filling the power steering system
Brake system
Design and specifications
Specifications of the brake mechanisms of the front wheels
Specifications of rear wheel brakes
Specifications of the brake actuator
Tightening torques of the main threaded connections, kgf.m
Brake mechanisms of forward wheels of the ATE brand. Replacement of brake pads
Replacing the brake pads of the front wheels with VWII brakes
Removal and installation of the brake mechanism of forward wheels of brand VWII
Removal and installation of a brake disk of back wheels
Replacing the brake pads of the rear wheels
Removal and installation of the main brake cylinder of a drive of brakes
Checking and adjusting the brake pressure regulator
Removal of air from a hydraulic drive of brakes
Bleeding the hydraulic drive of the brakes using a special installation
Removal of air from the brake hydraulic drive without special installation
Parking brake adjustment
Body
Body elements
Upper body panels
Body floor details
Diagram of control points of the body of Volkswagen cars «Passat» and «Santana»
Diagram of control points of the body of Volkswagen cars «Passat» and «Santana» with body «sedan»
Diagram of control points of the body of Volkswagen cars «Passat» and «Santana» with body «station wagon»
Diagram of control points of the body of Volkswagen cars «Passat» and «Santana» with body «hatchback»
Electrical equipment
Equipment and devices
Design and specifications
Technical characteristics of the battery
Generator Specifications
Starter Specifications
Technical characteristics of fuses
Headlight Specifications
Removal and installation of the generator
Disassembly and assembly of the generator
Alternator Drive Belt Tension Adjustment
Removal and installation of a starter
Disassembly and assembly of the starter
Removal and installation of the windshield wiper motor
Removal and installation of a combination of devices
Headlight adjustment
Removal and installation of a heater
Electrical circuits
Volkswagen wiring diagram legend «Passat» and «Santana»
1. Wiring diagram for Passat L, S, L5, GL and GLS 1981 model year
2. Wiring diagram for Passat C, CL, GL, GL5 and Santana LXy GX and GX5 cars 1982 model year
3. Wiring diagram for Passat C, CL, GL and Santana LX, GX 1984 model year
4. Wiring diagram for Passat CL5 and GL5 and Santana LX5 and GX5 1984 model year
7. Features of the electrical circuit of cars with a DS engine of the 1983 model year
8. Features of the electrical circuit of cars with a JS engine
9. Features of the electrical circuit of the model cars «Formule E» 1981 and 1982 model years
10. Features of the electrical circuit of the model cars «Formule E» 1983 model year
11. Features of the electrical circuit of the model cars «Formule E» with chassis number 32 V 087 125
12. Features of the electric equipment diagram of Santana cars «Formule E» from model year 1983
13. Features of the electrical circuit of cars with automatic transmission produced before August 1982
14. Features of the electrical circuit of cars with automatic transmission produced from August 1982
15. Features of the electrical circuit of cars with an automatic device for stopping and starting the engine
Passat B3
General information
User manual
On the environmental friendliness of the Volkswagen Passat
Vehicle security systems
General view of the controls
Car keys
Central locking
Backdoor
Car alarm system
Infrared remote control
Front seat adjustment
Rear seats of the car
Car luggage compartment
Pedals and handbrake
Manual Transmission
Automatic transmission
Height adjustable steering column
Car ignition lock
Starting the car engine
Dashboard
Control lights
Dashboard switches
Lever for switching direction indicators and dipped / main beam headlights
Constant Speed Device
Wipers/washers (right steering column switch)
Heating and ventilation (manual heater)
Heater with automatic control (Thermotronic)
Car air conditioner
Driving Tips
Running in a new car — the first 1500 km
Economical vehicle operation (recommendations)
Specifications and vehicle condition
Notes for vehicles with catalytic converter in the exhaust system
Vehicle braking
Maintenance instructions
Refilling the car
Applied fuel — gasoline engines
Applied fuel — diesel engines
Oil in automatic transmission
Power steering
Hood opening
Engine compartment
Engine oil
Cooling system
Radiator fan
Brake fluid
Car battery
Spark plug
Wedge-shaped drive belts
Car windshield washers
Wiper blades
Heater air intake filter
Car wheels and tires
Vehicle operation in other countries
Spare wheel of the car
Fuses of electrical circuits
Vehicle lifting
Starting the engine from an external battery
Towing a car
Car wash
Paintwork care
Protection of the bottom and body cavities with anti-corrosion agents
Protection of the engine compartment with anti-corrosion agents
Cushion upholstery care
Necessary tools for car maintenance
VW PASSAT maintenance card
Technical data
Engine characteristics
Speed characteristics
Fuel consumption
Wheel sizes
Tire pressure
Vehicle and trailer weight
Dimensions and filling volumes
Vehicle data
Power unit
Engine repair
Basic information about engines
The most important characteristics of engines
Removal and installation of the engine
V-belt / toothed belt drive
Loosening/tensioning of toothed belt
Removal and installation of a gear belt
Camshaft / valve train 4-cylinder
Removal and installation of a camshaft 4-cylinder
Cylinder head
Removal and installation of a head of cylinders
Camshaft chain drive 6-cylinder
Removal and installation of a head of cylinders 6-cylinder
Checking hydraulic poppets
Removal and installation of valves
Replacement valve stem seals
Checking the valve guides
Seat / valve seat finishing
Lapping of valve seats
Tensioning / changing the V-belt
Tensioning / replacing the V-ribbed belt
Starting the engine from another car
Towing a car
Visual check for oil leaks
Checking the V-belt / V-ribbed belt
Checking the condition and tension of the toothed belt
Compression test
Engine Troubleshooting
Ignition system
General information about the ignition system
TSZ-H ignition system
VEZ ignition system
Digifant ignition system
Precautions when working with electronic ignition systems
Checking the ignition coil
Checking high voltage wires
Checking the ignition distributor slider
Distributor for TSZ and Digifant ignition systems
Removal and installation of the distributor of ignition
Checking the TSZ-H System Switch
Hall sensor test
Adjusting the ignition timing and checking the knock sensor
Checking / adjusting the ignition timing
Ignition timing values
Spark plug
Check of a cover of the distributor of ignition
Checking electrical connections
Removal and installation of spark plugs
Diagnostics of malfunctions of system of ignition
Lubrication system
General information about the lubrication system
Oil circulation
Oil pan / oil pump
Dynamic oil pressure control
Checking hydraulic switches / oil pressure
Removal and installation of the oil pan / gasket replacement
Removing and installing / checking the oil pump
Engine oil change
Oil Circulation Troubleshooting
Cooling system
Coolant circulation
Coolant pump / thermostat
Coolant replacement
Removing and installing / checking the thermostat
Removal and installation of the pump of a cooling liquid
Checking the thermal switch of the electric fan
Removal and installation of a radiator
Checking the cooling system
Checking additional fan activation
Checking the low coolant level indicator
Checking the auxiliary coolant pump
Visual inspection of tightness
Checking the coolant level
Checking antifreeze
Antifreeze specifications
Diagnosis of malfunctions of the cooling system
Supply system
General information about the power system
Carburetor adjustment
Fuel supply problems with a carburetor
Accuracy when working with fuel supply systems
Carburetor device 2E3
Removal and installation of the carburetor
Check / adjust idling and CO content
Throttle adjustment
Checking the automatic device for enriching the combustible mixture at start-up
Removal and installation of an automatic device for enriching the combustible mixture at start-up
Checking and adjusting the idle speed of the crankshaft of a cold engine
Checking the thermo-pneumostatic valve
Checking the fuel cut-off valve
Checking and adjusting the performance of the accelerator pump
Vacuum limiter test (Pulldown)
Thermovalve test with time delay
Checking the intake manifold heating system
Removal and installation of the direct casing of inlet air
Checking the intake air heating
Removal and installation of the fuel pump
Removal and installation of the fuel level sensor
Air filter replacement
Fuel filter replacement
Carburetor Troubleshooting
Petrol injection system
General information about the injection system
Exhaust gas toxicity control
Safety precautions when working with injection systems
Mono-Jetronic injection system
Interrogating the memory device for fault codes
Checking idling and CO content
Checking the valve injectors / forced idle switch
Throttle Potentiometer Check
Oxygen sensor test
Checking the Temperature Sensor
Checking the intake manifold heating system
Electrical check of the Mono-Jetronic injection system
Digifant / Simos injection system
Check / adjustment of idling and CO content Digifant
Digifant Oxygen Sensor Adjustment Check
Digifant idle speed increase valve test
Checking the switch for forced idling and enrichment of the combustible mixture at full throttle
Removing and installing / checking valve injectors Digifant / Simos
Simos injection system from 10/94
Electrical check of the Digifant injection system
K-Jetronic injection system
KE-Motronic injection system
Checking / adjusting idling and CO content K-Jetronic
Checking the stabilization of the engine speed at idle K-Jetronic
Checking the forced idle switch K-Jetronic
Temperature sensor check K-Jetronic, KE-Motronic
Checking and adjusting the position of the damper of the flowmeter K-Jetronic, KE-Motronic
Checking the control lever and distribution piston K-Jetronic, KE-Motronic
Removal and installation of the starting fuel valve / thermal switch K-Jetronic
Motronic injection system
Prescribed CO values
Removing and installing / checking valve injectors K-Jetronic
Check / removal and installation of the fuel pump
Checking the fuel pump relay
Throttle adjustment
Checking the intake air heating
Air filter replacement
Diagnostics of malfunctions of injection systems K-Jetromic / Digifant
Diesel engine
Working principle of diesel engine
Turbocharger
Toothed belt tension adjustment
Toothed belt drive
Removal and installation of a gear belt / adjustment of management of the engine
Checking the preheating system / glow plugs
Removal and installation of glow plugs
Diesel injection system
Checking / replacing the fuel cutoff solenoid valve
Throttle adjustment
Cold start pull adjustment
Checking and adjusting idle speed / maximum speed
Checking the start of delivery of the high pressure fuel pump
Removal and installation of nozzles
Fuel supply in a diesel engine
Fuel Filter — Preheating System
Replacing the diesel engine air filter
Water removal / fuel filter replacement
Diagnostics of malfunctions of the injection system of diesel engines
Exhaust system
Exhaust gas exhaust system
Removal and installation of system of release of the fulfilled gases
Replacing pressure springs
Removal and installation of the subsequent muffler
Removal and installation of the oxygen sensor
Vehicles with catalytic converter
Car Catalyst Handling
Visual check of system of release of the fulfilled gases
Transmission
Clutch
Clutch device
Clutch drive
Removal and installation / clutch check
Removing air from the clutch actuator
Clutch cable replacement
Clutch Troubleshooting
Car gearbox
Removal and installation of a transmission
All wheel drive
Checking the oil level in the gearbox
Visual inspection of the gearbox for tightness
Gear shifter
Gear selector adjustment
Removal and installation of the gear selector lever
Removal and installation of cables of the switch of transfers
Automatic transmission
Checking the oil level / changing the oil in the automatic transmission
Automatic transmission gas draft adjustment
Chassis
Suspension
Front axle device
Front suspension device
Removal and installation of a rack of a forward shock-absorber
Shock absorber strut device
Removal and installation of the shock absorber / disassembly of the shock absorber strut
Removal and installation of cardan shaft
Cardan shaft device
Disassembly and assembly of the cardan shaft
Visual inspection of the front wheel suspension
General information about the rear axle
Rear shock absorber device
Removal and installation / disassembly of the rear shock absorber strut
Wheel with drum brake
Removal and installation of the bearing of a nave of a back wheel
Wheel bearing clearance adjustment
Wheel with disc brake
Steering
General information about steering
Steering device
Precautions when working with an inflatable airbag
Removing and installing the airbag assembly
Removal and installation of a steering wheel
Removal and installation of a tip of cross steering draft
Steering wheel free play check
Power steering vane pump
Checking the tightness of the steering gear
Removal of air from a steering drive
Elimination of vibrations of the steering wheel / front of the car
Steering service
Determination of chassis parameters
Brake system
General information about the brake system
Front brake caliper VW II (car models up to 9/93)
Removing and installing front disc brake pads VW II
Girling front brake caliper
Removing and installing Girling front disc brake pads
Front brake caliper Ate/Teves (cars with engines of 150, 174 hp since 10/93)
Removal and installation of overlays of a forward disk brake Ate/Teves
Girling rear brake caliper
Removal and installation of overlays of a back disk brake
Eliminate squealing disc brakes
Checking the thickness of the brake discs
Removal and installation of the brake disc / brake caliper
Brake drum device
Removal and installation of a brake drum
Brake shoe device
Removal and installation of brake pads
Removal and installation of the wheel brake cylinder
Brake fluid
Removal of air from the brake system
Replacing the brake pipe / brake hose
Checking the brake booster
Checking the brake force regulator
Handbrake adjustment
Description of the ABS system
Checking the brake fluid level
Checking the thickness of the brake linings
Visual inspection of the brake lines
Brake Fluid Replacement
Brake fault diagnosis
Wheels and tires
Wheel and tire sizes
Wheel and tire designations
Wheel replacement
Tire break-in and storage
Wheel balancing
Anti-skid chains
Emergency wheel
Tire service
Tire Fault Diagnosis
Body
Exterior
General information about the body
Removal and installation of a forward bumper
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of a forward facing
Removal and installation of facing of a cover of a luggage compartment
Removal and installation of facing of a back door
Removal and installation of an external mirror / replacement of glass of a mirror
Removal and installation of a protective overlay
Removal and installation of facing of a wheel arch / protective facing of doors
Removal and installation of the lower lining of the side member
Removal and installation of a beam of the lock with forward facing
Cleaning the drainage hoses of the sliding roof panel
Removal and installation of a lining of a roof
Removal and installation of a handrail of a roof
Interior
Removal and installation of a cable drive of a cowl
Removal and installation of the luggage compartment lid lock
Removal and installation of the lock / case of the cylinder of the lock of a back door
Removal and installation of the lock cylinder
Central locking system
Removal and installation of an executive element of the lock of a forward door
Removal and installation of the gas-filled shock-absorber of a back door
Removal and installation / adjustment of the door
Removal and installation of window glass of a forward door
Removal and installation of an external guide of window glass
Removal and installation of a window regulator of a forward door
Removal and installation of the door lock
Removal and installation of the door handle
Removal and installation of internal door seal
Removal and installation / adjustment of the rear door
Removal and installation of a window regulator of a back door
Removal and installation of window glass of a back door
Replacing the outer window glass guide
Trunk lid adjustment
Rear door adjustment
Removal and installation of facing of a door
Rear door lining
Removal and installation of the average console
Visual inspection of seat belts
Heating system
General information about the heating system
Removal and installation of the suction pipe
Check, removal and installation of the heater fan
Removal and installation of the heating control unit
Removal and installation / adjustment of heating system rods
Removal and installation of the blower
Compressor V-Belt Tension
Removing and installing the dust and pollen filter
Diagnosis of malfunctions of the heating system
Electrical equipment
Power devices
Electrical system
Measuring instruments
Measurement technique
Installation of additional components of the electrical system
Removing and installing the battery
Accumulator charging
Spontaneous battery discharge
Battery maintenance
Electronic anti-theft system
Replacing fuses
Location of fuses / relays
Car generator
Removal and installation of the generator
Replacing / checking the brushes of the generator / relay-regulator
Diagnostics of malfunctions of the generator
Removal and installation of a starter
Starter Troubleshooting
Lighting system
Main headlight and turn signal lamp
Replacing incandescent bulbs in cars before 9/93
Removal and installation of a headlight / a lantern of the index of turn
Removal and installation of a reflector
Removal and installation of the executive engine of regulation of a tilt angle of a headlight
Removal and installation of fog lights
Headlight adjustment
Rear light device
Replacing light bulbs in cars since 10/93
Replacing incandescent interior lighting
Replacing taillight bulbs
Replacing the license plate light bulb
Equipment and devices
Removal and installation of the instrument panel
Removing and installing the tachometer shaft cover
Removing and installing the printed circuit board
Arrangement of terminals of the instrument panel
Checking the voltage regulator
Replacement of light diodes
Removal and installation of the steering column switch
Removal and installation of the case of the lock of a shaft of a steering wheel
Removal and installation of facing of a steering column
Removal and installation of the ignition lock cylinder / steering wheel shaft
Removal and installation of radio
Entering the radio code
Removing and installing the antenna
Removing and installing roof antenna
Wiper system
Replacing the rubber band of the wiper blade
Removal and installation / adjustment of windshield washer nozzles
Front wiper drive
Rear wiper drive
Window washer system
Headlight washer system
Checking / replacing the washer pump
Removal and installation of the electric motor of screen wipers
Checking / adjusting the angle of the wiper blades
Diagnosis of malfunctions of the rubber band of the wiper blade
Electrical circuits
Familiarity with the electrical circuit
Battery, ignition switch and starter
Alternator, starter, intake manifold preheater
Mono-Motronic system control unit
Instrument panel, universal indicating instrument switch
Instrument panel diagram
Interior, luggage compartment, glove box lights
Lanterns, parking lights, direction indicators
Turn signal lights, brake lights, parking lights
Heated rear window, horn
Glass cleaning and washing system
Diesel Direct Injection Control Unit
Heated and adjustable exterior mirrors
Power Window Thermal Fuse, Power Window Switch
Seat heating for the driver and passenger next to the driver
Central locking system
Passat B4
General information
User manual
Indicator lamps on the instrument cluster
Controls and instrumentation
On-board computer
Hood opening
Ignition switch or instrument and starter switch
Starting a gasoline engine
Diesel engine start
Starting the Engine with the Auxiliary Battery
Gear shift
Lighting and signaling
Lamp replacement
Glass cleaners and washers
Interior ventilation and heating
Doors and windows
Rear view mirrors
Steering wheel adjustment
Seat belts
Front and rear seats
Spare wheel
Lifting and towing a car
Maintenance
View of the engine compartment
Checking the engine oil level
Engine oil change
Checking the coolant level
Air filter
Checking the fluid level in the power steering reservoir
Checking the fluid level in the hydraulic brake reservoir
Checking the electrolyte level in the battery
Tire pressure
General requirements for car repair
Technical data
Car models
Vehicle weight
Vehicle dimensions
Petrol 8-valve engines
Petrol 16-valve engines
Diesel engines
Performance indicators of cars
Refueling tanks and used fuels and lubricants
Passport data of the car
Tightening torques for main threaded connections
8-valve engine
Engine repair
Removal and installation of the power unit
Engine disassembly
Engine Assembly
Cylinder block. Device Features
Check of a technical condition and repair of the block of cylinders
Crank mechanism device
Connecting rod and piston group
Crankshaft and flywheel
Gas distribution mechanism
Cylinder head
Removal and installation of a head of cylinders
Features of car engine repair «Passat GT 1.8 G60 Syncro»
Cooling and lubrication system
Features of the cooling system device
Coolant replacement
Removal, disassembly and assembly of the water pump
Checking the cooling system
Features of the lubrication system device
Removing, disassembling, checking the technical condition and assembling the oil pump
Maintenance of the lubrication system
Supply system
Engine power system «EZ»
Checking and adjusting the carburetor
Ignition system
Features of the engine ignition system device «EZ»
Removal and installation of the sensor-distributor ignition
Setting the ignition timing with a stroboscope
Engine ignition system «RP» release before 1993
Fuel injection «Mono-Jetronic»
Central fuel injection system «MONO-JETRONIC»
Checking and adjusting the fuel injection system «MONO-JETRONIC»
Fuel pump
System self-diagnosis
Checking the electrical circuits of the system
Engine idle check
Checking and adjusting the throttle valve opening
Checking the idle speed controller
Ignition retard control valve check
Checking the Fuel Pressure Regulator
Throttle position sensor test
Checking the coolant temperature sensor
Checking the intake air temperature sensor
Injector test
Injector Ballast Resistor Check
Checking the oxygen content sensor in the exhaust gases
Checking the intake manifold heater
Throttle damper test
Control system «Mono-Motronic»
Integrated engine management system «MONO-MOTRONIC»
Checking and adjusting the fuel injection control subsystem
Checking the forced idle system
Fuel pump
Self-diagnosis
Ignition Timing Control Subsystem
KSUD check «Motronic 2.9» engine «AEK» car «Passat 1.6»
Control system «Digifant»
Integrated engine management system «DIGIFANT»
Fuel injection control subsystem
Checking and adjusting the engine idle
Checking the idle speed solenoid valve
Checking the supply voltage of the idle and full load switches on vehicles with an engine «PB»
Checking and adjusting the idle switch on the engine «RV»
Checking and adjusting the full load switch on the engine «RV»
Checking the system of forced stroke and enrichment of the mixture at full throttle opening on the engine «RV»
Checking the fuel pressure regulator and residual fuel pressure
Fuel pump
Checking the air flow meter
Checking the coolant temperature sensor
Checking the intake air temperature sensor
Checking the injectors
Checking the starter injector on the engine «2E»
Checking the intake manifold heater
Checking the oxygen content sensor in the exhaust gases
Checking the electrical circuits of the KSUD «DIGIFANT»
Ignition Timing Control Subsystem
Adjustment of the fuel injection control subsystem of cars «Passat GT 1.8 G60 Syncro»
Scroll blower «G60» cars «Passat GT 1.8 G60 Syncro»
Control system «Simos»
Integrated engine management system «SIMOS»
Checking and adjusting idling
Checking and adjusting the throttle valve opening
Checking the fuel pressure in the system
Checking the idle switch
Checking the supply voltage of the mass air flow meter
Checking the coolant temperature sensor
Checking the intake air temperature sensor
Checking the idle speed controller
Checking injection nozzles
Checking the oxygen content sensor in the exhaust gases
Checking the camshaft angle sensor
Checking the supply voltage of the crankshaft speed sensor
Checking the vehicle speed sensor
Checking the supply voltage and connection to «weight» controller
Ignition Timing Control Subsystem
Spark plug
Check of work of a subsystem of management of an angle of an advancing of ignition (UOP)
16-valve engine
Engine repair
Features of the device of gasoline 16-valve engines
Crank mechanism
Features of the gas distribution mechanism
Features of the cylinder head device
Removal and installation of a head of cylinders
Disassembly and repair of the cylinder head
Removal and installation of a belt of a drive of camshafts
Main technical data of the engine «AAA»
Features of the repair of the engine cylinder head «AAA»
Cooling and lubrication system
Cooling system. general information
Removal and installation of the water pump
Disassembly and assembly of the water pump
Lubrication system
Removal and installation of the oil pump
Dismantling, checking the technical condition and assembling the oil pump
Checking the oil pressure in the lubrication system
Fuel injection «K-Jetronic»
Fuel injection system «K-Jetronic»
The design of some devices of the injection system
Work in different modes
The location of the elements of the fuel injection system «K-Jetronic» and ignition systems
Engine idle adjustment
Throttle valve adjustment
Throttle cable adjustment
Checking the performance of the fuel pump
Checking the air flow meter
Adjusting the position of the pressure plate of the air flow meter
Pressure test
Checking the fuel pressure in the system
Adjusting the fuel pressure in the system
Checking the control pressure on a cold engine
Checking the control pressure on a warm engine
Checking Residual Fuel Pressure
Checking the fuel pressure in the system when the engine is stopped
Checking and adjusting the throttle position sensor
Checking the tightness of the injectors and the uniformity of fuel injection
Checking the starter injector
Checking the thermal timer
Pilot pressure regulator test
Check of the valve of stabilization of idling
Checking the coolant temperature sensor
Checking the enrichment of the mixture during acceleration with a cold engine
Checking the fuel cut during engine braking
Removal and installation of the block of the batcher-distributor with an air flow meter
Removal and installation of nozzles
Engine ignition system «KR»
Removal and installation of the distributor of ignition
Setting the initial ignition timing
Checking automatic ignition timing
Checking and adjusting the fuel injection system «KE-Jetronic» engine «PL»
Possible malfunctions of the fuel injection system «KE-Jetronic» engine «PL»
Control system «KE-Motronic»
Integrated engine management system «KE-Motronic»
Fuel injection control subsystem
Checking and adjusting the fuel injection control subsystem
Idle speed check
Adjusting the CO content in the exhaust gases
Checking and adjusting the idle switch
Checking and adjusting the full load switch
Air flow meter potentiometer adjustment
Adjusting the position of the pressure plate of the air flow meter
Checking the idle speed controller
Checking the supply voltage of the heating element of the oxygen content sensor in the exhaust gases
Checking the enrichment of the mixture
Checking the fuel cut at forced idle
Checking the canister solenoid shut-off valve
Checking the fuel pressure in the system
Self-diagnosis system
Checking and adjusting the subsystem
Fuel system of the engine «9A»
KSUD connection diagram «KE-Motronic» engine «9A»
Adjustment of the fuel injection control subsystem KSUD «Motronic» engine «AAA»
Possible malfunctions of the fuel injection control subsystem KSUD «Motronic» engine «AAA»
Control system «Digifant»
Integrated engine management system «Digifant 3.0/3.2»
Checking and adjusting the main components of the subsystem
Checking and adjusting the idle switch
Ignition Timing Control Subsystem
Check of work of a subsystem of management of an angle of an advancing of ignition
Diesel engine
Engine repair
Diesel engines. General information
Removal and installation of the engine
Engine disassembly
Engine Assembly
Cylinder block
Features of the device of the connecting rod and piston group
Checking the technical condition of the connecting rod and piston group
Features of the device of the crankshaft and flywheel
Features of the gas distribution mechanism
Features of the cylinder head device
Removal and installation of a head of cylinders
Dismantling, assembling, checking the technical condition and repair of the cylinder head
Removing and installing the camshaft drive belt
Cooling and lubrication system
Features of the cooling system device
Removal and installation of the water pump
Features of the lubrication system device
Removal and installation of the oil pump
Dismantling, checking the technical condition and assembling the oil pump
Maintenance of the lubrication system
Exhaust gas exhaust system
Power and control system
Features of the engine power supply system «1Y», «RA», «SB», «AAZ»
Power system with mechanical drive motors «1Y», «RA», «SB», «AAZ»
Removal and installation of injection pump
Fuel Injection Advance Adjustment
Diesel idle adjustment
Diesel Fast Idle Adjustment «AAZ»
Adjusting the maximum engine speed without load
Residual fuel adjustment
Removal and installation of nozzles
Dismantling and checking the technical condition of the injectors
Checking the operation of the nozzle needle valve
Checking and adjusting the injection start pressure of the injectors
Draining sediment from the fuel filter
Bleeding air from the fuel system
Diesel preheating system
Diesel power system malfunctions
Turbocharging system
Turbocharging system — general information
Removal and installation of a turbocharger
Boost pressure check
Features of the device of the turbocharging system
Operating principle of variable geometry turbocharger
Removal and installation of a turbocharger on the engine «AFN»
Exhaust Gas Recirculation Solenoid Check
Boost pressure check
Digital control system
Digital engine management system «1Z» AND «AFN»
The device and principle of operation of the digital diesel control system
Checking and adjusting the TsSU
Removal and installation of nozzles
Checking the injection start pressure of the injectors
Injector leak test
Checking the air flow meter and intake air temperature sensor
Checking the fuel temperature sensor
Checking the injection advance slider potentiometer
Checking the speed controller
Checking the electrical circuits of the central control room
Checking the voltage in the preheating system
Checking spark plugs
Transmission
Clutch
Clutch — device features
Removal and installation of clutch
Mechanical clutch drive
Checking clutch operation
Removing and installing clutch servo spring
Removing and installing clutch master cylinder
Removal and installation of the clutch slave cylinder
Pumping the clutch hydraulic drive
Manual gearbox
Features of the manual transmission device
Removal and installation of a transmission
Gearbox disassembly
Transmission input shaft
Input shaft assembly
Determination of the thickness of the adjusting ring of the input shaft bearings
Gearbox output shaft
Output shaft assembly
Selection of an adjusting ring for adjusting the preload of the output shaft bearings
Replacement of bearings of an axis of an intermediate gear wheel of a backing
Differential
Selection of an adjusting ring for differential bearings
Gearbox Assembly
Removal and installation of cables of switching and a choice of transfers
Adjustment of a drive of a gear change
Hydromechanical gearbox
Features of the hydromechanical gearbox type 096
Features of the hydromechanical gearbox type 01
Removal and installation of automatic transmission type 096
Checking the oil level in the gearbox
Changing the oil in the gearbox
Checking the oil level in the differential case
Checking the oil level and changing the oil in the crankcase of the gearbox type 096 CNK, 096 CRR, 096 CSK, 096 CNP And type 01M
Checking the oil level in the differential case
Replacing the strainer
Checking the gearbox control drive
Check of blocking of removal of a key of the switch of devices and a starter
Disassembly and assembly of the gearbox control drive
Adjustment of the control cable of the gearbox type 096 CNK, 096 CRR, 096 CSK, 096 CNP and type 01M
Differential
Wiring diagram of the hydromechanical gearbox control system
Adjustment of the electromagnetic stopper of the selector lever lock
Removal, installation and adjustment of a cable of blocking of the lever of the selector
Replacing the differential output shaft seals
Adjustment of the bearings of the main gear drive shaft
Adjustment of bearings of a driving gear of a drive of the main transfer
Adjustment of the moment of resistance to rotation of the differential
Front wheel drive
Features of the front wheel drive device
Removal and installation of shafts of a drive of forward wheels
Replacement of protective covers of external hinges of shafts of a drive of forward wheels
Replacement of protective covers of internal hinges of shafts of a drive of forward wheels
Disassembly and assembly of roller joints of equal angular velocities
Transmission «Syncro» cars «Passat GT 1.8 G60 Syncro»
Chassis
Car suspension
Features of the front suspension device
Removal and installation of telescopic struts and front suspension springs
Removal and installation of front suspension arms
Replacing the silent blocks of the front suspension arms
Front wheel alignment
Front wheel hubs
Features of the rear suspension device
Removing and installing shock absorber with rear suspension spring
Replacing the pneumatic shock absorbers of the rear suspension
Removal and installation of the block of management of the compressor of a regulator of provision of a body
Replacing the silent blocks of the rear suspension beam
Removal and installation of naves of back wheels
Adjustment of a backlash in bearings of naves of back wheels
Wheels and tires
Rear suspension of cars «Passat GT 1.8 G60 Syncro»
Steering
Features of the steering device
Removal and installation of a steering shaft
Removal and installation of the steering mechanism
Mechanical steering
Power steering
Brake system
Features of the brake system
Brake drive
Anti-Lock Braking System
The principle of operation of the brake system
Brake system operation
Checking the electrical circuits of the brake system
Precautions for vehicles with ABS
Removal and installation of the node of the electronic control unit with the valve body
Removal and installation of sensors of speed of rotation of forward wheels
Removal of air from a hydraulic drive of brakes
Front wheel brakes
Replacing the brake pads of the front wheels on cars manufactured since July 1995 with an engine «AVE»
Removal and installation of the brake mechanism of forward wheels
Disassembly and assembly of the brake mechanism of the front wheels
Removal and installation of a brake disk of forward wheels
Rear wheel drum brakes
Rear wheel disc brakes
Brake drive
Parking brake system
Body
Body elements
Features of the body device
Paintwork care
Lubrication of moving parts of doors and hood
Removal and installation of the body
Reference dimensions of body openings for Volkswagen sedans «Passat» release 1988-93
Reference dimensions of body openings of Volkswagen station wagons «Passat» release 1988-93
Removal and installation of facing of a radiator
Removal and installation of a forward bumper
Front and rear bumper repair
Bumper welding
Removal and installation of optical elements of headlights and front direction indicators
Removal and installation of front fenders
Removal and installation of front doors
Removal and installation of an upholstery of forward and back doors
Removal and installation of windows
Removal and installation of locks of forward doors
Removal and installation of rear doors
Removal and installation of wind and rear windows
Rear window heating element repair
Removal and installation of the glued internal rear-view mirror
Removal and installation of a cover of a luggage compartment
Removal and installation of a back of a door of cars with a body «station wagon»
Removal and installation of a back bumper
Removal and installation of the instrument panel
Removal and installation of the heater electric fan
Removal and installation of a heater radiator
Electrical equipment
Power devices
Electrical equipment. Device Features
Accumulator battery
Generator
Removal and installation of the generator
Alternator Drive Belt Tension Adjustment
Disassembly and assembly of the generator
Starter
Removal and installation of a starter
Disassembly and assembly of the starter
Starter check
Lighting and appliances
Lighting devices
Light and sound signaling devices
Headlight adjustment
Removal and installation of headlights
Removal and installation of fog lights
On-board computer
Removal and installation of a combination of devices
Ignition switch or instrument and starter switch
Outdoor light switch
Switch for headlights, direction indicators and parking lights
Windscreen wiper and washer switch
Windshield wiper and washer
Cleaner and washer of the rear window of cars with a body «station wagon»
Removal and installation of a cleaner of a windscreen
Removal and installation of a cleaner of back glass
Headlight washer
Rear window heating element
Clock with digital display
Electric windows
Interior heater electric fan
Central door locking system
Electric outside rear-view mirrors
Onboard electrical circuit
Mounting block
Electrical circuits
Car wiring diagram «Passat» with engine «RV»
Symbols on electrical equipment diagrams
Symbols used on wiring diagrams
Schemes of electrical equipment of cars with an engine «EZ»
Schemes of electrical equipment of cars with an engine «RP» and injection system «Mono-Jetromc»
Schemes of electrical equipment of cars with an engine «2E» with KSUD «Digifant»
Schemes of electrical equipment of cars with an engine «KR»
Schemes of electrical equipment of cars with an engine «9A» with KSUD «KE-Motronic»
Wiring diagrams for cars with ABS brakes
Schemes of electrical equipment of vehicles with turbocharger diesel
KSUD connection diagram «Digifant 3.0/3.2» vehicles with engine «AVR»
KSUD connection diagram «Simos» vehicles with engine «AGG»
Airbag Wiring Diagram
Passat B5
General information
User manual
Controls, instruments and equipment
Car keys
Doors, central locking
Trunk lid (back door of the station wagon)
Remote radio control of locks
Power window control
Rear view mirrors
Seat belts
Inflatable airbag system
Seat head restraints
Front seats
Front seats (manual adjustment)
Front seats (electrical adjustment)
Driver's seat memory
Storing seat and exterior mirror settings for forward movement
Calling up seat and exterior mirror settings for forward driving
Rear bench seat (Sedan)
Rear bench seat (station wagon)
Cover for long luggage
Seat armrests
Luggage compartment
Luggage shelf (station wagon)
Parking brake
Manual Transmission
Automatic transmission
Positions of the selector of an automatic transmission
Sequential automatic transmission
Positions of the selector of the sequential automatic transmission
Adjustable steering column
Egnition lock
Engine start
Engine stop
Control devices
Pilot lamps
Automatic control system with multifunctional pointer
Violations of paramount importance (red pictograms)
Violations of minor importance (yellow pictograms)
Navigation system
Breakers and switches
Steering column switch for direction indicators and headlights
Cruise control
Windshield wipers and washers
Heating and ventilation
Heating and ventilation air nozzles
Climate control
Air conditioning nozzles
Climate control «Climatronic»
Installation Air Nozzles «Climatronic»
Sliding sunroof panel
Interior lighting
Storage box
Power outlets in luggage compartment
How to drive economically
Vehicle braking
Anti-Lock Braking System
Traction control (reduced engine torque, ASR)
Anti-slip system with wheel braking (EDS)
Electronic stabilization system (ESP)
Power steering
Fuel (gasoline engines)
Fuel (diesel engines)
Work in the engine compartment
Opening the hood of the engine compartment
Fundamentals of safe car operation
Vehicle performance characteristics
Weekly checks
Starting the engine from an external source (another car)
If the engine does not start and the starter does not work
If the engine does not start even though the starter is working properly
Towing a car
Wheel replacement
Checking the tightness of connections
Weekly checkpoints
Engine oil level
Coolant level
Checking the wiper blades
Washer fluid level
Brake fluid level
Checking the electrical system
Checking the battery
Tires and tire pressure check
Types of tread wear
Maintenance
General maintenance information
Vehicle Specifications
Car service interval
Vehicle identification
Types of motor oils
Changing the oil and oil filter
Exhaust system check
Engine cooling system
Cooling system fan
Spark plug
Replacing spark plugs
Draining water from the fuel filter (diesel engines)
Fuel filter replacement (diesel engines)
Checking the tightness of the hoses and fluid leakage
Replacing the air filter element
Checking the condition of the poly V-belt
V-belts
Measuring the wear of toothed belts on diesel engines
Gearbox/final gear
Checking the protective cover of the drive shaft
Visual inspection of the gearbox for tightness
Checking the oil level in a manual transmission
Checking the oil in the main gear of automatic transmissions
Checking/replacing the oil level in an automatic transmission
Checking the front suspension and steering
Checking the dust covers of the front suspension joints
Shock absorber check
Radiator check
Checking electrical circuits
Brake fluid
Checking the brake fluid level
Brake Fluid Replacement
Checking the front brake pads
Checking the rear brake pads
Checking the brake hoses
Checking the fluid level in the power steering
Replacing the dust filter
Battery maintenance
Door hinge lubrication
Washer maintenance
Wiper blades
Checking the initial position of the wiper arm
Checking the Angle of the Wiper Arm
Replacing the battery in the remote control key
Resetting the Service indicator
Power unit
Engine repair
Engine Specifications
Engine device
Lower mudguard of the engine compartment
Removal and installation of a gear belt of petrol engines
Removal and installation of a head of the block of cylinders of engines 1,6-I and 1,8-I
Checking hydraulic valve lifters
Cylinder head repair
Gas distribution mechanism drive
Removal and installation of a head of the block of cylinders of the engine 2,3-I-VR5
Removal and installation of a gear belt of the diesel engine
Removal and installation of a head of the block of cylinders of the diesel engine
Removal and installation of a gear belt of the engine 2,8-I-V6
Removal and installation of a head of the block of cylinders of the engine 2,8-I-V6
Checking compression in the engine cylinders
Checking the engine with a vacuum gauge
Removal and installation of poly V-belt
General recommendations for engine oils
Engine oil circuit
Checking the oil pressure and oil pressure sensor
Removal and installation of the oil pallet
Starting the engine after a major overhaul
The main malfunctions when starting the engine
The main malfunctions of the lubrication system
Cooling system
Engine cooling system device
Adding coolant
The composition of the coolant mixture
Coolant replacement
Removal and installation of the thermostat
Removal and installation of a radiator
Water pump (engines 1.8-I and 1.6-I ADP)
Coolant hoses
Cooling system malfunctions
Fuel system (petrol)
Fuel system device
Fuel pump/fuel level sensor
Fuel filter on models with petrol engines
Accelerator cable adjustment (Gas engine)
Additional adjustment (Automatic transmission)
Fuel system (diesel)
Technical data of diesel engine management systems
Diesel fuel system device
Checking the diesel engine preheating system
Checking glow plugs
Removal and installation of glow plugs
Fuel heating system
Removal and installation of fuel injectors
The main malfunctions of the engine management system
Engine management
Technical data of engine management systems
Operation of the engine management system
Checking the fuel injection system
Sensors and actuators of the engine management system
Ignition system
Direct ignition system (except 1.6-I ADP engines)
Ignition system with ignition distributor (1.6-I ADP engine)
Removal and installation of the distributor of ignition
Fuel line and fuel injectors
Checking fuel injectors (4-cylinder petrol engine)
Checking the voltage supply to the fuel injectors
Checking the spray pattern and fuel injector tightness
The main malfunctions of the engine management system
Exhaust system
Exhaust system device
Exhaust system catalyst
Operation of vehicles with a catalyst
Diesel engine turbocharger
Silencer replacement
Oxygen sensor
Transmission
Clutch
Clutch device
Clutch Hydraulic Device
Clutch disc — removal, inspection and installation
Bleeding the hydraulic clutch
Basic clutch malfunctions
Car gearbox
General information about manual transmission
Removing the gearbox
Installing the gearbox
Gearbox repair
Dedicated automatic transmission
Adjustment of the gearshift mechanism of a special automatic transmission
Fully automatic transmission
Shift Cable Adjustment for Fully Automatic Transmission
Transmission of four-wheel drive cars
Drive shafts
Removal and installation of a power shaft
Grease for driveshaft joints
Replacement of the internal constant velocity joint
Replacement of the outer constant velocity joint
Disassembly of the outer constant velocity joint
Drive shaft failures
Chassis
Car suspension
Front suspension device
Front suspension shock absorber
Front suspension strut repair
Rear suspension device
Unscrewing the upper mounting of the rear shock absorber
Removal and installation of the shock absorber and rear suspension spring
Removal and installation of bearings/hubs of back wheels
Suspension strut of the rear suspension of all-wheel drive vehicles
Rear suspension strut repair
Checking the rear shock absorber
Shock Absorber Disposal
Wheels and tires
General information about wheels and tires
Tire instructions
Tire valve check
Wheel swap
Rims and tires
Spare wheel
Wheel replacement
Secret bolts for fixing wheels
Anti-skid chains
Vehicle lifting
Steering
Steering device
Removal and installation of an airbag
Removal and installation of a steering wheel
Transverse steering rod
Power steering pump installation
Front wheel alignment
The main malfunctions of the suspension and steering
Brake system
Specifications of the brake system
The device and operation of the brake system
ABS/EBV/EDS/ASR/ESP systems
Checking the vacuum brake booster
Replacing the front brake pads
Replacing the front brake pads on a Lucas caliper
Replacing the rear brake pads
Checking the brake disc
Removal and installation of a brake disk
Bleeding the hydraulic brake system
Brake lines and hoses
Brake Hose Replacement
Stoplight switch
Hand brake lever
Handbrake adjustment
Handbrake cable for front wheel drive vehicles
Handbrake cable for four-wheel drive vehicles
The main malfunctions of the brakes
Body
Exterior (external elements)
General information about body repair
Car body care
Caring for upholstery and rugs
Repair of minor body damage
Repair of severe damage to the body
Front cross panel
Installing the front transverse panel in the service position
Removing the front bumper
Removing the hood lock lever
Bumper Side Guide Bracket Adjustment
Rear bumper
Front fender
Facing of a niche of a forward wheel
Air intake grille
Removal and installation of a cowl
Hood adjustment
Radiator grille
Bonnet release cable
Disconnecting the hood release cable
Hood lock
Exterior rearview mirror/mirror glass
Exterior mirror housing
Roof railing/curb
Body side trim
Replacing the rubber bands of the wiper blades
Windshield washer nozzles
Wiper arms
Interior (internal elements)
Interior door trim
Differences when removing the upholstery of the right front door
Door mechanism control unit
Door seal
Side trim of the luggage compartment of Sedan models
Side trim luggage compartment models Station wagon
Rear luggage compartment trim on Sedan models
Trunk lid upholstery
Tailgate upholstery
Luggage compartment floor covering on Wagon models
Interior rear view mirror
Center console
Front ashtray
Rear ashtray
Decorative lever trim (Automatic transmission)
Decorative trims under the radio
Dashboard lower trim on driver's side
Glove box
Interior decorative trim of the exterior rearview mirror
Ceiling handle
Sun visors
Thresholds
Windshield and rear window
Front seats
Removing the head restraint
Side airbags
Back seat
Left rear seat back
Carpet covering
Interior decoration elements
Doors and covers
Trunk lid
Trunk lock
Trunk lid lock cylinder
Tailgate lock on Wagon models
Rear door lock cylinder
Rear door lock cylinder bracket
Front door
Front door lock cylinder
External door opening handle
Door lock
Manual lowering of the door glass
Door glass
Door bracket
Ventilation and heating
The device of the heating and ventilation system
Ventilation nozzles
Heater control panel
Central damper lever
Heater control unit
Heater resistor block
Heater and air conditioner control unit
Air conditioning compressor
Heater fan
Electrical equipment
Power devices
Battery Care Rules
Battery check
Accumulator charging
Removing and installing the battery
Charging system
Generator device
Replacement of generator brushes and voltage regulator
Engine start system
Removal and installation of starter
Starter pull relay
Main generator malfunctions
The main malfunctions of the starter
Lighting and appliances
Incandescent lamps
Vehicle electrical device
Electrical circuits
Open Circuit Detection
Fuse box location
Replacing exterior light bulbs
Replacing interior light bulbs
External lighting devices
Headlight range control motor
Headlight adjustment
Discharge lamps for dipped beam headlights
Instrument cluster
Multifunction steering column switches
Removing switches
Removal and installation of the radio receiver
High frequency loudspeakers
Low frequency loudspeakers
External radio antenna
Checking the rear window heater
Windshield wiper motor
Rear window wiper motor
Washer pump
Central locking system
Electrical circuits
Explanations for electrical diagrams
Location of relays and fuses
Symbols on electrical diagrams
Symbols of elements on electrical diagrams
Battery, ignition lock and overload relay for X-contact
Diagnostic connector, alternator lamps and instrument cluster
Instrument cluster, clock, odometer and lighting buzzer
Control lamps of the brake system, outdoor lighting
Instrument cluster, indicator, air temperature sensor
Handbrake lamp and washer fluid level sensor
Turn signal switch, light signaling (left-hand side)
Switch for light signaling and lamps (Right side)
Stoplight switch, brake lights and rear turn signals
Radio connector, cigarette lighter and instrument lighting
Dashboard illumination intensity control
Switch and glove box lighting
Fog lights, switch and tail lights
Dual tone horn and signal relay
Air recirculation control switch and motors
Rear window switch and heater
Windshield wipers, rear window wipers, wiper relay
Wiper switch and washer pump
Battery, starter and alternator
Motronic engine management system, alarm
Throttle, knock sensors, air temperature (Motronic engine)
Motronic engine, crankshaft speed and knock sensors
Motronic engine, air flow meter, fuel pump relay
Oxygen sensor, camshaft rotation valve (Motronic)
Oil pressure sensors, speed sensors, fuel system
Control lamps for oil pressure, temperature, buzzer
Battery, starter, alternator and glow plugs
Forced downshift, accelerator sensor
Air flow meter, engine stop valve
Accelerator and clutch pedal position sensors
Relay and glow plugs, oil pressure sensor
Oil pressure sensor, fuel system, relay
Instrument cluster
Passat B6
General information
User manual
Identification data
Replacing the battery in the remote control
Remote control of locks
Unlocking a separate door
Doors, central locking
Central locking key
Trunk lid
Security alarm system
Power window control
Power window operation with ignition on
Sliding sunroof panel
Fan drive from solar panels
Opening the hood of the engine compartment
Instrument panel and controls
Control and signal lamps
Breakers and switches
Steering column switch for direction indicators and headlights
Windshield wipers and washers
Interior lighting
Rear view mirrors
Coasters
Cigarette lighter
Boxes for things
Fuel filler flap
Trunk
Luggage rack
Roof rack
Spare wheel
On-board tool and jack
Front seats
Seat adjustment
Front seats (electrical adjustment)
Headrests
Armrests
Rear seats
Loading the Luggage Cover
Heating and ventilation
Heating, ventilation and air conditioning systems (HVAC)
Climate control
Engine start
Manual Transmission
Four and five speed automatic transmissions
Electronic parking brake
Anti-skid system
Parking warning alarm
Maintenance
Engine oil
Engine oil level control
Fuel for car
Diesel fuel
Checking the coolant level
Filling the washer fluid reservoir
Adjusting the position of the windshield washer nozzles
Replacing wiper blades
Brake Fluid Replacement
Accumulator battery
Car wheels and tires
Wheel replacement
Using the auxiliary battery when starting the engine
Towing a car
Filter replacement intervals
Timing belt replacement intervals
Service intervals for petrol and diesel engines
Vehicle specification
Technical terms, their abbreviation and interpretation
Petrol engine 1.6L
Engine repair
General recommendations for the maintenance and repair of engines
Removal and installation of the top casing of the engine
Checking the camshaft timing belt
Removing the engine
Engine installation
Engine disassembly and assembly
Removal and installation of poly V-belt
Removal and installation of a cover of the distributive mechanism
Replacing the crankshaft oil seal on the side of the belt pulley
Tightening method of the belt drive sprocket fixing bolt
Disassembly and assembly of pistons and connecting rod
Cylinder head
Checking the valve timing
Valve timing adjustment
Removal and installation of a case of camshafts
Removal and installation of a head of the block of cylinders
Compression test
Valve mechanism repair
Checking the valve guides
Replacement of valve stem seals
Cooling and lubrication system
Removal and installation of the oil pallet
Removal and installation of the oil pump
Removal and installation of elements of the cooling system
Draining and filling the coolant
Removal and installation of a radiator
Removal and installation of the water pump
Fuel injection system
Repair of the fuel injection system
Checking the tightness of the vacuum reservoir in the intake manifold
Removal and installation of the air filter
Removal and installation of nozzles
Checking the preheating of the intake air
Petrol engine 2.0L
Engine repair
Compression test
Removal and installation of the engine
Timing belt installation
Valve drive
Removal and installation of camshafts
Replacement of valve stem seals (with cylinder head installed)
Replacing the exhaust camshaft seal
Removal and installation of the phase shifter
Removal and installation of the valve of 1 regulator of phases of gas distribution
Removal and installation of poly V-belt
Replacing the crankshaft oil seal on the side of the belt pulley
Removal and installation of the sealing flange on the side of the belt pulley
Removal and installation of the crankshaft flange on the flywheel side
Removal and installation of a flywheel
Removal and installation of a conducted disk
Crankshaft
Pistons and connecting rods
Checking pistons, piston rings and cylinder diameter
Removal and installation of a cover of a head of the block of cylinders
Removing the cylinder head
Installing the cylinder head
Characteristics of 2.0 liter gasoline engines
Lubrication system
Checking the oil pressure and oil pressure sensor
Removal and installation of the holder of the oil filter
Emptying the oil filter housing
Oil pan removal and installation — BLX, BLY, BLR engines
Removing the oil pump with balance shaft drive
Installing and adjusting an oil pump with a balancer shaft drive
Cooling system
Checking the cooling system for leaks
Coolant drain
Coolant filling
Removal and installation of the water pump
Removal and installation of a pipe of giving of a cooling liquid
Curve Controlled Cooling System (BLX, BLY, BLR engines)
Removal and installation of the thermostat of the engine cooling system according to the algorithm
Removing and installing radiator fan and radiator fan 2 V177
Removing and installing the radiator
Fuel and exhaust systems
Removing fuel from the fuel tank when the fuel tank is more than 3 / 4 full
Pumping out fuel from a fuel tank filled less than 3/4
Function and power check
Fuel pressure check
Residual pressure test
Performance check
Electronic engine power control (electronic accelerator drive)
Removing and installing the accelerator pedal assembly
The principle of operation of the absorber
Fuel tank bleed check
General instructions for the injection system
Removal and installation of an inlet collector
Removal and installation of nozzles
Intake manifold switching test
Removal and installation of a final collector
Removal and installation of a reception pipe with the catalyst
Exhaust gas recirculation device (motors BLR, BLX, BVX, BVY)
General instructions for the ignition system
Removal and installation of ignition coils with output stages
Diesel engine 2.0L
Engine repair
Removing the engine
Removal and installation of poly V-belt
Replacing the crankshaft oil seal on the side of the belt pulley
Removal and installation of the sealing flange on the side of the belt pulley
Replacing the crankshaft oil seal on the flywheel side
Removal and installation of the engine shaft speed sensor
Removing and fitting the flywheel needle bearing
Piston and connecting rod
Cylinder head
Removal and installation of a cover of a head of the block of cylinders
Removal, installation and tension of a toothed belt
Removal and installation of a head of the block of cylinders
Valve mechanism
Removal and installation of roller levers of final valves
Removal and installation of roller levers of inlet valves
Checking the valve guides
Replacing valve stem seals
Removal and installation of camshafts
Removal and installation of an epiploon of a camshaft
Characteristics of a 1.6-liter gasoline engine
Characteristics of 2.0 liter diesel engines
Cooling and lubrication system
Engine oil
Removal and installation of the oil pump (with balance shaft module with chain drive)
Removal and installation of the oil pallet
Checking the oil pressure and oil pressure sensor
Checking the cooling system for leaks
Checking the pressure reducing valve in the expansion tank cap
Checking the oil cooler for leaks
Draining and filling the coolant
Removal and installation of fans with brackets
Removal and installation of the water pump
Removal and installation of the thermostat
Fuel and exhaust systems
Fuel pressure test
Removal and installation of the tandem pump
Fuel pump check
Removal and installation of the fuel supply module
Removal and installation of the fuel level sensor
Removing the fuel tank
Installation of hose connections with nipple connectors of the pressurization system
Safety measures when repairing a direct fuel injection system
Removal and installation of cable connection pump-injectors and glow plugs
Removal and installation of the pump nozzle
Replacing the O-rings of the unit injector
Free exhaust system installation
Exhaust gas recirculation system
Checking glow plugs
Removing, installing, checking ceramic glow plugs
Transmission
Clutch
Clutch differences
Removing air from the clutch assembly
Removing and installing the support bracket
Removing and installing the servo spring
Removal and installation of the clutch pedal
Removing and installing the clutch master cylinder
Hydraulic clutch system
Removal and installation of the clutch slave cylinder
Installing the gear shift actuator
Removing and installing a Sachs clutch
Removal and installation of LuK clutch
Checking the clutch drive
Gear shift drive repair
Removal and installation of a cuff with the button of switching and a noise isolation
Removal and installation of control cables — parts and assemblies
Removal and installation of the gear change drive
Adjustment of a drive of a drive of a gear change
Troubleshooting, their causes and solutions
Letter designations, conformity of units and filling volumes
Mechanical gearbox
Gearbox marking
Checking and filling transmission oil
Removing the gearbox
Installing the gearbox
Adjustment of a drive of a gear change
Automatic gearbox
Gearbox Description
Gearbox marking
Planetary gear and final drive
Checking the ATF level and topping up
Draining and filling ATF
Electrical / electronic components and their installation location
Removing the gearbox control lever with selector
Removal and installation of a cable of the selector of KP
Checking the selector lever cable
Selector lever cable adjustment
Removing and installing the handle
Checking the gearshift mechanism
Removing gearbox, Passat 2006 from «external» ATF cooling water cooler
Gearbox installation, Passat 2006 with «external» ATF cooling radiator
Drive shafts
Removing the flange shaft seal
Fitting the flanged shaft seal
Removal and installation of a power shaft
Removing the outer CV joint
Checking the outer CV joint
Checking the inner CV joint
Checking the performance of the SHRUS
Drive shaft with typoid joint AAR3300i for 6-speed automatic transmission 09M (four-wheel drive)
Chassis
Wheels and tires
General information on wheels and tires
Specification for wheel and tire conversions
Tire speed indices
Compound disks
Tire wear and mileage
High speed tire wear
Tire service
Evenly worn tires
Tread Height Measurement
Unilateral tire wear
Diagonal uneven wear
Tire rolling noise
Wheel balancing
Radial and lateral runout of wheels and tires
Minimization of mounted wheels
Side slip of the car
Side slip elimination
Tire damage
Radial tire design
Loss of tire pressure
Tire damage due to tire fitting errors (installation damage)
Tire sidewall marking
Wheel swap
General provisions for wheel alignment (RUUK) Passat car
Front axle camber correction
Rear axle camber adjustment
Adjustment of a convergence of wheels of a rear axle
Adjustment of a convergence of wheels of a forward axis
Passat wheel information from model year 2006
Check condition, wear pattern, pressure, tire tread depth
Car suspension
Checking the front suspension joint
Removal and installation of the front subframe
Removal and installation of the hinge of a forward suspension bracket
Removal and installation of the front suspension stabilizer
Removal and installation of the wheel bearing module
Removal and installation of a forward amortization rack
Rear wheel suspension repair (front-wheel drive)
Rear subframe repair
Replacing the body level sensor in the car
Removal and installation of the rear upper transverse arm
Removal and installation of the rear lower transverse arm
Removal and installation of back cross-section draft
Removal and installation of the rear trailing arm with support bracket
Repair of the rear trailing arm
Removal and installation of a back screw spring
Front suspension tightening torques
Rear suspension tightening torques (front-wheel drive)
Steering
General information about the steering mechanism
Steering wheel play check
Steering wheel force check
Bleeding the power steering system
Checking tie rod ends and seals
Checking constant velocity joints
Checking the tightness of the power steering
Checking the level of hydraulic booster fluid
Removal and installation of a steering wheel
Removal and installation of a steering column
Servicing and transporting the steering column
Checking the steering column for damage
Removing and installing the support bracket
Removal and installation of a damper
Removal and installation of the steering mechanism
Removal and installation of anther
Removing the tie rod
Tie rod installation
Tightening torques for steering parts
Possible malfunctions, their causes and remedies (steering with power steering)
Brake system
General information about the brake system
Electronic elements of the brake system
Brake components
Brake Specifications
Pressure leak test
Checking the brake fluid level
Brake Fluid Replacement
Visual inspection of the brake system for leaks and damage
Checking the thickness of the front and rear brake pads
Removal and installation of brake pads
Removal and installation of the electromechanical parking brake control unit
Removal and installation of a drive of a parking brake
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal and installation of the piston for brake caliper FN 3
Removal and installation of the brake caliper piston
Removing and installing brake light switch F
Removal and installation of the main brake cylinder
Removal and installation of the brake booster
Repair of brake pipelines
General information on anti-lock braking system
Removal and installation of the speed sensor on the front axle
Removal and installation of the speed sensor on the rear axle
Removal and installation of the speed sensor on the rear axle (four-wheel drive)
Removal and installation of the low pressure sensor in the brake booster
Possible malfunctions, their causes and remedies
Body
Exterior (external elements)
Design features
Removal and installation of facing of a forward bumper
Removal and installation of facing of a back bumper
Removal and installation of a forward fender liner
Removal and installation of a back fender liner
Removal and installation of mirror glass
Removal and installation of the side mirror housing
Removal and installation of an overlay
Removal and installation of the lateral indicator of turn
Removal and installation of a rear-view mirror
Removal and installation of a radiator grille
Removing and installing the emblem
Removing and installing license plate holder
Removal and installation of roof rails
Removing the bracket
Installing the holder
Installing a new bracket
Removal and installation of a waterproof lining
Hood adjustment
Hood lock adjustment
Trunk lid adjustment
Lock shackle adjustment
Door adjustment
Removing the windshield
Electrical equipment
Power devices
General information about electrical equipment
Searching for a short circuit
Accumulator battery
Generator and its drive belt
Removal and installation of a three-phase generator (1.6 l engine with injection)
Removing and installing poly V-belt pulley without freewheel mechanism
Removal and installation of a poly-V-belt pulley with a freewheel mechanism, manufacturer Bosch
Removal and installation of the voltage regulator, manufacturer Bosch
Removal and installation of a starter (engine 1.6 l FSI, automatic transmission)
Removal and installation of a starter (1.6 l engine with injection, manual transmission)
Removal and installation of a starter (2.0l TDI engine, DSG gearbox)
Lighting and appliances
Removal and installation of a headlight
Headlight adjustment
Replacing the Low Beam Bulb
High Beam Bulb Replacement
Parking light bulb replacement
Removal and installation of the headlight range control servo (Hella manufacturer)
Removal and installation of the headlight range control servo (manufacturer Valeo)
Headlight adjustment check
Checking the headlight alignment using the alignment screen without adjustment line 15°
Headlight adjustment with gas discharge lamps
Headlight adjustment with halogen lamps
Main headlights with gas discharge lamps
Replacing the discharge lamp
Removal and installation of forward lanterns of the index of turn
Removal and installation of illumination in a lateral mirror for simplification of landing
Removal and installation of a back lantern in a body sidewall
Removing and installing license plate lights (sedan)
Removal and installation of license plate lighting, station wagon (Variant)
Removal and installation of the contact switch of a cowl
Removal and installation of the light switch
Removal and installation of the headlight range control and the button backlight control and instrument panel
Removal and installation of a control lamp of deactivation of a pillow of safety of the forward passenger
Removal and installation of illumination of a glove box
Removal and installation of a control lamp of function SAFE of the central lock
Replacement of a plafond of illumination of a forward part of salon
Removal and installation of switches of the central console
Removal and installation of the main fuse box
Removal and installation of the switching block in the left part of a motor compartment
Removal and installation of the relay box on the left side of the front panel
General instructions for car electrical repairs
CAN bus wiring repair
Broken wire with repair in two places
Repair of contacts in connector housings
Mechanical locking of the connector housing
Round contacts
Flat contacts with asymmetrical locking tabs
Electrical circuits
Climatronic air conditioner wiring diagram (part 1)
Climatronic air conditioner wiring diagram (part 2)
Climatronic air conditioner wiring diagram (part 3)
Climatronic air conditioner wiring diagram (part 4)
Climatronic air conditioner wiring diagram (part 5)
Climatronic air conditioner wiring diagram (part 6)
Wiring diagram of the climate control system (part 1)
Wiring diagram of the climate control system (part 2)
Wiring diagram of the climate control system (part 3)
Wiring diagram of the climate control system (part 4)
Golf 1
General information
Specifications
Deciphering the VIN number of the car
Engine Specifications
Specifications of the lubrication system
Specifications of the cooling system
High pressure fuel pump specifications
Transmission Specifications
Chassis and Electrical Specifications
Weight characteristics of cars
Vehicle dimensions
Refueling volumes (in liters)
Maintenance
Location of elements in the engine compartment
Checking the engine oil level
Checking the coolant level
Checking the brake fluid level
Checking the fluid level in an automatic transmission
Checking the fluid level in the washer reservoir
Tire pressure check
Vehicle lighting check
Checking direction indicators and hazard warning lights
Checking brake lights
Checking the windshield wiper and washer
Brake check
Regular maintenance and planning
Safe workplace
Checking the engine oil level
Additional oil filling
Engine oil consumption
Engine oil quality and specification
Correct choice of oil viscosity. Seasonal and multigrade oils
Engine oil change
Oil filter replacement
Mechanical transmission leak test
Fluid level control in an automatic transmission
Main gear of an automatic transmission
Lubrication of rods, hinges and locks
Clutch, brake and throttle linkages
Troubleshooting
Power unit
Engine repair
Description of diesel engine design
Separate engine components
Running in a new engine
Uncontrolled increase in speed
Measurement of compression in cylinders
Turning the crankshaft of the engine
Top dead center search
Valve clearance
Adjustment of valves
Toothed belt adjustment
Checking the condition and tension of the toothed belt
Toothed belt tension
Toothed belt replacement
Removal and installation of a head of cylinders
Choosing the Right Cylinder Head Gasket
Removing the camshaft
Removing cup pushers
Removing valves
Validation of valves and heads
Replacement of seals (valve stem seals) valve stems
Additional valve lapping
Engine leak test (oil leak)
Engine damage
Dismantling the engine
Disconnecting the engine from the gearbox
Engine installation
Exhaust and turbocharger
Description of the design of the turbocharger
Removal and installation of a turbocharger
Possible malfunctions in the turbocharger
Description of the design of the exhaust system
Checking the condition of the exhaust system suspension
Release System Update
Removing the exhaust system
Removing the front exhaust pipe
Removing the exhaust pipe
Cooling system
Description of the engine cooling system
Checking the coolant level
Coolant replenishment
Freeze protection
Checking the tightness of the cooling system
Radiator — design description
Replacement of hoses intended for the coolant
Radiator cleaning
Coolant drain
Filling the cooling system
Removing the radiator
Removing the expansion tank
Cooling system plug
Checking the safety and vacuum valve
Thermostat — design description
Removing the thermostat
Thermostat check
Water pump — removal and installation
V-belt — check
Radiator fan — design description
Radiator Fan Malfunctions
Removing the fan motor
Electrolysis in the cooling system
Checking the heatsink and fan housing
Checking the thermal switch
Malfunctions in the cooling system
Fuel system
All about diesel fuel
Winter diesel fuel
Normal fuel consumption
How does the car itself affect fuel consumption
Driving with fuel economy
Draining the fuel tank
Removing the fuel tank
Fuel tank replacement
Fuel quantity sensor
Fuel tank ventilation
Gravity valve
Fuel filter
Bleeding the fuel system
Fuel injection system
Fuel supply scheme
High pressure fuel pump
Fuel pump operation
Fuel injectors
Removal and installation of fuel injectors
Fuel injector disassembly
The switch of inflow of fuel to atomizers
Adjusting the start of delivery of the high pressure fuel pump
Gas draft — removal and installation
Gas draft adjustment (for manual transmission)
Accelerator pedal drive adjustment (for automatic box)
Cold start accelerator cable
Idling check
Air filter — cleaning and replacement
Malfunctions in the diesel injection system
Transmission
Clutch and drive shafts
How the clutch works
Clutch test
Clutch pedal free play
Driving with a broken clutch cable
Clutch rod replacement
Installing and removing the clutch
Faults in the clutch assembly and solutions
Drive shafts — general description
Checking the covers of the semi-axial hinges
Troubleshooting for axle shafts
Removing the drive shaft
Drive shaft disassembly
Car gearbox
General description of a manual transmission
Shift Assembly Adjustment
Switch shaft adjustment
Removal and installation of a transmission
Replacing the release clutch (release bearing)
Noise in gearbox
Automatic transmission — general information
Checking automatic transmission shift modes
Faults in the automatic transmission
Removing the automatic transmission
Main gear — general information
Chassis
Suspension and wheels
Description of the design of the front suspension and steering
Description of the design of the rear suspension
Chassis struts and shock absorbers
Checking wheel bearing play
Shock absorber check
Shock Absorber Malfunctions
Installing the suspension strut on supports
Disassembly of the front wheel suspension
Dismantling the stabilizer
Wishbone Replacement
Ball joint replacement
Removing the suspension strut chassis
Shock absorber and spring replacement
Adjustment of wheel mounting angles
Signs of incorrect wheel alignment
Measuring angles when installing wheels
Replacing the rear suspension strut
Replacing the rear shock absorber and coil spring
Rear axle replacement
Rear axle strut replacement
Wheel bearing dismantling
Wheel bearing play adjustment
Wheel axle replacement
Steering
Checking the protective cover of the steering mechanism
Checking the dust caps and play of the tie rod joints
Checking the ball joint dust caps
Ball joint play check
Steering play check
Tie Rod Joint Replacement
Replacement of the tie rod and cuff of the steering mechanism
Wheel bearing replacement
Steering wheel replacement
Brake system
General description of the braking system
Brake Fluid — General Description
Checking the brake fluid level
Brake check
Checking the tightness and serviceability of the brake system
Floating caliper cam disc brakes
Measuring Disc Brake Lining Thickness
Checking the condition of the brake discs
Replacing Disc Brake Linings
ATE floating caliper disc brake (lining replacement)
Floating caliper disc brake «Girling» (lining replacement)
Cam disc brake mechanism (lining replacement)
Providing mobility at the caliper and piston of the disc brake
Removing the brake caliper
Piston cup replacement
Removing the brake disc
Drum brakes — general description
Checking the thickness of drum brake linings
Checking the brake pedal travel
Additional adjustment of drum brakes
Removing the brake drum
Monitoring the condition of the brake drums
Dismantling of brake pads in cars produced before August 1978
Dismantling of brake pads in cars produced after August 1978
Replacing brake pads
Hand brake — design description
Checking the free travel of the handbrake lever
Replacement of draft of a manual brake
Handbrake adjustment
Hydrovacuum booster — design description
Checking the brake booster
Brake force regulator — design description
Checking the brake force regulator
Working with the hydraulic brake system
Removing the brake pipeline
Brake Hose Replacement
Removing the wheel brake cylinder
Removing the brake master cylinder
Removing the brake booster
Bleeding the brake system
Brake Fluid Replacement
Brake system malfunctions
Wheels and tires
What tires to install
Tire design and designation
Rims and their combinations with tires
Which wheel bolts to use
Tire pressure check
Wide tires and rims
Tire monitoring
Wheel change
Steel cord tire repair
Wheel imbalance
Buying new tires
Winter tires
Body
Heating and ventilation
Description of the heating and ventilation system
Checking heating and ventilation
Removing the tap of the heating system
Removing the heater core
Removing the actuators of the heating system
Fan Troubleshooting
Removing the heating fan
Removing the fan switch
Removing the air outlet nozzles
Troubleshooting in the heating system
Exterior (external elements)
Removable body parts
Removal and installation of the engine hood
Hood lock adjustment
Broken hood link
Removing the grille
Removing the trunk lid
Removing the rear cover lock
Removing the front bumper
Replacing the plastic cladding
Fenders and wheel arch inserts
Removing trims and wheel arch extensions
Removing the front spoiler of the model «Golf»
Outside mirror
Decorative trims and trims
Body preservation works
Interior (internal elements)
Removing the seats
Seat back latch repair
Removing the seat headrest
Removing skins (interior panels)
Removing drawers and lids (release before July 1980)
Removing drawers and lids (release after August 1980)
Doors and windows
Removal and installation of a door
Removing the lining (plating) doors
Removing the door lock
Removing the door handle
Removing the lock cylinder
Removing the side glass
Removing the power window
Removal and installation of a windshield
Electrical equipment
Equipment and devices
Electrical and Electronic Engineering — General Description
Electrical wires — general information
Fuses are conventional and with flat plugs
Checking control devices and bulbs
Removing the dashboard
Replacement of lamps illuminating appliances
Disassembly of the instrument panel
Voltage stabilizer — check and replacement
Fuel level sensor — check
Coolant temperature gauge
Switching indicator
Speedometer (speed indicator)
Removing the flexible speedometer drive shaft
Clock and direction indicator control
Control lamp for brake system, high beam and battery
Oil pressure warning light
Pre-incandescent warning light
Key switch — removal and installation
Steering column switch — removal and installation
Starter and glow switch
Driving with a faulty starter and glow switch
Switch test
Relays and control devices
Heated rear window
Checking the windshield wiper and washer
Removing the lever, brush and rubber part of the wiper
Wiper motor — check and replacement
Wiper malfunctions and how to fix them
Rear window cleaner
Removing the rear window wiper motor
Filling water for washing glass
Rear wiper malfunctions
Windshield washers — removal, adjustment and check
Radio receiver — removal and installation
Mounting the radio antenna
Installing speakers
Lighting system
Lighting check and spare lamps
Replacing headlight bulbs
Parking light bulb replacement
Replacing the lamp in the fog lamp in the grille
Replacing the bulb in the fog lamp under the bumper
Removal and installation of a headlight
Fog lamp in the grille
Checking the installation of headlights
Replacing the bulbs in the front turn signal
Replacing bulbs in the rear lights
Reversing light switch
Rear license plate lamp
Interior lamp
Door contact switch
Replacing interior lamps
Installation of fog lights
Checking alarms and direction indicators
Checking brake lights
Checking the sound and light signal
Power devices
How the battery works
Battery technical data
Maintenance free batteries
Battery acid level control
Removing the battery
Battery Care
Checking the Battery State of Charge
Accumulator charging
Starting with a dead battery
Alternator — general information
Voltage regulator
Checking the contact brushes of the generator
Checking the tension of the V-belt
Checking the condition of the V-belt
Removal and installation of a wedge-shaped belt
Torn V-belt
Removing the alternator
Driving with a faulty alternator
Battery monitoring device
Battery and alternator faults
Description of the starter design
Removing the starter in a car with a manual transmission
Removing the starter in a car with an automatic transmission
Replacement of contact brushes of a starter
Starter malfunctions and solutions
Pre-incandescent system
Glow plugs — selection and replacement
Detection of defects in glow plugs
Troubleshooting in the pre-glow system
Complications that occur when starting the engine
Pre-glow indicator light does not light up
Electrical circuits
The structure of electrical circuits
Rear window cleaner and glass washer (after August 1977)
Front and rear fog lamp (until July 1982)
Diesel model «Golf-L» (release after August 1977)
Diesel and turbodiesel models «Golf/Jetta» (after August 1982)
Brake warning light (after August 1978)
Wiring diagram for trailer hitch
Golf 1
General information
Characteristics
Sequence of release of models Volkswagen Golf, Jetta, Scirocco
Vehicle identification
Vehicle dimensions and weight
Data for maintenance
Data for engine adjustment
Engine data 1.1/1.3L
Engine data 1.5/1.6/1.8L
Engine electrical data
Cooling system data
Fuel System Data
Clutch and manual transmission data
Automatic transmission data
Steering data
Suspension data
Brake system data
Electrical data
User manual
Checking a car on the ground
Checking a car lifted by a lift
Engine stalled or won't start
Checking engine systems
Safety measures during work
Replacing a wheel, jacking up the car and installing supports
Basic tool and equipment
Basic repair operations
Accumulator charging
Starting the engine from the battery of another car
How to turn the engine crankshaft
Engine lift
Maintenance
Maintenance Schedule
Vehicle maintenance work
Tool and equipment
Engine oil and filter
Air filter
Fuel filters
Cooling system
Brake fluid
Battery check
Drive belt
Clutch adjustment
Oil in manual and automatic transmission
Brake system
Wheels and tires
Exhaust system
Lighting and appliances
Windshield wipers and washers
Lubrication work
Power unit
Engine adjustment
General information about engine tuning
Tool and equipment
Spark plug
Compression test
Valve clearances
Distributor and ignition timing
Carburetor adjustment
Fuel injection system (injection engine)
Engine 1.1/1.3
General information about 1.1 / 1.3 l engines
Tool and equipment
Camshaft drive belt (toothed belt)
Camshaft oil seal
Cylinder head
Crankshaft seals
Oil pump
Removal and installation of the engine
Engine repair
Exhaust system (exhaust system)
Engine 1.5/1.6/1.8
General information about engines 1.5/1.6/1.8 l
Tool and equipment
Valve clearances
Toothed belt
Camshaft
Cylinder head
Crankshaft seals
Auxiliary shaft oil seal
Oil pump
Removal and installation of the engine
Engine repair
Possible engine malfunctions
Engine electrical equipment
General information about the electrical equipment of the engine
Tool and equipment
Checking the charging circuit
Removal and installation of the generator
Generator repair
Ignition distributor
Ignition coil
Starter check
Removal and installation of a starter
Starter repair
Replacement of sensors
Possible malfunctions of the electrical equipment of the engine
Cooling system
General information about the cooling system
Tool and equipment
Coolant replacement
Removal and installation of a radiator
Radiator fan and thermal switch
Checking and replacing the thermostat
Hoses and clamps
Coolant pump
Coolant temperature sensor
Cabin heater
Possible malfunctions of the cooling system
Fuel system
General information about the fuel system
Tool and equipment
Fuel pump
Air filter
Carburettor drive
Removal and installation of the carburetor
Solex PICT/PIC carburetors
Pierburg/Zenith 1B3 carburetors
Carburettors Zenith 2B2/2B5
Carburetor Pierburg 2E2
Fuel injection system
Removal and installation of the fuel tank
Possible malfunctions of the fuel system
Transmission
Clutch and manual gearbox
General information about the clutch and mechanical box
Tool and equipment
Clutch cable
Clutch — 1.1 / 1.3 L engines
Clutch — engines 1.5/1.6/1.8 l
Shift Drive — 1.1/1.3L Engines
Shift Drive — 1.5/1.6/1.8L Engines
Gearbox 084 — engines 1.1 /1.3 l
Gearbox 020 — engines 1.5/1.6/1.8 l
Type 084 Transmission Repair — 1.1/1.3L Engines
Differential 084 — engines 1.1 / 1.3 l
Type 020 Transmission Repair — 1.5/1.6/1.8L Engines
Output shaft and differential — engines 1.5/1.6/1.8
Possible malfunctions of the clutch and manual transmission
Automatic gearbox
General information about automatic transmission
Tool and equipment
Transmission tests in a braked state
Selector lever cable
Starter lock switch
Removal and installation of transmission
Torque converter oil seal
Possible malfunctions of automatic transmission
Chassis
Steering
General information about steering
Tool and equipment
Adjustment of a convergence of forward wheels
Steering rods and joints
Steering gear
Steering shaft
Steering column
Possible steering problems
Front suspension
General information about the front suspension
Tool and equipment
Replacing wheel bearings
Telescopic strut shock absorbers
Ball joint replacement
Front suspension arms and bushings
Stabilizer bar
Drive shafts
Rear suspension
General information about the rear suspension
Wheel bearings
Replacing shock absorbers
Hub trunnion replacement
Rear axle and anti-roll bar
Brake system
General information about the brake system
Tool and equipment
Hydraulic brake system
Bleeding the brake system (air removal)
Front brake calipers (Teves)
Front brake calipers (Girling)
Front brake calipers (VW Mk II)
Replacing the rear drum brake pads
Rear brake cylinders
Master brake cylinder
Servo brake booster
Brake pressure regulator
Hand brake
Possible malfunctions of the brake system
Electrical equipment
Lighting and appliances
General information about electrical equipment
Tool and equipment
Lamp replacement
Lamp replacement
Fuses, relay and turn signal breaker
Instrument panel
Ignition switch / steering column lock
Switches and cigarette lighter
Windshield wipers and washers
Sound signal
Gear Shift/Fuel Consumption Indicator
Possible malfunctions of electrical equipment
Electrical circuits
How to use diagrams
Symbols and designations of electrical circuits
Codes (designations) elements of electrical connection diagrams
A Devices
B Sensors and horn
C Battery
E Light bulbs
F Fuses
G Generator
H Light signaling
K Relay
M Electric motors
P Gauges and gauges
R Resistors
S Switches
T Transformers
X Connectors
Y Electromagnets
Body
Body and equipment
General information about the body and equipment
Tool and equipment
Front fender
Bumpers
Doors and upholstery
Door handles and locks
Hood lock and its drive (cable)
Radiator grille
Telescopic tailgate stop
Front seat
Speedometer cable
Dashboard
Optional equipment
General information about optional equipment
Removal and installation tool
Installing the radio and speakers
Antenna Installation
RF interference suppression
Child seat
Additional lighting fixtures
Towbar and towbar electrical equipment
Golf 2
General information
Characteristics
Towing a car trailer (trailer)
Trailer instruction manual
Engine — general information
Exhaust gas control system
Transmission — general information
Technical data: steering gear, suspension, brakes, body/chassis
Vehicle technical data
Vehicle weight
Vehicle designation
Car care
Volkswagen Golf and Jetta steering system: preliminary information
Car operation: the first 1500 km of run and subsequent
Safety rules for car operation
Driving: economical and with minimal air pollution
Instructions for driving a car with a trailer
Car care: fuel tank
Car care: fuel supply
Car care and pollution protection
External car care
Care of the interior of the car
Car protection against corrosion
Engine Hood Care
Engine compartment maintenance
Engine oil: specification and viscosity
Consumption and replacement of engine oil
Engine Oil Filter Care
Fuel System Care (only for diesel engines)
Transmission oils
Air Cleaner Care
Air filter care
Power steering
Cooling System Care
V-profile belt
Car brake fluid care
Battery Care
Detergent bottle for windshield cleaning
Replacement wiper blades
Tire care (wheels)
New tires: life, wear and replacement
Tire Specifications
Tires used in winter
Driving in difficult operating conditions
Driving a car in winter
Additional accessories, modifications and replacement of component parts and assemblies
Maintenance
General principles for repairs
Small Repair Tool Kit
Work safety during maintenance
Service interval
Faults in the electrical system
Vehicle maintenance
Jack and tools for self-maintenance
Spare wheel
Wheel replacement
Circuit breakers
Lamp replacement
Headlight adjustment
Installing and replacing the radio
Emergency start
Emergency towing of vehicles with a technical assistance vehicle
Vehicle lifting
Power unit
Engine repair
Engine technical data
Engine housing
Crankcase bleed system
Oil sump
Flywheel — removal, repair and installation
Engine Assembly
Starting the engine after repair and adjustment
Engine fault tables
Engine 1.05/1.30
Removing the engine from the car
Disconnecting the gearbox
Engine equipment
Distribution belt and distribution gears
Camshaft
Crankshaft seals
Removing the engine head
Removing the engine head
Grouting engine head valves
Mounting the engine head
Installing the head on the engine
Valve clearances
Pistons and connecting rods. extraction
Piston control and repair
Installation of pistons and connecting rods
Crankshaft: extraction, control, repair, installation
Installing the engine in a car
Engine 1.60/1.80
Removing the engine from the car
Fuel Injected Engine — Extraction
Engine equipment
Camshaft
Engine head
Valve clearances — adjustment
Removing pistons and connecting rods
Installing the engine in a car
Distribution belt and distribution gears
Cooling and lubrication system
Technical data of the cooling and lubrication system
Cooling system device
Action of the cooling system
Periodic maintenance of the lubrication and cooling system
Coolant drain
System rinse
Filling the lubrication and cooling system
Antifreeze — general information and replacement
Radiator — removal and installation
Radiator fan
Radiator fan thermal switch
Thermostat — 1.1 and 1.3L engines
Thermostat — 1.6 and 1.8 L engines
Water Pump — 1.1 and 1.3L Engines
Water Pump — 1.6L and 1.8L Engines
Water temperature sensor, thermal switches
Lubrication system device
Checking the engine oil level
Engine oil change
Oil Pump — 1.1 and 1.3L Engines
Oil Pump — 1.6L and 1.8L Engines
Power and exhaust system
Carburetor engines
Tools and equipment for repair
General description of gasoline power systems
Air filter insert — replacement
Air filter assembly
Intake air temperature controller
Fuel Pump — Carburetor Engines
Fuel Pump — Gasoline Injection Engines
Fuel sump
Fuel tank
Fuel level sensor
Fuel tank check valve
Gas cable
Gas cable — automatic transmission
Gas pedal
Starting Equipment Cable — 1.1L Engine
Carburetor — removal and installation
Carburetor — 31 PIC-7
Engine speed control — manual choke PIC carburetor
Engine speed control — PICT carburetor with automatic choke
Carburetor Zenith 1ВЗ
Carburetor Zenith 2B5
Carburetor 2E2
Adjusting the clearance of the carburetor start diaphragm 2E2
Carburetor 2EZ
Subsea manifold preheating
Manifolds — suction and exhaust
Table of malfunctions of the carburetor power system
Petrol injection systems
General description of the injection system
Air mass meter
Fuel supply
Fuel distributor
Cold start valve
Engine heating valve
Additional air valve
Fuel Injection System — Service Interval
Replacing the Air Filter Insert
Engine idle speed — adjustment
Exhaust gas composition adjustment
Cold start valve and temporary thermal switch
Additional air valve
Engine heating valve
Enrichment system during cold engine revs
Fuel injectors
Flow meter plate and control piston
Fuel distributor
Air mass meter
Pressure regulator
Fuel supply pump
Fuel pump located outside the fuel tank
Fuel filter
Pressure accumulator
Suction manifold
Exhaust manifold (exhaust)
Table of malfunctions of the gasoline injection system
Exhaust system service
Transmission
Clutch
Technical data
Clutch device
Clutch — adjustment
Clutch cable — replacement
Clutch pedal — disassembly and assembly
Clutch — gearbox 084
Clutch — 084 control
Clutch release mechanism — 084
Clutch 020 — disassembly and assembly
Clutch 020 — control
Clutch release mechanism 020
Clutch fault table
Car gearbox
Technical data
General characteristics of a manual transmission
Transmission Inspection Frequency
Removing the gearbox 084
Disassembly and repair of gearbox 084
Clutch housing — repair
Gearbox housing — repair
Box input shaft 084
Box output shaft 084
Synchronizers — box 084
Differential mechanism — box 084
Gearbox assembly 084
084 gearbox gear selection mechanism
Removing gearbox 020, 4-speed and 5-speed
Disassembly and repair of gearbox 020, 4-speed
Gearbox assembly 020, 4-speed
Disassembly and repair of gearbox 020, 5-speed
Input and output box shafts 020, 5-speed
Synchronizer box 020, 4 and 5 speed
Gearbox assembly 020, 5-speed
020 gear select mechanism
General characteristics of the automatic transmission
Maintenance of automatic transmission
Removing the automatic transmission
Overload test
Automatic transmission selector cable
Carburetor cable and gas pedal cable
Transmission fault table
Drive shafts
Technical data
Drive shafts: device
Drive shaft — replacement
Drive joints
Disassembly of the outer hinge
External Hinge Assembly
Installing the external hinge on the axle shaft
Internal hinge
Disassembly of the inner joint
Mounting the inner hinge
Inner Hinge — gti Models
Drive flange seal
Chassis
Brake system
Technical data
Brake system device
Service Intervals for the Brake System
Brake pedal
Servo
Brake cylinder
Rigid and flexible brake lines
Brake force corrector
Front wheel brake calipers
Front brake disc
Rear wheel brake calipers
Rear brake disc
Rear drum brakes
Removal of air from the brake system
Hand brake lever
Table of malfunctions of the brake system
Steering
Technical data
Control system device
Maintenance and care
Steering wheel
Steering column
Steering lock
Steering gear cover
Steering rods and ball joints
Steering gear (without amplification)
Steering Gear Assembly
Power control system
Front wheel installation, adjustment
Fault table
Suspension
Technical data
Front and rear suspension device
Maintenance and care
Front suspension spring column
Dismantling of a column of a spring of a forward suspension bracket
Front stabilizer
Wheel balancing
Tire service
Fault Table — Wheels and Tires
Body
Body and equipment
Front buffer
Radiator protection
Front end
Mounting the front
Rear buffer
Replacing the buffer pad
Front fender disassembly
Disassembly and assembly of the wheel hub
Pipelines that drain water from the roof
Roof eaves
Side decorative cornice
External door handle
Central blocking of door locks
Door lock
External rear view mirror
Door lining
Front door
Dismantling the interior door handle
Manual glass lifting mechanism
Door glass
Body side glass replacement
Removing and installing the front seat
Trunk lid
Heating
Front window wiper
Rear window wiper
Glass sprinkler
Dividing board
Electrical equipment
Lighting and appliances
Technical data
Electrical system device
Battery
Battery test under load
Maintenance free batteries
Removing and installing the battery
Accumulator charging
Alternator
Removal and installation of the generator
V-belt replacement
Generator brush replacement
Generator disassembly
Control of generator elements
Starter
Starter disassembly
Control of starter elements
Ignition system
The device and principle of operation of the classical ignition system
TSZ-H ignition system
VEZ ignition system
Precautions When Repairing Electronic Ignition Systems
Removing the ignition distributor
Checking breaker contacts
Replacing breaker contacts
Setting the ignition timing
Capacitor check
Cap check
Gallotron check
Checking the TSZ-H control system
Spark plug
Type of spark plug
Lighting equipment
Replacing headlight bulbs
Replacing the side light bulb
Headlight replacement
Lighting installation (Sveta)
Replacing the front turn signal bulb
Removing the cover of the rear complex (connected) lamps
Replacing the Registration Table Lamp (numbers)
Relay in Golf and Jetta
List of electrical equipment
Mass points summary
Detailed wiring diagrams
Electrical circuits
Overload shut-off valve and suction manifold heater (models up to 07.87)
Starter, alternator, battery and ignition system (models 1.1, 1.3 and 1.6 up to 07.87)
Oil pressure sensor (models 1.1, 1.3 and 1.6 up to 07.87)
Light bulbs for lighting the glove box and trunk, radio and cigarette lighter for cigarettes (models 1.1, 1.3)
Light and signage switch (models 1.1, 1.3 and 1.6 up to 7.87)
Main and rear lighting and flash signal switch (models 1.1, 1.3 and 1.6 up to 07.87)
Fog lighting and heated rear window (models 1.1, 1.3 and 1.6 up to 07.87)
Pointers and warning lighting (models 1.1, 1.3 and 1.6 up to 07.87)
Brake lights, blowers, reversing lights and radiator fan (models 1.1, 1.3 and 1.6 up to 7.87)
Two-tone signal, signaling the tightening of the hand brake and monitoring the level of brake fluid (models 1.1, 1.3 and 1.6 up to 07.87)
Wiper motor and glass sprinkler (models 1.1, 1.3 and 1.6 golf up to 12.85 and Jetta up to 07.87)
Rear window wiper (models 1.1, 1.3 and 1.6 up to 12.85)
Suction manifold heater and automatic suction (models 1.3 up to 07.86)
Starter, alternator, battery and ignition system (1.8 models with carburetor)
Overload shut-off valve and suction manifold heater (1.8 models with carburetor)
Gauge table, stash light, shift diagram, fuel gauge and oil pressure gauge (models before 07.85)
Table of indicators and multifunctional sensor (models 1.8 to 07.85)
Central locking, interior lighting, trunk lighting, radio and cigarette lighter (models 1.8 to 07.85)
Light switch, switchboard and license plate lighting (models up to 07.87)
Rear lighting and light, headlight flash signal switch (models 1.8 to 07.85)
Rear fog light and heated rear window (models 1.8 to 07.85)
Pointers and control lights (models 1.8 to 07.85)
Brake lights, blower, reversing lights and radiator fan (models 1.8 to 7.85 g.)
Two-tone signal, hand brake tightening signaling and brake fluid level indicator light (models 1.8 to 7.85 g.)
Sprinkler and wipers (models 1.8 to 7.85 g.)
External mirror control, sprinkler and rear window wiper (model 1.8 to 12.85)
Electric window lift (1.8 models with carburetor up to 7.87 g.)
Starter, alternator, battery and ignition system (1.8 models with fuel injection up to 7.84 g.)
Fuel supply system, gear changes and fuel gauge (1.8 models with fuel injection)
Starter, alternator, battery, ignition system and system that increases engine speed during heating (1.8 models with fuel injection from 8.84 to 7.87)
Fuel system, gear change system, fuel gauge and coolant level (models 1.8)
Main light sprinkler on all models
Radiator fan (250 W). Models 1.6 and 1.8
Elements installed in an automatic transmission (models 1.6)
Headlight adjustment control in all models
Multifunction pointer (models 1.8)
Starter, alternator, battery and ignition system (1.1 models since 8.85)
Intake manifold heater, automatic suction and idle boost system during engine warm-up (1.1 models since 8.85)
Starter, alternator, battery and ignition system (1.3 models since 8.85)
Suction manifold heater, automatic suction (models 1.3 with 8.85 g.)
Starter, alternator, battery (1.8 16V models)
Ignition system (1.8 16V models)
Coolant level indicator light (1.8 16V models)
Idle speed stabilization system and overload shut-off valve (1.8 16V models)
Fuel supply system (1.8 16V models)
Starter, alternator, battery and ignition system (1.6 models from 8.85 to 7.87)
Radiator fan (models 1.6 and 1.8 from 3.86 to 7.87)
Wipers in all models of cars Golf from 1.86 to 7.87
Front and rear window wipers and sprinkler on all Golf models
Starter, alternator, battery and ignition system (1.6 models since 8.87)
Inlet manifold heater and automatic suction (1.6 models since 8.87)
Indicator table, optical and acoustic low oil pressure indicator and rev counter (models from 8.87)
Car interior and trunk lighting, radio (models from 8.87)
Light and license plate switch (models from 08.87)
Main lighting, tail light, headlight flash signal switch, brake light switch and reversing light switch (models from 08.87)
Pointers and control lamps in all models from 8.87
Motors for automatic window opening (1.6 models from 08.87)
Handbrake, brake fluid level warning light, low coolant level indicator and more on all models from '87.
Rear window wipers and radiator fan (fuel injected models 1.1, 1.3 and 1.8 from 08.87)
Automatic transmission (1.6 models from 01.89)
Alternator, battery, starter and ignition system (models 1.6 and 1.8 with carburetor from 01.89)
Radiator fan and fresh air supply (models 1.6 and 1.8 with carburetor from 01.89)
Automatic suction and inlet manifold heater (models 1.6 and 1.8 with carburetor from 01.89)
Ignition system and overload shut-off valve (models 1.6 and 1.8 with carburetor from 01.89)
Distribution board and oil pressure sensor (models 1.6 and 1.8 with carburetor from 01.89)
Distribution panel: revometer, fuel and temperature gauge (models 1.6 and 1.8 with carburetor from 01.89)
Handbrake tightening signaling and brake fluid level warning light (models 1.6 and 1.8 with carburetor from 01.89)
Cache lighting, cigarette lighter, radio and cassette container lighting (models 1.6 and 1.8 with carburetor from 01.89)
Lighting of the car interior, trunk and registration number (models 1.6 and 1.8 with carburetor from 01.89)
Main lighting, side lighting and headlight switch (models 1.6 and 1.8 with carburetor from 01.89)
Indicators of turns of control bulbs and the switch of dimensional lights (models 1.6 and 1.8 with carburetor from 01.89)
Direction and rear lights (models 1.6 and 1.8 with carburetor from 01.89)
Light switch and brake light switch (models 1.6 and 1.8 with carburetor from 01.89)
Reversing light, heated rear window, two-tone signals (models 1.6 and 1.8 with carburetor from 01.89)
Rear fog lights and heated front window sprinklers (models 1.6 and 1.8 with carburetor from 01.89)
Windshield wipers and sprinklers (models 1.6 and 1.8 with carburetor from 01.89)
Electrically mounted exterior mirrors on all models from 01.89
Golf 2
General information
Introduction to guide
Description of design features of cars Golf 2
Vehicle identification
General instructions for maintenance and repair
Technical data for maintenance and repair
Tightening torques for threaded connections
Lifting a car with a jack
User manual
Controls and instruments
Hood opening
The location of components and parts in the engine compartment
Ignition switch lock
Car engine start
Multifunction display
Gear shift
Steering wheel tilt adjustment
Lighting and signaling
Windscreen wipers and washers (Golf)
Ventilation and heating
Ventilation and heating with air conditioning system
Gear indicator and fuel consumption indicator
Doors and windows
Front seat adjustment
Wheel replacement
Checking the level of working fluids
Replacing the air filter element
Tire pressure check
Petrol engines 1.3 l
Engine repair
Removal and installation of the engine
Engine disassembly
Engine Assembly
Cylinder head — general information
Removing the cylinder head without removing the engine
Dismantling of a head of the block of cylinders
Cylinder head repair
Cylinder head assembly
Installation of the cylinder head
Checking hydraulic valve clearance compensators
Camshaft oil seal replacement
Removing pistons and connecting rods from the cylinder block
Measurement of cylinder diameters
Inspection of piston rings, ring grooves and connecting rods
Assembling the connecting rod and piston group
Installation of pistons and connecting rods in cylinders
Cylinder block — check
Removing the crankshaft
Checking the crankshaft
Installing the crankshaft
Removing the crankshaft seals
Installation of crankshaft seals
Flywheel replacement
Gas distribution mechanism — design description
Toothed belt replacement
Checking and installing valve timing
Replacing the camshaft without removing the engine
Lubrication system
Engine lubrication system — design description
Replacing the oil pan
Oil pump replacement
Oil pump adjustment
Oil filter replacement
Oil pressure check
Possible malfunctions of the lubrication system and how to eliminate them
Cooling system
Engine Cooling System — Design Description
Coolant replacement
Radiator check
Radiator Banners
Checking the radiator fan
Checking the thermal switch
Coolant pump replacement
V-belt tension adjustment
Thermostat replacement
Cabin heater repair
Possible malfunctions of the cooling system
Carburetors
Solex 1B3 carburetor replacement
Solex 1B3 carburetor disassembly
Solex 1B3 carburetor adjustment
Weber TLA carburetor disassembly
Weber TLA carburetor adjustment
Carburetor Pierburg 2E3 — design description
Pierburg 2E3 carburetor adjustment
Calibration data for carburetors
Possible malfunctions of the power supply system of carburetor engines
Supply system
Fuel injection systems — general information
Description of the Digijet injection system
Adjustment of the idling parameters of the Digijet injection system
Possible malfunctions of injection systems
Fuel pump and filters
Fuel level sensor
Fuel tank — removal and installation
Inertial and vent valves
Exhaust manifold replacement
Replacement of components of system of release of the fulfilled gases
Ignition system
Safety of working with the ignition system
Contact ignition system
Transistor ignition system TSZ-H
Checking the ignition coil
Checking the ignition distributor slider, wires, candle tips
Removal and installation of the distributor of ignition
Replacing the contact group of the breaker (contact ignition system)
Checking the angle of the closed state of the contacts (contact ignition system)
UZSK adjustment (contact ignition system)
Capacitor check (contact ignition system)
Hall sensor test (electronic ignition systems)
Checking the Switch (electronic ignition systems)
Lead angle adjustment (moment) ignition
Spark plug
Maintenance work on the ignition system
Petrol engines 1.6/1.8 l
Engine repair
Camshaft drive — design description
Removal and installation of a camshaft
Valve clearance adjustment
Removal and installation of a head of the block of cylinders (8V)
Removal and installation of a cover of a head of the block of cylinders (16V)
Removing camshafts (16V)
Removing the cylinder head (16V)
Supply system
Bosh KE-Jetronic fuel injection system
Mono-Jetronic Fuel Injection System
Digifant fuel injection systems
Exhaust manifold replacement
Ignition system
General description of the ignition system
Electronic ignition system VEZ
Removal and installation of the distributor of ignition VEZ
Checking the VEZ ignition system
Checking the lead angle (moment) Ignition Digifant
Lead angle adjustment (moment) Ignition Digifant
Spark plug
Diesel engines
Engine repair
Description of diesel and turbodiesel engines
Removal and installation of the engine
Engine disassembly
Engine Assembly
Cylinder head
Dismantling the cylinder head from the engine installed on the car
Dismantling of a head of the block of cylinders
Checking valve springs
Checking the valve guides
Checking valve seats
Checking valves
Checking the cylinder head
Checking the camshaft (engine with hydraulic pushers)
Checking hydraulic valve lifters
Cylinder head assembly
Installing the cylinder head
Pistons and connecting rods — design description
Extraction of parts of the connecting rod and piston group from the cylinder block
Checking the details of the connecting rod and piston group
Assembling the connecting rod and piston group
Installing the connecting rod and piston group
Measuring the end play of the crankshaft
Removing the crankshaft
Replacing the crankshaft seals
Checking the crankshaft
Installing the crankshaft
Cylinder block — check
Flywheel — replacement
Replacing the intermediate shaft
Automatic transmission drive
Gas distribution mechanism — design description
Timing Belt Banners
Camshaft Replacement
Camshaft oil seal replacement
Valve clearance adjustment
Maintenance of diesel and gasoline engines
Lubrication system
Description of the design of the engine lubrication system
Replacing the oil pan
Oil pump replacement
Oil pump repair
Oil filter replacement
Oil cooler replacement
Oil pressure check
Cooling system
Description of the design of the engine cooling system
Coolant replacement
Checking and replacing the radiator
Checking the coolant level
Fluid Pump Replacement
Liquid Pump Repair
V-belt tension adjustment
Thermostat replacement
Power and exhaust system
General description of the diesel engine power system
Fuel filter service
High pressure fuel pump banners (injection pump)
Checking and adjusting the compression torque (Bosch pump)
Checking and adjusting the compression torque (CAV pump)
Accelerator thrust adjustment
Trigger Adjustment
Idle speed adjustment
Maximum speed adjustment
Nozzle replacement
Turbocharger replacement
Turbocharger Installation
Turbocharger check
Replacing the intake and exhaust manifolds
Starter candles
Exhaust manifold replacement
Transmission
Clutch
Clutch (petrol engine models)
Clutch replacement (petrol)
Clutch cable replacement (petrol)
Replacing the clutch release bearing (petrol)
Clutch (diesel engine models)
Clutch replacement (diesel)
Clutch cable replacement (diesel)
4-speed gearbox 084
Technical data for gearboxes
Gearbox replacement
Gearbox disassembly
Gearbox housing repair
Disassembly of the input shaft
Dismantling the output shaft
Checking the wear of gearbox parts
Output shaft assembly
Input shaft assembly
Output shaft installation
Installing the input shaft
Assembling the stem lock
Main gear and differential repair
Assembling the final drive and differential
Gear selector repair
5-speed gearbox 085
Gearbox replacement
Gearbox disassembly
Dismantling the input shaft
Dismantling the output shaft
Gearbox Assembly
Disassembly of the differential mechanism
Installing the Gear Selector
4-speed gearbox 020/4R
General description of the four-speed gearbox 020 (4R)
3gearbox replacement
Gearbox disassembly
Input shaft assembly
Installation of the secondary shaft
Installation of the main gear
Adjustment after gearbox assembly
Input shaft adjustment
Output shaft adjustment
Final drive installation
Replacing and adjusting the gear selection mechanism
5-speed gearbox 020/4T
Five-speed gearbox (model 020/4T or 9A)
Gearbox disassembly
Installing the primary and secondary shaft
Assembling the gearbox housing
Gearbox adjustment
Installing the Gear Selector
Checking the oil level
Automatic gearbox
Checking the transmission oil level
Transmission oil change
Vacuum chamber adjustment
Gearbox replacement
Drive shafts
Replacing drive shafts
Replacement of the internal constant velocity joint (SHRUS)
Replacement of the outer constant velocity joint (SHRUS)
Replacing the anti-vibration weight
Four-wheel drive cars
Chassis
Steering
General description of steering
Steering gear replacement
Adjustment of backlash in the steering mechanism
Twin Shaft Steering Column Banners
Solid shaft steering column replacement
Replacing the intermediate shaft
Replacing the steering rod on the removed steering gear
Replacing the steering rod on the steering mechanism installed on the car
Front wheel alignment
Power steering replacement
Tie Rod Banners (with hydraulic booster)
Power steering fluid replacement
Adjustment of backlash in the steering mechanism (with hydraulic booster)
V-belt tension adjustment
Car suspension
Front suspension — design description
Replacing front suspension elements
Dismantling the front suspension
Front suspension repair
Front suspension assembly
Replacing components and parts of the front suspension
Rear suspension — design description
Replacing the rear axle beam
Rear shock absorber and spring replacement
Replacement of bearings of naves of back wheels
Checking the rear wheel alignment
Wheels and tires
Brake system
General description of the braking system
Replacing the front brake pads
Repair of front brake calipers
Front brake disc repair
Checking and replacing the rear brake pads
Brake Master Cylinder — Design Description
Replacing the master brake cylinder (GTZ)
Vacuum brake booster — design description
Pressure regulator — removal and installation
Removal of air from the brake system, replacement of brake fluid
Parking brake — design description
Checking the free play of the parking brake
Replacing the parking brake cable
Parking brake adjustment
Anti-lock braking system (ABS)
Possible malfunctions of the brake system
Body
Body elements
General description of the car body
Radiator grill — removal and installation
The upper cross member of the radiator frame
Installation and adjustment of the hood lock
Front bumper — removal and installation
Rear bumper — removal and installation
Front fender — removal and installation
Electric Rear View Mirror
Rear view mirror without electric drive
Internal door upholstery — removal and installation
Front seat — removal and installation
Doors, locks and windows
Door handle — removal and installation
Door lock cylinder — removal and installation
Door lock cylinder — replacement and repair
Internal door handle
Door window glass replacement
Window regulator without electric drive
Power window mechanism
Replacement of windshield and side windows
Electrical equipment
Equipment and devices
General description of onboard electrical equipment
Headlight adjustment
Headlight lamp banners
Wiper — design description
Replacing fuses
Use of electrical diagrams
Electrical circuit structure
Power devices
Generator replacement
Bosch generator repair
Motorola Generator Repair
Possible generator malfunctions
Accumulator battery
Possible battery problems
Description and test of the starter
Starter Replacement
Starter repair
Golf 3
Petrol engine
Engine repair
Engine with a displacement of 1.4 liters
Engine with a displacement of 1.8 liters
Engine with 2.0 L displacement
Technical parameters of the gasoline engine
Motor tightening torques
Removal and installation of the engine
Separation of engine and gearbox
Aligning the position of the engine and gearbox
Engine disassembly and assembly
Cylinder head and valves
Removing the cylinder head
Dismantling of a head of the block of cylinders
Cylinder head valve springs
Cylinder head valve seats
Cylinder head valves
Cylinder head
Camshaft
Cylinder head assembly
Installation of the cylinder head
Hydraulic pushers
Replacement of a sealing ring of a camshaft
Pistons and connecting rods
Cylinder block
Crankshaft and main bearings
Crankshaft sealing rings
Drive mechanism
Removing the toothed belt
Mounting the toothed belt
Checking and adjusting the reference marks
Intermediate shaft
Compression pressure control
Lubrication system
Engine lubrication system
Dismantling and installation of the crankcase
Oil pump
Oil filter
Oil pressure control
Oil radiator
Cooling system
Engine cooling system
Cooling media
Radiator and fan
Water pump
Thermostat
Coolant circulation pump
Ignition system
Ignition system. General information
Safety precautions
Distributor. General information
Maintenance of the ignition distributor
Removal and installation of the distributor of ignition
Ignition distributor repair
Setting the ignition timing
Spark plug
Diesel engine
Engine repair
Suction motor with a displacement of 1.9 liters
Turbodiesel with a displacement of 1.9 liters
Diesel engine. general information
Diesel principle
Cylinder block
Crankshaft
Pistons
Cylinders
Cylinder head gasket
Cylinder head and camshaft
Toothed belt
Hydraulic pushers
Lubrication system
Crankcase ventilation
Checking the engine for oil loss
Running in a new engine
Engine life
Compression pressure measurement
Engine Troubleshooting
Diagnostics of malfunctions of a gear belt
Diagnostics of malfunctions of a laying of a head of the block of cylinders
Work on the cylinder head
Bearing damage
Removal and installation of the engine
Turbocharged diesel engine
Boost pressure regulator
Removing the turbo
Troubleshooting
Diesel injection system
Diesel injection system. general information
High pressure fuel pump
Cold start accelerator
Suction Diesel Fuel Injection System
Fuel injection system on a turbodiesel engine
Nozzles
Injection timing adjustment (start of filing) injection pump
Gas thrust
Cold start accelerator thrust
Idling check
Checking exhaust gases for soot content
What is an air filter for?
Diagnosis of malfunctions of the diesel injection system
Fuel injection system «Digifant» 2 liter engine
Pre-glow system
Diesel engine pre-heating system. general information
Two different pre-filament systems
Operation of the pre-glow system
Glow plugs
Troubleshooting in the pre-glow system
Glow Plug Troubleshooting Sequence
Checking the fuse (all engines)
Checking the voltage supply (all engines)
Checking glow plugs (all engines)
Checking the pre-glow relay
Checking the glow plug relay (55 kW turbodiesel)
Checking the automatic glow time control device (55 kW turbodiesel)
Checking the temperature sensor of the pre-glow system (all engines)
Pre-glow indicator lamp does not light up
Transmission
Clutch
Clutch technical parameters
Clutch. general information
Clutch mechanism
Clutch cable replacement
Clutch removal
Clutch overhaul
Clutch installation
Clutch release mechanism
Clutch malfunctions
Gearbox and drive shafts
Gearbox technical parameters
Tightening torques for gearbox screw connections
Transmission. general information
Dismantling and installation of the M5 box
Disassembly of the M5 gearbox
Checking Gearbox Parts
Gearbox Assembly
Gearbox and differential adjustment
Dismantling and installation of box 02A
Gearbox disassembly 02A
Automatic four-speed gearbox. General information
Removing the automatic transmission
Checking the oil and working fluid levels in the automatic transmission and final drive
Front drive shafts
Dismantling and installation of the drive shaft
Drive shaft repair
Removal and installation of shock absorber
Restoration of rubber cuffs
Chassis
Steering
Steering technical parameters
Tightening torques of steering threaded connections
Power steering gear
Removing the steering gear
Steering gear installation
Restoration of transverse steering rods
Filling the hydraulic system
Bleeding the hydraulic system
Checking the hydraulic system for leaks
Steering wheel free play adjustment
Adjusting the tension of the V-belt of the hydraulic power steering pump
Mounting and dismantling of the hydraulic parts of the power steering
Height adjustable steering column
Dismantling and installation of the hydraulic power steering pump
Installing the front wheels
Wheel alignment
Camber
Longitudinal inclination of wheels
Negative rolling radius
Differential wheel angle
Brake pressure regulator
Wheels and suspension
Suspension technical parameters
Suspension screw tightening torques
Wheels and tires. General information
Front wheel suspension. general information
Dismantling and installation of shock absorber
Dismantling the suspension strut
Shock strut repair
Shock absorber assembly
Dismantling and installation of individual suspension parts
Rear suspension. general information
Dismantling and installation of the rear axle
Dismantling and installation of suspension struts
Rear wheel bearings
Geometric design of the rear wheels
Brake system
Technical parameters of the brakes
Brake tightening torques
Brake system. general information
Brake adjustment
Replacing the brake pads of the front wheel disc brake
Repair of a brake saddle of a disk brake of forward wheels
Refinement of the brake discs of the front wheels
Inspection of brake pads and their replacement of the drum brake mechanism of the rear wheels
Brake support plates of the drum brake of the rear wheels
Wheel brake cylinder
Refinement of brake drums rear wheel brakes
Master brake cylinder
Dismantling and installation of the main brake cylinder
Brake drive booster
Bleeding the brakes
Dismantling and installation of brake pads of the disc brake of the rear wheels
Repair of a brake saddle of a disk brake of back wheels
Refinement of brake discs rear wheel brakes
Hand brake
Dismantling and installation of hand brake cables
Dismantling and installation of the hand brake lever
Anti-lock device
Dismantling the elements of the anti-lock device
Electrical equipment
Lighting and appliances
Technical parameters of electrical equipment
Electrical equipment. general information
Accumulator battery
Checking the battery
Alternator
Precautions when working with the charger
Checking the built-in generator
Dismantling and installation of the alternator
Automotive Generator Repair «Bosch»
Automotive Generator Repair «Valeo»
Starter
Dismantling and installation of the starter
Disassembly and assembly of the starter
Dismantling and installation of an incandescent lamp
Dismantling and installation of headlights
Dismantling and installation of a servomotor for adjusting the range of lighting
Headlight adjustment
Fog lights
Net cleaner
Front turn signal light
Back light
Electrical circuits
Generator, starter, ignition switch
Cooling fan, fresh air fan
Injection control device, intake port preheating system
Injection control unit, lambda probe, ignition system
Gauges, oil pressure switch, long-range thermometer temperature sensor
Gauges, Signal Lights, Fuel Supply, Long Range Thermometer
Removable instrument cluster, multi-function indicator, tachometer gauge
Interior lighting, rear ashtray lighting, license plate lights
Handbrake and brake fluid warning device, luggage compartment lighting
Light range control
Headlights, parking lights, dipped beam and signal light
Flashing lights and circular signal flashers, parking light switches
Light switches and fog tail lights
Reversing light, heated rear window and two-tone signal
Windshield wiper and washer
Wiper and washer, rear brake lights
Starter, battery, alternator and ignition system
Power system with built-in system «Digifant»
Ignition system, injection system «Digifant»
System control device «Digifant», lambda probe and injection nozzles
Coolant shortage detection device and oil pressure monitoring
Tachometer sensor, oil pressure switch with VR6 engine
Alternator, starter, ignition switch with VR6 engine
Control device «Monotronic», lambda probe and ignition system with VR6 engine
Control device «Motronic», engine speed sensor, throttle potentiometer
Control device «Monotronic», injection valve, air quantity sensor with VR6 engine
Control device «Motronic», current relay, pump for pumping coolant with VR6 engine
Golf 4
General information
User manual
Controls, instruments and equipment
Control devices
Pilot lamps
On-board computer with multifunction pointer
Operation control
Violations of paramount importance (red pictograms)
Violations of minor importance (yellow pictograms)
Navigation system
Car keys
Car door
Backdoor
Central locking
How to unlock only one of the front door locks
Central locking button
Security alarm system
Remote radio control of locks
Unlocking and locking the vehicle
Power windows
Power window operation with ignition on
The operation of the power windows when the ignition is off.
Sliding sunroof panel
Breakers and switches
Electronic stabilization system ESP
Anti-slip system ASR
Steering column switch for direction indicators and headlights
Interior lighting
Windshield wipers and washers
Wiper blades
Replacing wiper blades
Rear view mirrors
Rear window heating
Sun visors
Front seats
Driver's seat
Driver's seat memory
Front passenger seat
Seat adjustment by electric drive
Seat and exterior mirror adjustments for forward movement
Exterior mirror adjustment when reversing
Radio remote control key
Recalling seat and mirror settings for forward travel
Calling up the right mirror setting when reversing
Instructions for using the blocking switch E
Initializing the silena memory system
Seat head restraints
Armrests
Seat heating
Adjustable steering column
Mounting eyes
Luggage shelf
Rear bench seat
Coasters
Ashtrays
Heating and ventilation
Heating and ventilation air nozzles
How to defrost windshield and side windows
How to prevent fogging of the windshield and side windows
How to quickly raise the temperature in the cabin
How to keep the cabin pleasantly warm
Ventilation (fresh air supply to the cabin)
Climate control controls
Nozzles for supplying air to the air conditioner
How to set normal air cooling mode
How to set the maximum air cooling mode
Cabin ventilation
Economical operation of the air conditioner
Violations in the operation of the air conditioning system
Climate control «Climatronic»
Using the unit «Climatronic»
Use «Climatronic» when working in automatic mode (AUTO)
Deviation from the standard automatic installation mode «Climatronic»
Installation Air Nozzles «Climatronic»
Economical plant operation «Climatronic»
Plant failures «Climatronic»
Manual Transmission
Automatic transmission
Positions of the selector of an automatic box
Recommendations for choosing the positions of the automatic box
Parking brake
Egnition lock
Cruise control
Turning on cruise control
Installation (memorization) desired driving speed
Changing the set travel speed
Momentary deactivation of cruise control
Final deactivation of cruise control
Inflatable airbags
Action of inflatable pillows
Deactivating the front passenger airbag
Side airbags
Operation of the side airbag system
Refueling
Fuel for gasoline engines
Fuel for diesel engines
Vehicle braking
Anti-Lock Braking System
Traction control (EDS)
Traction control with torque reduction (ASR)
Power steering
Engine compartment hood
Towing eyes
Driving a car
Weekly checks
Triggering from an external source (another car)
If the engine does not start and the starter does not work
If the engine does not start even though the starter is working properly
Wheel replacement
Towing a car
Checking the tightness of connections
Weekly checkpoints
Checking the engine oil level
Checking the coolant level
Checking the wiper blades
Checking the washer fluid level
Checking the brake fluid level
Checking the electrical system
Battery check
Tires and tire pressure check
Vehicle identification
Maintenance
Vehicle maintenance
Vehicle Specifications
Service interval
Maintenance Schedule
Viscosity and engine oil specifications
The quality of motor oils
Mixing engine oil
Changing the oil and oil filter
Changing the oil filter on diesel engines
Exhaust system check
Engine cooling system
Checking the level and density of the coolant
Loss of coolant
Adding coolant
Replacing the air filter element
Checking the condition of the poly V-belt
Spark plug
Replacing spark plugs
A few practical tips for choosing candles and their maintenance
Fuel filter replacement (diesel engines)
Checking the tightness of the hoses and fluid leakage
V-belts
Measuring the wear of toothed belts on diesel engines
Gearbox/final gear
Checking the protective cover of the drive shaft
Visual inspection of the gearbox for tightness
Checking the oil level in a manual transmission
Checking the oil level in the main gear of the automatic transmission
Checking/replacing the oil level in an automatic transmission
Checking the front suspension and steering
Checking the dust covers of the front suspension joints
Shock absorber check
Radiator check
Wiring check
Checking the fluid level in the power steering
Brake fluid
Checking the brake fluid level
Brake Fluid Replacement
Checking the front brake pads
Checking the rear disc brake pads
Checking the rear brake pads of drum brakes
Checking the brake hoses
Checking the condition of the seat belts
Airbags
Door hinges
Replacing the dust filter
Accumulator battery
Checking the electrolyte level
Battery operation in winter conditions
Battery charge
Disconnecting the battery from the on-board network
Removing and installing the battery
Buying a battery
Windshield washers
Wiper blades
Checking the initial position of the wiper arm
Replacing the battery in the remote control key
Resetting the Service indicator
Power unit
Petrol engines
Gasoline engines
Technical characteristics of engines
Removal and installation of the lower mudguard of the engine compartment
Removing the engine 1.6-/1.8-I
Engine installation 1.6-/1.8-I
Removal of a gear belt of engines 1,6-/1,8-I
Installing the piston of the first cylinder at TDC of 1.6-/1.8-I engines
Inspection of the toothed belt of engines 1.6-/1.8-I
Installation of a gear belt of engines 1,6-/1,8-I
Engine cylinder head 1.6-I
Removal of a head of the block of cylinders of engines 1,6-/1,8-I
Preparation of the engine head 1.6-/1.8-I for installation
Installing the engine head 1.6-/1.8-I for installation
Checking hydraulic valve tappets for 1.6-/1.8-I engines
Dismantling of a head of the block of cylinders of engines 1,6-/1,8-I
Cleaning and checking the cylinder head of 1.6-/1.8-I engines
Cylinder head assembly for 1.6-/1.8-I engines
Toothed belt engine 1.4-I
Removal of a head of the block of cylinders of the engine 1,4-I
Installation of a head of the block of cylinders of the engine 1,4-I
Engine timing gear drive 2.3-I-VR5
Removal and installation of a head of the block of cylinders of the engine 2,3-I-VR5
Checking compression in the engine cylinders
Removing the V-ribbed belt for engines 1.6-/1.8-I
Installing the V-ribbed belt for 1.6-/1.8-I engines
Removing the V-ribbed belt of engines 1.4-I
Installing the V-ribbed belt of engines 1.4-I
Removing the V-ribbed belt of engines 2.3-I
Installing the V-ribbed belt for 2.3-I engines
Engine Oil Recommendations
Engine oil circuit
Checking the oil pressure and oil pressure sensor
Removal and installation of the oil pallet
Starting the engine after a major overhaul
Engine Troubleshooting
The main malfunctions of the lubrication system
Diesel engines
Diesel engines — general information
Technical characteristics of diesel engines
Removal and installation of the power unit
Toothed belt for TDI and SDI diesel engines
Removing the toothed belt
Setting the piston of the first cylinder to TDC
Installing and tensioning the toothed belt
Checking the toothed belt tensioner
Removal and installation of a head of the block of cylinders
Removal and installation of an inlet collector of the diesel SDI engine
Checking compression in the engine cylinders
Removal and installation of poly V-belt
Checking the oil pressure and oil pressure sensor
Removal and installation of the oil pallet
Diesel engine troubleshooting
The main malfunctions of the lubrication system
Cooling system
Elements of the cooling system
Adding coolant
The composition of the coolant mixture
Coolant replacement
Coolant drain
Filling the cooling system
Removing the thermostat
Checking the functionality of the thermostat
Installing a thermostat
Removing the heatsink and fan
Heat sink and fan installation
Removal and installation of the water pump on the 4-cylinder petrol engine
Removal and installation of the water pump on a 5-cylinder gasoline engine
Removal and installation of the water pump on the diesel engine
Coolant hoses
Cooling system malfunctions
Fuel system (petrol)
Fuel tank of vehicles with gasoline engines
Removal and installation of the fuel pump / fuel level sensor
Removal and installation of the fuel filter (gasoline engines)
Accelerator cable adjustment
Removing and installing the air filter housing
Remote check of the fuel pump
Checking the voltage supply of the fuel pump
Checking the performance of the fuel pump
Checking the fuel pump relay
Control system (petrol)
Engine management system
Technical data of the engine management system
Operation of the engine management system
Checking the fuel injection system
Sensors and actuators of the engine management system
Ignition system
Ignition coil device
Spark plug
Removal and installation of the fuel line and nozzles
The main malfunctions of the engine management system
Fuel system (diesel)
Vehicles with diesel engines
Direct fuel injection
Diesel fuel system technical data
Checking the diesel engine preheating system
Checking glow plugs
Removal and installation of glow plugs
Fuel heating system
Fuel injectors
Removal and installation of fuel injectors
High pressure fuel pump injection timing
The main malfunctions of the engine management system
Exhaust system
Exhaust system device
The device and use of the catalyst
Removal and installation of the exhaust system
Exhaust system alignment
Replacing the middle / rear muffler
Removal and installation of one muffler
Removal and installation of a lambda sensor
Transmission
Clutch
Removing the clutch disc
Checking the clutch disc
Installing the clutch disc
Removing the clutch disc on vehicles with 1.4 and 1.6-I engines
Checking the clutch disc on vehicles with 1.4 and 1.6-I engines
Installing the clutch disc on vehicles with 1.4 and 1.6-I engines
Bleeding the hydraulic clutch
Bleeding with a pressure bleed kit
Basic clutch malfunctions
Car gearbox
Gearbox Description
Removal and installation of a transmission (engines 1.8/1.9/2.3-I)
Removal and installation of a transmission (engines 1.4/1.6-I)
Removal and installation of an automatic transmission
Gear shift mechanism
Removal and installation of the case of the lever of a gear change
Gear shift cable adjustment (engines 1.4-/1.6-I)
Gear shift cable adjustment (engines 1.8-/1.9-/2.3-I)
Checking shift cable adjustment
Evaluation of the performance of an automatic transmission
Adjustment of draft of a cable of the lever of a gear change
Checking shift cable adjustment
Drive shafts
Removal and installation of a power shaft
Replacing the protective covers of the drive shaft
Mounting position of disc springs
Filling joints with grease
Drive shaft failures
Chassis
Car suspension
Front suspension device
Removing the front suspension strut
Installing the front suspension strut
Removing and assembling the shock absorber and front suspension spring
Rear suspension device
Removal and installation of the shock absorber and rear suspension spring
Checking the rear shock absorber
Shock Absorber Disposal
Steering
Steering Description
Removal and installation of an airbag
Removal and installation of a steering wheel
Removal and installation of a tip of steering draft
The main malfunctions of the suspension and steering
Wheels and tires
General information about wheels and tires
Guidelines for the use of directional tires
Tire wear indicators
Checking the valve
Wheel swap
Rims and tires
Spare wheel
Wheel replacement
Secret bolts for fixing wheels
Anti-skid chains
Vehicle lifting
Brake system
Description of the braking system of the car
Technical specifications
Brake system diagram
Removing the front brake pads on the FS-III caliper
Installing the front brake pads on the FS-III caliper
Removing the brake pads on the FN-3 caliper
Installing brake pads on FN-3 caliper
Removing the rear brake pads on disc brakes
Installing rear brake pads on disc brakes
Checking the brake disc
Removal and installation of a brake disk
Handbrake adjustment
Removing the rear brake pads on drum brakes
Installing rear brake pads on drum brakes
Removal and installation of the back working brake cylinder
Bleeding the hydraulic brake system
Bleeding the brakes — the main method (two people)
Bleeding the brakes — using the one-way valve kit
Bleeding the brakes — using a pressure bleeding kit
Bleeding the brakes — all methods
Brake lines and hoses
Checking the vacuum brake booster
Removal, installation and adjustment of the brake light switch
Removal and installation of cables of a manual brake
The main malfunctions of the brakes
Body
Exterior (external elements)
General information about body repair
Body Care
Repair of minor body damage
Repair of severe damage to the body
Front body panel
Removal and installation of a forward bumper
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of facing of a niche of a forward wing
Removal and installation of facing of a niche of a back wing
Removal and installation of a cowl
Hood adjustment
Removal and installation of the lock of a cowl
Removal and installation of the handle of opening of the lock of a cowl
Removal and installation of a radiator grille
Removal and installation of a lateral lining of a body
Gutter cleaning
Removal and installation of an external rear-view mirror/glass of a mirror
Removing the exterior mirror housing
Interior (internal elements)
Caring for upholstery and rugs
Removal and installation of an internal rear-view mirror
Removal and installation of a rear-view mirror with a rain sensor
Auto-dimming interior rear view mirror
Removal and installation of the front section of the center console
Removal and installation of the rear section of the center console
Removal and installation of the rear ashtray / cup holder
Removal and installation of the forward holder of glasses
Removal and installation of the upper trim in the driver's footwell
Removal and installation of a ware box
Removal and installation of a side covering of space for legs
Removal and installation of overlays of thresholds
Removal and installation of the bottom facing of the central rack
Removal and installation of the right lateral covering of a luggage space
Removal and installation of a covering of a floor of a luggage space
Removal and installation of the rear trim of the luggage compartment
Removal and installation of a forward seat
Side airbags
Removing the rear bench seat cushion
Removal and installation of a back of a back seat
Ventilation and heating
Elements of the heating and ventilation system
Removing and installing air nozzles
Installing the central damper lever
Removal and installation of the heater fan and additional resistor
Removal and installation of control cables for the heating and ventilation system
The damper that regulates the temperature of the air supplied to the passenger compartment
Removal and installation of the heater control unit
Vehicle interior ventilation
Air recirculation valve actuator
Air conditioning system
A/C compressor brackets
Car doors and sunroof
Removal and installation of a rack of a back door
Tailgate/Tailgate Adjustment
Removal and installation of the lock of a back door
Removal and installation of a door
Removal and installation of interior door trim
Removal and installation of the internal door lock button
Removal and installation of door glass
Removal and installation of an arm of a door
Removal and installation of the external handle of opening of a door
Removal and installation of the lock cylinder housing
Removal and installation of the door lock
Central locking system
Removal and installation of the top upholstery of a back door
Removal and installation of the bottom upholstery of a back door
Hatch drive
Removal and installation of a glass movable cover of the hatch
Removal and installation of consolidation of a cover of the hatch
Removal and installation of fairings of the hatch
Removal and installation of a sun-protection blind
Removal, adjustment and installation of the hatch opening drive mechanism
Checking the parallel movement of the sunroof
Washers and glass cleaners
Replacing the rubber bands of the wiper blades
Windshield washer nozzle adjustment
Removal and installation of windshield washer nozzles
Removal and installation of nozzles of a washer of back glass
Removal and installation of wiper arms
Removal and installation of the windshield wiper motor
Removal and installation of tanks and washer pump
Removal and installation of the rear window wiper motor
Electrical equipment
Power devices
Battery Care Rules
Battery check
Accumulator charging
Removing the battery
Installing the battery
Notes on batteries with vent plugs
Battery Charging System
Description of the generator
Removal and installation of the generator
Replacement of generator brushes and voltage regulator
Main generator malfunctions
Description of the starter
Engine start system
Removal and installation of a starter
Check, removal and installation of the traction relay of a starter
The main malfunctions of the starter
Lighting and appliances
General information about electrical equipment
Incandescent lamps
Electrical circuits
Open Circuit Detection
Open circuit detection
Short circuit source detection
Bad ground detection
Location and purpose of the fuses
Replacing exterior light bulbs
Removal and installation of an additional signal of braking
Replacing interior light bulbs
Removal and installation of headlights
Removal and installation of a back lantern
Headlight adjustment
Removal and installation of the executive engine of the corrector of light of headlights
Removal and installation of a combination of devices
Removal and installation of steering column switches
Removal and installation of switches
Removal and installation of the radio receiver
Removing and installing tweeters
Removal and installation of subwoofers
Phone Installation Recommendations
External antenna
Checking the rear window heater
Electrical circuits
Explanations for electrical diagrams
Wiring plan (VW Golf since September 1997)
Location of relays and fuses
Symbols on electrical diagrams
Symbols of elements on electrical diagrams
Scheme 1. Battery, ignition switch and overload relay for X-terminal
Scheme 2. Instrument cluster and traffic safety
Scheme 3. Instrument cluster, tachometer, tachograph
Scheme 4. Instrument cluster, control of the tightened hand brake lever...
Scheme 5. Turn signal switch, dimmer and light switch...
Scheme 6. Hazard light switch with turn signal relay, front and right lamps
Scheme 7. Brake light switch, brake light, fog light...
Scheme 8. Rear right side light, brake light, right reversing light...
Scheme 9. Diagnostics, radio, cigarette lighter
Scheme 10. Light switch
Scheme 11. Two-tone horn, glove box light, license plate light
Scheme 12. Headlight beam corrector, headlight range control actuator
Scheme 13. Heater fan and recirculated air switch, heater fan...
Scheme 14. Rear window heater, rear window wiper motor...
Scheme 15. Wiper switch, wiper motor
Scheme 16. Front cover, reading lamp left rear, signal lamp left door
Scheme 17. Right rear reading lamp, right door signal lamp
Scheme 18. Starter, generator
Scheme 19. Control unit for the 4AV fuel injection system, ignition system...
Scheme 20. Control unit for the 4AV fuel injection system, throttle control unit...
Scheme 21. Control unit for the 4AV fuel injection system, intake manifold pressure sensor...
Scheme 22. Control unit for the 4AV fuel injection system, Lambda sensor...
Scheme 23. Oil pressure sensor, fuel pump, fuel gauge...
Scheme 24. Instrument cluster, optical and acoustic oil pressure check...
Scheme 25. Instrument cluster, coolant temperature gauge, fuel gauge...
Scheme 26. Generator, starter (diesel engines)
Scheme 27. Diesel direct injection system control unit, KICK-DOWN, idle switch...
Scheme 28. Diesel direct injection system control unit, coolant temperature sensor...
Scheme 29. Control unit for diesel direct injection system
Scheme 30. Diesel Direct Injection Control Unit, Suction Line Changeover Valve
Scheme 31. Diesel direct injection system control unit, speed control switch (GRA)...
Scheme 32. Diesel direct injection system control unit, glow plugs
Scheme 33. Fuel gauge, low coolant level sensor
Scheme 34. Instrument cluster, optical and acoustic oil pressure check, speed sensor...
Scheme 35. Instrument cluster, coolant temperature gauge, fuel gauge
Scheme 36. Heated wiper nozzles
Scheme 37. Reversing lamps left, left rear position light, brake light, fog lamp
Scheme 38. Electrical outlet for the operation of a vehicle with a trailer, fog light switch
Scheme 39. Rear right side light, brake light, left reverse lamp...
Scheme 40. Left fog lamp, left headlight, left parking light...
Scheme 41. Right fog lamp, fog lamp relay, right lamp...
Scheme 42. Light switch, fog light switch, light switch
Scheme 43. Fog lamp, right rear parking light, brake light, reversing lamp
Scheme 44 Radio, CD changer, front speakers
Scheme 45. Radio, front speakers, rear speakers
Scheme 46. Radio receiver, antenna
Golf 5
General information
User manual
Introduction to instructions for Volkswagen Golf 5
Car control panel
Buttons on the multifunction steering wheel
Dashboard
Display in the instrument panel
On-board computer (MFA)
Warning and information messages on the display
Main menu on the instrument panel display
Signal and control lamps
Car keys
Central locking
Locking the rear side doors when transporting children
Remote control of locks
The security alarm system turns on the alarm mode when you try to break into the car
Heater control
Air conditioner control
Climate control
Egnition lock
Manual Transmission
Automatic transmission
Manual gear shift «tiptronic»
Turning on cruise control
Car technical data
Maintenance
Starting the engine using a booster battery
Towing a car
Poddomkrachivanie car
Maintenance — general information
Maintenance — work plan
Maintenance — work
Engine oil level — check
Engine oil and oil filter — change
Coolant — level check
Fuel filter — replacement (diesel)
Air filter — filter element replacement
V-belt — check
Exhaust System — Visual Inspection
Toothed belt — check
Spark plugs — replacement
Transmission. main gear
Automatic Transmission — Checking the Transmission Oil Level
DSG Automatic Transmission — Oil and Oil Filter Change
Haldex differential — oil change
Front suspension and steering
Brakes. Tires. wheels
Brake lining thickness — check
Brake lines — check
Brake Fluid — Change
Tire Tread Height Measurement
Tire pressure — check
Tires and wheels — designations
Wheel balancing
Anti-skid chains
Removal and installation of wheels
Tire pressure monitoring
Some tips for caring for tires
Tire repair kit — check and change
Tire pressure monitoring indicator — setting
Belts and airbags
Cabin filter — replacement
Vehicle electrical system
Accumulator battery — check
Glass Wiper Blades — Check Home Position
Troubleshooting
Determination of engine malfunctions and their elimination
Determination of malfunctions of the engine cooling system and their elimination
Possible malfunctions of the heating system, their causes and remedies
Determination of malfunctions of the gasoline injection system and their elimination
Determination of malfunctions of the brake system and their elimination
List of starter malfunctions and their elimination
Identifying Generator Faults and Troubleshooting
Identifying Battery Faults and Troubleshooting
Determination of malfunctions of a screen wiper and their elimination
Power unit
Engine repair
Engine Specifications
Vehicle and engine identification
Upper engine cover — removal and installation
Gas distribution mechanism drive (gasoline engine 1.4 liters, 75 hp. With.)
TDC of the piston of the cylinder No. 1 (gasoline engine 1.4 liters, 75 hp s., VSA)
Cylinder head (gasoline engine 1.4 liters, 75 hp s., VSA)
Cylinder head (1.4/1.6 liter FSI petrol engines, BKG/BLN/BAG/BLF/BLP)
Gas distribution mechanism drive (petrol engine 1.6 liters, 102 hp. With.)
TDC of the piston of the cylinder No. 1 (gasoline engines 1.6 liters, 102 liters. s., BGU/BSE/BSF)
Cylinder head (gasoline engines of 1.6 liters, 102 liters. s., BGU/BSE/BSF)
Gas distribution mechanism drive (gasoline engine FSI 2.0 liters, 150 hp. With.)
Cylinder head (petrol engines 2.0 liters, 150 hp s., AWX/BLR/BLX/BLY)
Gas distribution mechanism drive (diesel engines 1.9/2.0 liters, 55-77 kW)
TDC of the piston of the cylinder No. 1 (diesel engines 1.9 / 2.0 liters, 75/90/100/105 liters. s., AVQ/BRU/BJB/BKC/BLS/BDK)
Toothed belt — installation (diesel engines 1.9 / 2.0 liters, 75/90/100/105 liters. s., AVQ/BRU/BJB/BKC/BLS/BDK)
Cylinder head cover and block head — removal and installation
Gas distribution mechanism drive (diesel engines 2.0 liters, 100/103 kW)
TDC of the piston of cylinder No. 1 and laying the toothed belt
Tightening torques for threaded connections of engine mount parts
Ribbed belt — removal and installation
Engine — starting
Engine lubrication system
Oil pump and oil pan (FSI 1.4/1.6 liter petrol engines)
Cooling and ventilation system
Engine cooling system
Coolant — replacement
Thermostat — removal and installation
Thermostat — check
Water pump — removal and installation
Radiator — removal and installation
Radiator blower fan — removal and installation
Heater and air conditioner
Outside temperature sensor — removal and installation
Central deflector — removal and installation
Side deflectors — removal and installation
Interior air vents — removal and installation
Heater / air conditioner control unit — removal and installation
Temperature damper cable Removal and installation
Air distribution damper actuator — removal and installation
Electric motor and additional resistance of the interior blower fan — removal and installation
Heating element — removal and installation
Fuel system
Fuel Injection Specifications (petrol)
General description of the fuel system and precautions (petrol)
Fuel injection system — general check (petrol)
The lower part of the intake tract — removal and installation (1.6 liter BGU/BSE/BSF petrol)
Working principle of diesel engine
Glow plugs — removal and installation (diesel)
Preheating device — check (diesel)
General provisions for the fuel system
Fuel pump and fuel gauge sensor — removal and installation
Fuel gauge sensor — removal and installation
Fuel filter — removal and installation
Air filter — removal, installation and disassembly
General information about the exhaust system
System of release of the fulfilled gases — removal and installation
Primary and secondary mufflers — replacement
Ignition system
General description and security measures
Candles and ignition coils (petrol)
Glow plugs — replacement (diesel)
Ignition system — diagnostics
Measurement of signals from sensors and other components of the ignition system with an oscilloscope
Transmission
Clutch
General description of clutch
Clutch pedal — removal and installation
Clutch master cylinder — replacement
Mechanical gearbox
General information about manual transmission
Gear Select Cables — Adjustment
Gearshift mechanism — removal and installation
Gearbox — removal and installation
Automatic gearbox
General information about automatic transmission
Removal and installation of the automatic transmission control mechanism
Checking the automatic transmission control mechanism
Removing the selector cable of the automatic transmission control mechanism
Installing the shift cable
Shift Cable Adjustment
Transmission pan and oil intake — removal and installation
Multifunction switch — removal, installation and adjustment
Valve body and sensors — removal and installation
Chassis
Brake system
Brake Specifications
General information about the brake system
Brake pads of disc brakes of the front wheels — removal and installation
Front wheel brake caliper — removal and installation
Rear disc brakes
Rear wheel brake pads — removal and installation
Rear wheel brake caliper — removal and installation
Brake disc — check
Brake disc — removal and installation
Parking brake cable — removal and installation
Parking brake — adjustment
Brake System — Bleeding
Vacuum brake booster — check
Brake hoses — removal and installation
Stoplight switch — removal and installation
Car suspension
General Suspension Information
Car front suspension
Front suspension strut — removal and installation
Front suspension strut — disassembly
Drive shaft — removal and installation
Drive Shaft — Disassembly
Drive shaft — replacement of the cuff CV joint
Hub bolt — removal and installation
Car rear suspension
Rear suspension coil spring — removal and installation
Rear suspension shock absorber — removal and installation
Rear suspension shock absorber — disassembly and assembly
Steering
Steering — general information
Airbags — precautions
Airbag unit on the steering wheel — removal and installation
Steering wheel — removal and installation
Tie rod end — removal and installation
Steering gear cuff — removal and installation
Body
Interior (internal elements)
Salon — general provisions
Rear-view mirror — removal and installation
Sun visor — removal and installation
Handle above the door — removal and installation
Cover of the gear lever — removal and installation
Center console — removal and installation (Golf)
Center console — removal and installation (Touran)
Footwell side molding — removal and installation (Touran)
Overlay of a radio receiver and block of switches of a heater — removal and installation
Facing of a steering column — removal and installation
Instrument panel — removal and installation
Dashboard lower trim, driver's side (Touran)
Dashboard lower trim, driver's side (Golf)
Dashboard upper trim, driver's side (Golf)
Cover under the side of the heater switches (Golf)
Glove box — removal and installation
Overlay of a threshold of a door — removal and installation
Facing of a forward rack — removal and installation (Golf)
Facing of the central rack — removal and installation (Golf)
Upper lining of the rear pillar — removal and installation (Golf)
Trim above the rear wheel arch inside the cabin (Golf)
Lateral facing of a back part of salon (Golf)
Trunk shelf — removal and installation (Golf)
Side upholstery of the trunk — removal and installation
Facing of a back cross member — removal and installation
Decorative overlay of the ceiling cross member — removal and installation
Door sill trim — removal and installation
Facing of a forward rack — removal and installation (Touran)
Facing of the central rack — removal and installation (Touran)
Facing of a back rack — removal and installation
Lateral upholstery of a back part of salon — removal and installation
Facing of a back rack D — removal and installation (Touran)
Trunk floor — removal and installation (Touran)
Facing of the back panel — removal and installation (Touran)
Front seat — removal and installation
Rear seat — removal and installation (Golf)
Side armrests of the rear seats — removal and installation (Golf)
Rear seats — removal and installation (Touran)
Belt guide bracket (Golf)
Exterior (external elements)
Body — general description and precautions
Mudguard of the engine — removal and installation
Fairing grille — removal and installation
The upper cross member of the front end — installation in the service position
Front bumper — removal and installation
Rear bumper — removal and installation
Radiator grill — removal and installation
Front fenders — removal and installation
Fender liner — removal and installation
Moldings — removal and installation
Hood — removal and installation
Hood — fit
Bonnet lock — removal, installation and fitting
Hood lock cable — removal and installation
Gas-filled emphasis — removal and installation
Mirror glass — removal and installation
Rear view mirror housing — removal and installation
Side rear-view mirror — removal and installation
Doors and covers
Tailgate — removal, installation and fitting
Tailgate lock — removal and installation
Trunk lock cover — removal and installation (Jetta)
Upholstery of a back folding door — removal and installation
Door — removal and installation (Golf)
Door — fit (Golf)
Front door — device (Golf)
The outer part of the front door — removal and installation
Side rear door — removing and installing the outer part of the door
Door lock and outer door handle bracket — removal and installation
Side door amplifiers — removal and installation
Door glass — removal and installation
Power window motor — removal and installation
Power windows — removal and installation
External door handle — removal and installation
Lock cylinder — removal and installation
Door — removal and installation (Touran)
Door lock — removal and installation (Touran)
Window regulator — removal and installation (Touran)
Power window motor — removal and installation (Touran)
Door upholstery — removal and installation
Window regulator handle — removal and installation
Electrical equipment
Power devices
Battery — removal and installation
Battery — check
Generator — voltage test
Generator — removal and installation
Starter — removal and installation
Washers and wipers
Wiper — removal and installation
Windshield washer jets — removal and installation
Rear window washer jet — removal and installation
Headlight washer jet — removal and installation
Washer reservoir — removal and installation (Golf)
Washer reservoir — removal and installation (Touran)
Windshield wiper brush holders — removal and installation
Windshield wiper motor (Golf)
Windshield wiper motor (Touran)
Tailgate glass wiper arms — removal and installation
Rear window wiper motor — removal and installation
Rain sensor — removal and installation (Golf)
Lighting and appliances
Opening plug connections
Sound signal — removal and installation
Batteries in the remote control
Parking aid sensors — removal and installation
Fuses — replacement
Lighting fixtures — general provisions
Headlight bulbs — replacement (Golf)
Headlight bulbs — replacement (Touran)
Headlight — removal and installation
Executive electric motor of the tilt regulator of the optical axis of the headlights (Golf)
Fog lights — removal and installation
Rear headlamp — removal and installation (Golf)
Rear headlamp — removal and installation (Touran)
Side repeater — removal and installation
Door lighting lamp — removal and installation
License plate light — removal and installation
Additional brake light — removal and installation
Interior lights — replacing light bulbs (Golf)
Interior lights — replacing light bulbs (Touran)
Instrument panel — removal and installation
Steering column switches — removal and installation
Light switch — removal and installation
Switches in the cabin — removal and installation (Golf)
Switches in the cabin — removal and installation (Touran)
Radio receiver — removal and installation
CD changer on the center console — removal and installation
Speakers — removal and installation (Golf)
Speakers — removal and installation (Touran)
Antenna signal amplifier — removal and installation
Roof antenna — removal and installation
Electrical circuits
Reading electrical diagrams
Symbols of the most important components and parts
Instructions for reading electrical circuits
Scheme 1. Battery, terminals 30 and 15 of the power relay...
Scheme 2. Switching relay of the on-board electrical system, fuses
Scheme 3. Left headlight, left and right fog lamp...
Scheme 4. Right headlight, dimmer, switch lights...
Scheme 5. Right marker, left marker, left fog lamp bulb...
Scheme 6. Light switch, fog light switch...
Scheme 7. Bulb of an additional brake light, license plate light...
Scheme 8. Relay for steering column adjustment system, glass cleaner switch...
Scheme 9. Cruise control switch, X terminal unloader relay, steering column angle relay...
Scheme 10. Ignition lock, steering column tilt relay, turn signal switch...
Scheme 11. Hood contact switch, rain and light sensor, dual washer pump relay 2...
Scheme 12. Windshield wiper motor, washer pump, rear window heater...
Scheme 13. Low tone horn, double tone horn relay, fuel door motor...
Scheme 14. Front interior lamp, left reading light in the rear of the cabin...
Scheme 15. Cigarette lighter, 12 V socket, rear cigarette lighter, driver's vanity mirror light...
Scheme 16. Emergency light switch, alarm lamp...
Scheme 17. Heater switches, additional resistance of the interior blower fan...
Scheme 18. Instrument panel, anti-theft reading coil, parking brake light sensor...
Scheme 19. Instrument panel, engine oil pressure sensor, outside air temperature sensor...
Scheme 20. Instrument panel, on-board electrical system switching relay, warning lights...
Scheme 21. Instrument panel, diagnostic connector, warning lights
Scheme 22. Switching relay of the on-board electrical system, diagnostic socket
Polo 3
General information
User manual
Information about Polo Classic, Polo Variant and Caddy
Location of switches, instruments and control levers
Removing and adjusting head restraints
Seat adjustment
Rear seats
Parking brake system drive lever
Manual transmission
Steering wheel height adjustment
Ignition switch
Dashboard
Signal lights
Device switches
Heating and ventilation system
Air conditioner controls
Opening and closing the hood
Engine compartment
Checking the levels of the main working fluids
Wheel swap
Spare wheel
Main and additional fuses
Replacing incandescent lamps
Starting the engine from the auxiliary battery
Identification plates
Maintenance
Engine Specifications
Scheduled maintenance
Replacing the air filter element
Replacing spark plugs
Checking the oil level in the manual transmission
Checking the thickness of the brake linings
Power unit
Petrol engines 1.4 and 1.6
Technical characteristics of engines AEX, APQ, AKV, ANX 1.4 l and AEE, ALM 1.6 l
Removing and installing ribbed belt
Checking the self-adjusting tension roller
Timing Belt Installation
Cylinder block, camshaft and flywheel
Connecting rod and piston group
Cylinder head
Compression test
Gas distribution mechanism
Valve seat processing
Removal and installation of a camshaft
Checking hydraulic lifters
Checking the valve guide
Lubrication system
Checking the oil pressure and oil pressure sensor
Cooling system
Supply system
Accelerator cable adjustment
Fuel pump check
Gasoline vapor recovery system with carbon filter
Exhaust gas exhaust system
Fuel injection and ignition control system
Self-diagnosis of the injection system
Connecting a fault code reader VAG 1551
Checking and clearing the fault memory
Reading the measured value block and basic settings
Checking the fuel pressure regulator and holding pressure
Checking the operating modes of the engine
Checking the intake manifold pressure sensor
Checking the coolant temperature sensor
Checking the intake air temperature sensor
Checking the oxygen sensor (lambda probe)
Checking the Oxygen Sensor Heater
Injector test
Checking and adjusting the ignition timing
Hall sensor test
Checking the ignition coil
Checking the knock sensor
Fault codes
Petrol engines 1.4 (V16)
Technical characteristics of engines APE, AUA 1.4 16V
Engine disassembly
Removing and installing ribbed belt
Checking the valve timing
Removing and installing timing belt
Cylinder block, sealing flange and flywheel
Connecting rod and piston group
Cylinder head
Removal and installation of the camshaft housing
Compression test
Gas distribution mechanism
Valve seat processing
Checking the valve guide
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Fuel pump check
Electronic engine management system (EPC)
Checking the Accelerator Pedal Position Sensor
Gasoline vapor recovery system
Exhaust gas exhaust system
Exhaust gas recirculation system
Fuel injection and ignition control system
Self-diagnosis of the injection system
Connecting a tester
Checking and clearing the fault memory
Reading a block of measured values
Checking the intake manifold pressure sensor
Checking the intake air temperature sensor
Checking the coolant temperature sensor
Checking the crankshaft speed sensor
Checking the fuel pressure regulator and holding pressure
Hall sensor test
Checking the ignition coil
Fault codes
Petrol engines 1.6 and 1.8
Specifications for 1F, AFT 1.6l and ADZ 1.8l engines
Engine disassembly
Removing and installing timing belt
Crankshaft
Connecting rod and piston group
Cylinder head
Compression test
Gas distribution mechanism
Valve seat processing
Checking hydraulic lifters
Checking the valve guide
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Accelerator cable adjustment
Fuel pump check
Gasoline vapor recovery system with carbon filter
Exhaust gas exhaust system
Fuel injection and ignition control system Mono-Motronic
Self-diagnosis of the injection system
Connecting a fault code reader VAG 1551
Fault memory interrogation
Clearing the fault memory
Reading the measured value block and basic settings
Checking the oxygen sensor and lambda control
Checking the Oxygen Sensor Heater
Checking the operating modes of the engine
Checking the coolant temperature sensor
Injector test
Checking the intake air temperature sensor
Installing the ignition distributor
Checking and adjusting the ignition timing
Hall sensor test
Checking the ignition coil
Fault codes
Diesel engines 1.7 and 1.9
Diesel engines AKW, ANV 1.7 SDI, AEY 1.9 SDI, AFN, AHU and ALE 1.9 TDI, 1Y 1.9 D
Engine disassembly
Timing belt drive with single pulley injection pump
Timing belt drive with double pulley injection pump
Sealing flange and flywheel / drive plate / pressure plate
Crankshaft
Connecting rod and piston group
Checking piston protrusion at TDC
Cylinder head
Compression test
Gas distribution mechanism
Valve seat processing
Checking the valve guide
Checking hydraulic lifters
Replacement of the vortex chamber (only on 1Y engines)
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Supply system
Fuel filter
Accelerator pedal
Checking the Accelerator Pedal Position Sensor (engines AEY, AFN, ANV, AHU, AKW, ALE)
Accelerator pedal position sensor adjustment (engines AEY, AFN, ANV, AHU, AKW, ALE)
Turbocharged diesel engine
Intercooler (intercooling of charge air)
Exhaust gas recirculation system
Checking the elements of the exhaust gas recirculation system
Checking the mechanical EGR valve
Diesel injection control system
Self-diagnosis of the injection system
Connecting a fault code reader VAG 1551
Fault memory interrogation
Clearing the fault memory
Reading a block of measured values
Removal and installation of injection pump
Checking the valve timing
Checking the injectors
Checking the crankshaft speed sensor
Checking the coolant temperature sensor
Checking the temperature sensor in the intake manifold (on engines AFN, AHU, ALE)
Checking the intake air temperature sensor (on engines AEY, ANV, AKW)
Checking the fuel temperature sensor
Checking the nozzle needle displacement sensor
Fault codes
Diesel engines 1.9 D and TD
Specifications for AGP, AQM, AYQ 1.9 D and AGR, ALH 1.9 TD engines
Engine disassembly
Ribbed belt
Sealing flange and flywheel
Connecting rod and piston group
Checking piston protrusion at TDC
Cylinder head
Intake manifold
Removing and installing timing belt
Compression test
Gas distribution mechanism
Valve seat processing
Checking the valve guide
Checking hydraulic lifters
Lubrication system
Checking oil pressure and pressure sensor
Cooling system
Fuel filter
Accelerator pedal
Checking the Accelerator Pedal Position Sensor
Accelerator pedal position sensor adjustment
Turbocharged diesel engine
Intercooler (intercooling of charge air)
Diesel injection control system
Self-diagnosis of the injection system
Connecting a fault code reader VAG 1551
Fault memory interrogation
Clearing the fault memory
Reading a block of measured values
Removal and installation of injection pump
Checking the injectors
Checking the crankshaft speed sensor
Checking the coolant temperature sensor
Checking the fuel temperature sensor
Checking the nozzle needle displacement sensor
Checking the air mass meter
Intake manifold changeover valve check
Fault codes
Transmission
Mechanical gearbox 085
Manual transmission identification
Specifications manual transmission
Clutch drive
Clutch cable without automatic adjuster
Clutch cable with automatic adjuster
Clutch release mechanism
Gear shift mechanism
Checking the oil level in the manual transmission
Disassembly and assembly of the gearbox
Differential
Mechanical gearbox 020/02K
Manual transmission identification
Specifications manual transmission
Checking the oil level in the manual transmission
Chassis
Front suspension
Subframe, anti-roll bar and lower control arm
Removal, installation and check of a spherical support
Removal and installation of the lower arm
Removal and installation of a stretcher
Rounded fist
Shock absorber strut
Half shafts with hinges of equal angular speeds
Half shafts with hinged type «tripod»
Checking the inner CV joint
Checking the outer CV joint
Wheel alignment
Front wheel camber adjustment
Adjustment of a convergence of a forward wheel
Rear suspension
Rear suspension of Classic, Estate cars
Wheel bearing for cars Classic, Estate
Shock absorber strut Classic, Estate
Rear suspension of Caddy cars
Car Wheel Bearing Caddy
Removal and installation of a spring of cars Caddy
Steering
Steering column, steering wheel and driver's airbag
Removal and installation of a pipe of a steering column with a steering column
Pipe for adjusting the steering column height
Driver's airbag
Steering gear
Checking the length of the left tie rod
Power steering pump
Brake system
Technical data of brake mechanisms up to 09.99 of release
Technical data of brake mechanisms from 10.99 of release
Front brakes with brake calipers «VW I» and «VW II»
Removal and installation of brake pads and brake caliper up to 01.96 of release
Removal and installation of brake pads and brake caliper from 01.96 of release
Front brakes with brake calipers «Girling/Lucas»
Removal and installation of brake pads and brake caliper «Girling/Lucas»
Brake calipers «VW I» and «VW II» front brakes
Removal and installation of the brake caliper piston
Brake calipers «Girling/Lucas» front brakes
Removal and installation of the brake caliper piston «Girling/Lucas»
Rear drum brakes
Rear disc brakes
Brake Master Cylinder and Vacuum Brake Booster
Brake force regulator
ABS anti-lock braking system
Self-diagnosis of the brake system
Fault codes
Body
Exterior
Bumper reinforcement with mounts
Front fender
Hood and opening cable
Gas tank cap
Front and rear door
Central locking
Removal and installation of the pump of the central lock
Front and rear bumper
Radiator grille
Drain cover
Front and rear wheel liner
Outside rear view mirror
Body dimensions of cars
Interior
The location of some elements inside the cabin
Driver's glove box
Removal and installation of an internal upholstery of a door
Removal and installation of the instrument panel (until 09.99 release)
Removal and installation of the instrument panel (from 10.99 release)
Electrical equipment
Equipment and instruments (until 2000)
Removal and installation of a starter (gasoline 1.4 l)
Removal and installation of a starter (gasoline 1.6 and 1.8 l)
Car generator
Removal and installation of the instrument panel
The location of the bulbs in the instrument panel
Resetting the service display
Windshield wipers and washers
Removal and installation of elements of a screen wiper
Adjustment of glass and headlight washers
Headlight adjustment
Back light
Removing and installing multifunction switches
Internal switches on the instrument panel
Equipment and instruments (after 2000)
Removal and installation of the instrument panel
Rear view of instrument panel
Instrument cluster self-diagnosis preparation
Instrument panel fault codes
Removing and installing the immobilizer control unit
Removal and installation of the light switch
Removal and installation of switches on the instrument panel
Heating system and air conditioning
Removal and installation of the dust and pollen filter
Removal and installation of deflectors
Removal and installation of regulators of a heater
Disassembly and assembly of the heater
Location of elements of the air conditioning system
A/C compressor bracket (ARE engine)
AC compressor electromagnetic clutch (Sanden)
Evaporator and condenser device
Electrical circuits
How to read and use wiring diagrams
Battery, ignition switch (from 11.1995 release)
Fresh air fan (from 11.1995 release)
Fuel gauge, coolant level and temperature gauge (from 11.1995 release)
Signal and indicator lights, distance meter (from 11.1995 release)
Tachometer, parking brake control switch (from 11.1995 release)
Door light switch, interior dome light (from 11.1995 release)
Distributor of wires for self-diagnosis, cigarette lighter (from 11.1995 release)
Headlight range adjustment, horn (from 11.1995 release)
Headlights, parking light (from 11.1995 release)
Manual switch for low beam headlights and light signal (from 11.1995 release)
Hazard Light System (from 11.1995 release)
Rear turn signal, brake signal (from 11.1995 release)
Headlight switch (from 11.1995 release)
License plate light, reversing lights (from 11.1995 release)
Wipers and washers, heated rear window (from 11.1995 release)
Rear window washer and wiper (from 11.1995 release)
Battery, ignition switch (from 08.1997 release)
Fresh air fan (from 08.1997 release)
Fuel gauge, level and temperature o. and. (from 08.1997 release)
Signal and indicator lights, distance meter (from 08.1997 release)
Tachometer, parking brake sensor (from 08.1997 release)
Door light switch, interior dome light (from 08.1997 release)
Diagnostic connector, cigarette lighter (from 08.1997 release)
Double horn, heated rear window (from 08.1997 release)
Windshield wipers and washers (from 08.1997 release)
Rear window cleaner and washer (from 08.1997 release)
Manual switch for low beam headlights and light signal (from 08.1997 release)
Emergency light signaling (from 08.1997 release)
Headlights, parking lights, front direction indicators (from 08.1997 release)
Rear turn signal, brake light (from 08.1997 release)
Headlight switch (from 08.1997 release)
License plate light (from 08.1997 release)
Headlight range adjustment (from 08.1997 release)
Wiring diagrams (petrol)
Alternator, starter, fuel pump, fuel gauge (from 10.1995 release)
Simos system control unit, ignition system (from 10.1995 release)
Simos system control unit, oxygen sensor (from 10.1995 release)
Simos system control unit, air mass meter (from 10.1995 release)
Oil temperature sensor, oil pressure sensor (from 10.1995 release)
Instrument panel, oil pressure control (from 10.1995 release)
Alternator, starter, intake manifold preheater (from 10.1995 release)
Mono-Motronic system control unit, ignition system (from 10.1995 release)
Mono-Motronic system control unit, throttle potentiometer (from 10.1995 release)
Mono-Motronic system control unit, oxygen sensor (from 10.1995 release)
Instrument panel, fuel gauge (from 10.1995 release)
Alternator, starter, intake manifold preheater (from 08.1997 release)
Mono-Motronic system control unit, ignition system (from 08.1997 release)
Mono-Motronic system control unit, throttle potentiometer (from 08.1997 release)
Mono-Motronic system control unit, oxygen sensor (from 08.1997 release)
Instrument panel, fuel gauge (from 08.1997 release)
Instrument panel, oil pressure control (from 08.1997 release)
Alternator, starter, fuel pump, fuel gauge sensor (from 08.1997 release)
Simos system control unit, ignition system (from 08.1997 release)
Simos system control unit, oxygen sensor (from 08.1997 release)
Simos system control unit, air mass meter (from 08.1997 release)
Oil temperature sensor, oil pressure switch (from 08.1997 release)
Instrument panel, trip odometer (from 08.1997 release)
Generator, starter (from 12.1997 release)
Mono-Motronic system control unit, ignition system (from 12.1997 release)
Coolant temperature sensor (from 12.1997 release)
Injectors, Throttle Position Control (from 12.1997 release)
EVAP reservoir solenoid valve, speed sensor (from 12.1997 release)
Instrument panel, fuel gauge (from 12.1997 release)
Ignition switch, wire distributor for terminal 30 (from 10.1999 release)
Motronic control unit, Hall sensor, ignition coil (from 10.1999 release)
Throttle position regulator (from 10.1999 release)
Knock sensor, injectors (from 10.1999 release)
Stop Lamp Switch, Speed Sensor (from 10.1999 release)
Cooling Fan Thermal Switch (from 10.1999 release)
Coolant temperature gauge, speedometer (from 10.1999 release)
Tachometer, generator warning light (from 10.1999 release)
Battery, starter, ignition switch (from 10.1999 release)
Alternator, relay-regulator, wire distributor for terminal 30 (from 10.1999 release)
Simos system control unit, Hall sensor (from 10.1999 release)
Throttle control unit (from 10.1999 release)
Pneumatic switch / power steering (from 10.1999 release)
Knock sensor I, air mass meter (from 10.1999 release)
Simos system control unit, 1st cylinder injector (from 10.1999 release)
Catalyst oxygen sensor, oxygen sensor heating (from 10.1999 release)
Clutch pedal sensor, brake pedal sensor, speed sensor (from 10.1999 release)
Fuel level sensor, fuel priming pump (from 10.1999 release)
Speedometer, oil pressure warning light (from 10.1999 release)
Oil pressure buzzer, alternator light (from 10.1999 release)
Starter, alternator, relay-regulator, ignition switch (from 10.1999 release)
Ignition coil, wire end to spark plug (from 10.1999 release)
Idle switch, coolant sensor (from 10.1999 release)
Motronic control unit, clutch pedal sensor (from 10.1999 release)
Motronic control unit, knock sensor I, injectors (from 10.1999 release)
Oxygen sensor, air flow meter (from 10.1999 release)
EVAP solenoid valve, fuel pump relay (from 10.1999 release)
Fuel gauge sensor, fuel priming pump (from 10.1999 release)
Coolant temperature gauge, speedometer (from 10.1999 release)
Warning sound oil pressure warning light (from 10.1999 release)
Battery, starter, generator, relay-regulator (from 05.2000 release)
4LV injection control unit, voltage supply (from 05.2000 release)
Direct injection system control unit (from 05.2000 release)
Intake air temperature sensor, Hall sensor (from 05.2000 release)
Engine speed sensor, knock sensor (from 05.2000 release)
Injectors, engine immobilizer control unit (from 05.2000 release)
Oxygen sensor before and after the catalyst (from 05.2000 release)
Stop Lamp Switch, Clutch Pedal Sensor (from 05.2000 release)
Fuel level sensor, fuel priming pump, speed sensor (from 05.2000 release)
Speedometer, oil pressure warning light (from 05.2000 release)
Control unit with a block of indicators in the instrument panel (from 05.2000 release)
Wiring diagrams (diesel)
Battery, generator (from 01.1998 release)
Diesel direct injection system control unit (from 01.1998 release)
Dispenser, injector needle displacement sensor (from 01.1998 release)
Voltage supply relay terminal 30, glow plugs (from 01.1998 release)
Glow plugs, fuel cut-off valve, injection start valve (from 01.1998 release)
Multifunction indicator sensor, speed sensor (from 01.1998 release)
Instrument panel, coolant level gauge (from 01.1998 release)
Instrument panel, oil pressure control (from 01.1998 release)
Battery, generator (from 12.1997 release)
Diesel direct injection system control unit (from 12.1997 release)
Dispenser, injector needle displacement sensor (from 12.1997 release)
Voltage supply relay terminal 30, glow plugs (from 12.1997 release)
Glow plugs, fuel cut-off valve, injection start valve (from 12.1997 release)
Multifunction indicator sensor, speed sensor (from 12.1997 release)
Instrument panel, coolant level gauge (from 12.1997 release)
Speedometer, multifunction indicator switch (from 12.1997 release)
Battery, starter, generator, relay-regulator (from 10.1999 release)
Diesel direct injection system control unit (from 10.1999 release)
Engine crankshaft speed sensor (from 10.1999 release)
Exhaust gas Recirculation valve (from 10.1999 release)
Glow Plug Relay, Glow Plugs (from 10.1999 release)
Coolant temperature sensor, injection start valve (from 10.1999 release)
Fuel cut control unit (from 10.1999 release)
Thermal switch for cooling fan (from 10.1999 release)
Control unit with a block of indicators in the instrument panel (from 10.1999 release)
Warning sound alarm for oil pressure monitoring (from 10.1999 release)
Starter, battery, generator, relay-regulator (from 10.1999 release)
Glow plugs, voltage supply relay terminal 30 (from 10.1999 release)
Intake manifold pressure sensor (from 10.1999 release)
Boost pressure control solenoid valve (from 10.1999 release)
Glow plug relay for coolant (from 10.1999 release)
Coolant temperature sensor (from 10.1999 release)
Stop Lamp Switch, Clutch Pedal Sensor (from 10.1999 release)
Oil Pressure Sensor, Fuel Gauge Sensor (from 10.1999 release)
Coolant temperature gauge (from 10.1999 release)
Tachometer, warning light for oil pressure control (from 10.1999 release)
Battery, starter, generator, relay-regulator (from 05.2000 release)
Diesel direct injection system control unit (from 05.2000 release)
Fuel temperature sensor, throttle travel sensor (from 05.2000 release)
Terminal 30 voltage supply relay, clutch pedal sensor (from 05.2000 release)
Stop Lamp Switch, Intake Manifold Temperature Sensor (from 05.2000 release)
Glow Plug Relay, Glow Plugs (from 05.2000 release)
Coolant temperature sensor, speed sensor (from 05.2000 release)
Coolant temperature gauge, speedometer (from 05.2000 release)
Regulator relay, fuse box, battery (from 05.2000 release)
Electronic engine blocking control unit (from 05.2000 release)
Dispenser, fuel temperature sensor, throttle travel sensor (from 05.2000 release)
Engine crankshaft speed sensor (from 05.2000 release)
Kick-down switch, idle switch (from 05.2000 release)
Fuel cut-off valve, glow plug relay (from 05.2000 release)
Fan thermal switch, cooling fan (from 05.2000 release)
Polo 4
General information
User manual
Vehicle and engine identification
Engine Specifications
Car wash
Paintwork care
Underbody/Cavity Corrosion Protection
Cushion upholstery care/cushion cleaning
Elimination of damage from stone strikes
The tool
Starting the engine from the battery of another car
Towing a car
Vehicle lifting
Vehicle controls
Car dashboard
Light signaling devices on the panel of devices
Switches inside the car
Emergency alarm system
Steering column multifunction switch
System «Cruise control»
Rear window heater
Interior lighting
Windshield wipers and washers
Seat heaters
Power windows with electric drive
Rear view mirrors
Top hatch (roof panel)
Engine compartment hood
Heating, ventilation and air conditioning in the cabin
Climatronic air conditioning controls
Front seat adjustment
Airbags
Steering column adjustment
Car keys
Central locking
Unlocking and locking the doors
Manual Transmission
Automatic transmission
Engine start
Engine stop
Maintenance
Maintenance at non-scheduled intervals (Longlife-Service)
Maintenance at scheduled intervals
Maintenance with engine oil change
Maintenance card
Additional work within the scope of maintenance
Maintenance work
Engine and exhaust system
Engine/Engine Compartment: Visual check for leaks
Checking/Refilling Engine Oil
Engine oil change/oil filter change
Draining engine oil
Oil filter replacement
Filling with engine oil
Checking the level/filling the coolant
Checking / increasing the concentration of antifreeze
Removing water from the fuel filter
Fuel filter replacement
Engine air filter: filter element replacement
Poly V-belt check
Visual check of system of release of the fulfilled gases
Checking the condition of the toothed belt
Replacing spark plugs
Repair thread under the spark plug in the cylinder head
Standard spark plugs for POLO/IBIZA car engines
Gearbox/final gear
Visual inspection of the gearbox for leaks
Manual transmission / final drive: checking the oil level
Automatic transmission: ATF level check
Front Axle/Steering
Checking tie rod ends and ball joints
Checking the corrugated covers of cardan shafts
Checking the oil level in the power steering reservoir
Brakes/Tires/Wheels
Checking the brake fluid level
Checking the thickness of the brake linings
Visual inspection of the brake lines
Brake Fluid Replacement
Checking the tread pattern of a tire
Checking tire inflation pressure
Tire valve check
Replacing a bottle of sealant for repairing damaged tires
Body/interior
Visual inspection of seat belts
Visual Inspection of the Airbag Assembly
Replacing the replaceable element of the fine air filter
Sliding roof panel: cleaning/lubricating the guide rails
Lubricating the door travel stop and fastening pins
Electrical system
Checking electricity consumers
Checking the battery
Checking the rubber bands of the wiper blades/adjusting the setting angle of the arm
Checking the initial position of the wiper blades
Resetting the maintenance interval indicator
Power unit
Engine repair
Gasoline engine with a displacement of 1.2 liters
Engine timing gear
Cylinder head of AZQ gasoline engine with a displacement of 1.2 liters and a power of 47 kW (64 hp)
Cylinder Head — AWY 1.2L 40kW Gasoline Engine (55 hp)
1.4 liter petrol engine, 55/74 kW (75/100 hp)
Toothed belt drive for petrol engine AUA/BBY/AUB/BBZ with a displacement of 1.4 liters and a power of 55/74 kW (75/100 hp)
Setting the engine crankshaft to the ignition TDC position for cylinder 1
Timing Belt Installation Instructions for AUA/BBY/AUB/BBZ 1.4L 55/74kW Petrol Engines
Cylinder head for AUA/BBY/AUB/BBZ petrol engine with a displacement of 1.4 liters and a power of 55/74 kW (75/100 hp)
AXU 1.4L petrol engine with direct fuel injection
Diesel engine with a displacement of 1.4 liters
Diesel engine with a displacement of 1.9 liters
Timing belt drive diesel engine ASY with a displacement of 1.9 liters and a power of 47 kW (64 hp)
Removal and installation of a gear belt (SDI engine)
Cylinder head (SDI engine)
Toothed belt drive (PD-TDI engine)
Removal and installation of a gear belt (PD-TDI engine)
Cylinder head cover/cylinder head (PD-TDI engine)
Removal and installation of the V-ribbed belt of a gasoline engine AWY / AZQ with a displacement of 1.2 liters
AUA/AUB/BBY/BBZ/AXU 1.4L petrol engine
Diesel engine with a displacement of 1.4 liters: removal and installation
Diesel engine with a displacement of 1.9 liters: removal and installation
Engine start
Engine Troubleshooting
Oil pressure control values
Cooling and lubrication system
Lubrication system
Checking the oil pressure and oil pressure sensor
Oil pump/oil pan
Coolant circulation
Antifreeze
Coolant replacement
Removal and installation of the thermostat
Checking the diesel engine thermostat
Removal and installation of the pump of a cooling liquid (gasoline engines)
Removal and installation of the pump of a cooling liquid (diesel engines)
Removal and installation of a radiator
Diagnosis of malfunctions of the cooling system
Control system
Petrol injection and ignition system
Safety precautions when working with a gasoline engine injection system
Operation of the petrol engine management system
Sensors and actuators for injection systems
Checking / adjusting the idle speed / ignition timing / CO content
General check of the injection system
Intake Manifold/Fuel Manifold/Valve Injectors
Specifications for petrol injection systems
Diagnostics of malfunctions of systems of injection of petrol engines
Ignition system
Ignition Coils/Spark Plugs
Injection system (diesel)
Mixing methods for diesel engines
Preheating system
Removal and installation of glow plugs
High pressure fuel pump / injector / unit injector
Checking the preheat system
Diagnostics of malfunctions of systems of injection of diesel engines
Travel fuel economy
Supply system
Supply system. General information
Rules for safety and cleanliness when working with the fuel supply system
Safety regulations for working with the power system
Fuel tank/fuel pump/fuel filter
Removal and installation of the fuel pump / fuel level sensor
Removal and installation of the fuel level sensor
Removal and installation of the fuel filter of the petrol engine
Fuel filter of a diesel engine with a working volume of 1.4 liters
Fuel filter of a diesel engine with a working volume of 1.9 liters
Removal and installation / disassembly of the air filter
Exhaust system
Exhaust gas exhaust system
Preventing Catalytic Converter Damage
Operation of the catalytic converter
Turbocharger for 1.4/1.9 l PD-TDI engine
Exhaust system device (1.2L petrol engine)
Exhaust system device (1.4L petrol engine)
Exhaust system device (1.4L diesel engine)
Exhaust system device (1.9L diesel engine)
Removal and installation of system of release of the fulfilled gases
Replacing the pre/post muffler
Check of tightness of system of release of the fulfilled gases
Chassis
Front suspension
General information
Front wheel suspension
Removal and installation of an amortization rack
Suspension strut / shock absorber / coil spring
Disassembly of the shock absorber / shock absorber / removal and installation of a coil spring
Check/removal and installation of the spherical hinge
Removal and installation of cardan shaft
Cardan shaft / corrugated covers of the cardan shaft / cardan joints of constant angular velocity
Dismantling the cardan shaft
Rear suspension
Rear wheel suspension
Removal and installation of a back twisted spring
Removal and installation of the rear shock absorber
Dismantling and assembling the shock absorber
Shock absorber check
Rear wheel hub
Removing the rear wheel hub
Steering
Steering/ Inflatable airbag
Safety precautions when working with an inflatable airbag
Removing and installing the POLO airbag assembly
Removal and installation of a steering wheel
Removal and installation of a tip of steering draft
Steering gear/tie rods/bellows/wiring diagram
Wheels and tires
Wheels and tires. general information
Tire inflation pressure
Designations of tires and disk wheels / date of manufacture
Wheel balancing
Changing wheels / keeping the direction of rotation
Removal and installation of a wheel
Anti-skid chains
Tire care
Incorrect tire wear
Brake system
Brake system. General information
Specifications of the brake system
Front disc brake FS-II
Front disc brake FS-III
Removal and installation of front brake pads on POLO cars
Removal and installation of front brake pads of IBIZA cars
Rear drum brake mechanism
Removal and installation of brake shoes of a back drum brake
Rear disc brake mechanism
Removal and installation of rear disc brake pads
Checking the thickness of the brake discs
Removal and installation of the brake disc / brake caliper together with the shoe guide
Handbrake adjustment
Removal and installation of the wheel brake cylinder
Removal of air from the brake system
Removal and installation of a hose of a brake drive
Checking the brake booster
Handbrake Lever/Wiring Diagram
Removal and installation of cable traction of a manual brake
Removal and installation of the switch of a signal of braking
Rear wheel bearing/hub
Brake fault diagnosis
Body
Interior
Important work and safety instructions
Removal and installation of spacer / spring clips
Removal and installation of an internal rear-view mirror
Removing and installing the ceiling handle
Removing and installing sun visor
Removal and installation of the center console of POLO cars
Removal and installation of the central console of IBIZA cars
Removal and installation of an overlay of the console of radio / knot of management of system of heating
Removal and installation of the dashboard of POLO cars
Removal and installation of facing of the lever of a manual brake
Removal and installation of lateral covers of the dashboard
Removal and installation of storage shelves for POLO cars
Removal and installation of the upper casing in the footwell of IBIZA vehicles
Removal and installation of a cover of a ware box of cars IBIZA
Removal and installation of a ware box of cars POLO
Removal and installation of facing of a rack And cars POLO
Removal and installation of facing of a rack In cars POLO
Removal and installation of the top facing of a rack With the car POLO
Removal and installation of the rear side trim of POLO cars
Removal and installation of the bottom facing of a rack With cars POLO
Removal and installation of an overlay of a threshold
Removal and installation of a support of a cover of a luggage compartment
Removal and installation of lateral facing of a luggage compartment
Removal and installation of facing of the closing back part of a body
Removal and installation of internal facings of IBIZA cars
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of a forward seat belt
Safety instructions for handling electric seat belt tensioners
Removing and installing the front seat belt guide bracket
Removal and installation of an eyelet of a forward seat belt
Removal and installation of the mechanism of adjustment on height of a forward seat belt
Removal and installation of the lock of a forward seat belt
Removal and installation of a back seat belt of cars POLO
Removal and installation of a back seat belt of cars IBIZA
Exterior
Exterior of the body
Safety precautions when performing bodywork
Windshield damage from rocks
Removal and installation of the lower casing of a motor compartment
Removal and installation of a lattice of a fairing
Moving the lock beam into position for maintenance work
Removal and installation of the front bumper / bumper casing of POLO cars
Removal and installation of the front bumper / bumper casing IBIZA
Removal and installation of the rear bumper / bumper casing POLO
Removal and installation of the rear bumper / bumper casing IBIZA
Removal and installation of a forward wing
Removal and installation of facing of a wheel arch
Removal and installation of a radiator grille
Removal and installation / adjustment of the hood of the engine compartment
Removal and installation / adjustment of the lock of a cowl of a motor compartment
Removal and installation of cable traction of the lock of a cowl of a motor compartment
Tailgate POLO
Removal and installation / adjustment of the rear door
Removal and installation of the rear door lock POLO
Removal and installation of facing of a back door of POLO
Removal and installation of facing of a back door of IBIZA
Removal and installation of the POLO door
Door adjustment
Door handle and door lock
Removal and installation of the door handle
Removal and installation of the lock cylinder
Removal and installation of the door lock POLO
Removal and installation of the holder of the front door mechanisms together with the POLO power window
Removal and installation of the rear door mechanism holder together with the POLO power window
Removal and installation of the POLO power window motor
Removal and installation of facing of a door
Removal and installation of facing of a door of IBIZA
Removal and installation of the handle of the mechanism of a window regulator
Removal and installation of the case of an external rear-view mirror POLO
Removal and installation of an external rear-view mirror (with electric drive) /mirror glass POLO
Removal and installation of an external rear-view mirror (manually operated) /mirror glass POLO
Removal and installation of an external rear-view mirror IBIZA
Removal and installation of a lateral protective slip
Electrical equipment
Equipment and devices
Electrical equipment system. general information
Installation of additional components of the electrical system
Troubleshooting in the electrical system
Checking the health of the electrical switch
Relay test
Rear window heating test
Disconnecting electrical connectors
Checking the brake signal
Removing and installing the POLO onboard power supply control unit
Removal and installation of a sound signal
Removal and installation of batteries in the key with radio remote control
Removal and installation of batteries / incandescent lamps in a key with illumination
Replacing fuses
Removing and installing the POLO fuse holder
Removing and installing the battery/battery holder
Cleaning the battery poles
Checking the battery
Spontaneous battery discharge
Charging the battery
Storage of the battery
Diagnostics of battery malfunctions
Removing and installing the generator / checking the charging voltage of the generator
Removal and installation of the relay regulator / replacement of brushes of the relay regulator
Diagnostics of malfunctions of the generator
Removal and installation of a starter
Check of the traction relay of a starter
Starter Troubleshooting
Removal and installation of the instrument panel
Removal and installation of steering column switches
Removal and installation of light switches
POLO: Headlight Beam Tilt Adjuster
Radio/Heater Control Switches on Console
Power window switches in the driver's door
Passenger door switch next to the driver/tailgate
Driver door mirror switch
Removal and installation of radio POLO
Removing and installing loudspeakers
Removal and installation of the antenna on the roof of POLO
Wiper system
Replacing the rubber band of the wiper blade
Removal and installation of a nozzle of a washer of a windscreen
Removal and installation of a nozzle of a washer of back glass
Removal and installation of the washer system pump
Removal and installation of a tank of system of washers
Removal and installation of the windshield wiper arm
Removal and installation of the electric motor of screen wipers of a windscreen
Removal and installation of the lever / electric motor of a screen wiper of back glass
Diagnosis of malfunctions of the rubber band of the wiper blade
Lighting system
Lamp table
Replacing POLO headlight bulbs
Replacing headlight bulbs IBIZA
Removal and installation of a headlight
Removal and installation of a lateral lantern of the index of turn
Removal and installation of the fog lamp POLO
Removal and installation of the fog lamp IBIZA
Removal and installation of an additional signal of braking
Replacing an incandescent lamp for a license plate light
Removal and installation of a back lantern POLO
Removal and installation of a back lantern (only Limousine models)
Removal and installation of a back lantern of IBIZA
Replacement of incandescent lamps for interior lighting POLO
Replacement of incandescent lamps for interior lighting IBIZA
Electrical circuits
Familiarity with the electrical circuit
Construction of electrical circuits
Symbols in electrical diagrams
Battery, ignition and starter switch...
Heated rear window switch, terminal X unload relay, cigarette lighter
Wiper and washer relay, wiper switch...
Contact switches for the rear door, rear seat back, engine compartment hood...
Fresh air fan switch, heating element switch...
Electrical system control unit, fuse holder
Fuse holder, 12 volt socket
Data bus diagnostic interface, diagnostic connector, horn relay...
The control unit with the block of the indicating devices in a panel of devices...
Handbrake switch, brake fluid level contact...
Touareg 1
General information
Vehicle device
Vehicle dimensions
Vehicle identification
Vehicle engine number
Technical data of the Touareg
Additional equipment installed on cars
Set of keys
Remote control of locks
Central locking
Central locking keys
Children's castle
Security alarm
Backdoor
Opening and closing windows
Controls and instruments
Controls on the multifunction steering wheel
Control devices
Black and white display in the instrument panel
Color display in the instrument panel
Warning and information messages on the display
Signal and control lamps
Electric sunroof control
Outdoor lighting control
Emergency alarm system
Steering column switch for headlights and direction indicators
Wiper control
Mirror management
Fuel filler flap
Opening the hood of the engine compartment
Facilitate entry into the car
Heated front seats
Front center armrest with storage box
Central armrest with two drawers for small items
Rear center armrest
Rear center console
Ashtrays and cigarette lighter
Regular fire extinguisher
Luggage compartment
Dividing grid
Roof rack
CD receiver control panel
Air conditioner control
Climate control 2C-Climatronic
Seats and safety
Tips for the driver and passengers
Head restraint adjustment
Front seat adjustment
Electrically adjustable steering wheel
Folding and replacing the rear seatback
Seat Belt Warning Light
Putting on the seat belt
Removing the seat belts
Pretensioners and their action
Inflatable airbags
Front airbags
Side airbags
Window airbags
Deactivating and connecting airbags
Maintenance and management
Engine start
Emergency ignition key removal
Starting a gasoline engine
Diesel engine start
Stopping the petrol engine
Keyless entry
Automatic transmission
Manual gear shift — «Tiptronic» (selector)
The use of kickdown
Manual Transmission
Using air suspension
Suspension stiffness control
Parking brake
Car parking
Cruise control (CHA)
Design features of an off-road vehicle
Differential lock
Intelligent systems
Power steering
Catalytic converter
Retrofitting a vehicle with a towing device
Work in the engine compartment
Vehicle batteries
Wheels and tires
Car tool, spare wheel, tire repair kit, jack
Wheel replacement
Circuit breakers
Help with starting the engine
Towing a car
Poddomkrachivanie car
Power unit
Engine checks
Engine Specifications
Inspection for leaks and damage
Checking the condition of the poly V-belt
Removal and installation of poly V-belt (petrol engine 4,2L)
Removal and installation of poly V-belt (petrol engine 3.2L)
Checking the belt pulleys for misalignment (petrol engine 4,2L)
Removal and installation of the lower noise-proof screen of a motor compartment
Removal and installation of the top casing of the engine
Compression test (petrol engine 3.2L)
Compression test (diesel engine 5.0L)
Petrol engine 3.2L
Specifications of the 3.2L petrol engine
Removing the power unit
Removal and installation of the left and right pillows of a support of the engine
Removal and installation of a conducted disk
Removal and installation of an epiploon from outside a flywheel
Replacing the crankshaft seal on the vibration damper side
Replacing the crankshaft sealing flange on the vibration damper side
Removal and installation of the crankshaft
Removing and installing the side cover
Removal and installation of a cover of a head of the block of cylinders
Removal and installation of a head of the block of cylinders
Checking the valve timing
Valve timing adjustment
Removing the camshafts
Installation of camshafts
Checking the axial displacement of the camshafts
Camshaft marking
Replacement of valve stem seals
Checking the valve guides
Valve seat processing
Valve sizes
Checking pistons, piston rings and cylinder diameter
3.2L petrol engine mounting torques
Petrol engine 4.2L
Specifications of the 4.2L petrol engine
Checking the valve guides
Replacing the crankshaft seal on the vibration damper side
Removal and installation of a leading disk
Removal and installation of the flange on the side of the drive disc
Removing, installing and tensioning the timing belt
Checking the axial clearance of the camshafts
Replacing camshaft seals
Replacing Hall sensor seals
Removal and installation of camshafts and valve timing regulators
Diesel engine 5.0L
5.0L Diesel Engine Specifications
5.0L Diesel Engine Mounting Torques
Removing the engine
Removal and installation of pillows and support of the engine
Crushing and installing the driven disk
Removal and installation of the crankshaft support ramp
Front flange seal and vibration damper
Replacing the crankshaft seal on the vibration damper side
Replacing the crankshaft oil seal on the timing side of the engine
Replacement of an epiploon of a shaft of a drive of the generator
Timing cover installation
Removal and installation of the camshaft drive gear
Checking the valve timing
Valve timing adjustment
Removal and installation of heads of the block of cylinders
Removal and installation of covers and linings of heads of the block of cylinders
Repair of cylinder heads
Valve seat processing
Checking the valve guides
Replacing valve stem seals
Checking the pressurization system for leaks
Installation of hose connections with nipple connectors
Turbocharger check
Cooling system
Removal and installation of elements of the cooling system (petrol engine.)
Draining and filling the coolant (petrol engine.)
Removal and installation of a radiator (petrol engine.)
Removal and installation of the water pump (petrol engine.)
Pressure testing of the cooling system (petrol engine.)
Cooling system (diesel engines)
Draining and filling the coolant (diesel engine.)
Removing and installing the fan mount (diesel engine.)
Crushing and installing a radiator (diesel engine.)
Removal and installation of fittings of the cooling system (diesel engine.)
Removal and installation of the water pump (diesel engine.)
Lubrication system
Removal and installation of elements of the lubrication system (petrol engine.)
Removing and installing oil nozzle (petrol engine.)
Removal and installation of the check valve of a drain of oil (petrol engine.)
Disassembly and assembly of the oil pump (petrol engine.)
Removal and installation of the oil pallet (petrol engine.)
Checking the oil pressure sensor (petrol engine.)
Oil pressure check (petrol engine.)
Checking the engine oil level (diesel engine.)
Oil lines in the oil pan (diesel engine.)
Application of sealant (diesel engine.)
Unscrewing and screwing the oil filter cap (diesel engine.)
Checking the oil pressure and oil pressure sensor (diesel engine.)
Checking the oil pressure at the front of the engine (diesel engine.)
Injection system
General instructions for the injection system (petrol engine.)
Checking the injectors (petrol engine.)
Checking the amount of injected fuel (petrol engine.)
Checking the Fuel Pressure Regulator and Residual Pressure (petrol engine.)
Removal and installation of the engine control unit (petrol engine.)
Removal and installation of the anti-theft engine control unit (petrol engine.)
Checking and adjusting the position of the pump injector pistons (diesel engine.)
Removal and installation of an inlet collector (diesel engine.)
Removal and installation of the pump nozzle (diesel engine.)
Replacing the O-rings of the unit injector (diesel engine.)
Exhaust system
Exhaust gas exhaust system
Exhaust alignment
Removal and installation of an exhaust manifold and a reception pipe with primary catalysts
Secondary air supply system
Combination valve test
Fuel supply system
Fuel System Components (petrol engine.)
Plan for connecting fuel lines and parts in the fuel tank (petrol engine.)
Safety measures when working in the power system (petrol engine.)
Fuel filter replacement (petrol engine.)
Fuel tank drain (petrol engine.)
Removal and installation of the fuel supply module, fuel level sensor and ejection pumps (petrol engine.)
Checking the power supply of the pumps (petrol engine.)
Electronic engine power control (electronic accelerator drive)
Activated carbon absorber
Transmission
Automatic gearbox 09D
Checking the level and topping up the ATF oil
ATF level check
Torque converter test
Pumping fluid from the torque converter
Torque converter installation
Gear shift drive repair
Removal and installation of the handle of the selector
Checking and adjusting the selector rod
Removal and installation of draft of the selector
Removal and installation of an overlay
Removing and installing the frame
Removing and installing selector lock solenoid N380
Removing and installing selector lock solenoid N110
Removal and installation of the selector switch (lever locked in position «R») F319
Removal and installation of the gear change drive
Removal and installation of a transmission, cars with the R5 diesel engine
Removal and installation of a transmission, cars with gasoline engines V6 and V8
Removal and installation of highways and radiator ATF
Removing and installing automatic transmission control unit J217
Replacement of a sealing ring of a secondary shaft
Removal and installation of the oil pallet
Removal and installation of the mesh oil filter
Removing and installing pressure sensor for hydraulic system 1 in automatic transmission G193 and hydraulic system 2 in automatic transmission G194
Removal and installation of the spool box
Removal, installation and adjustment of the multifunction switch F125
Mechanical gearbox 08D
Transfer case marking
Letter designations, filling volumes of units (transfer case)
Letter designations, gear ratios, filling volumes (main forward gear)
Letter designations, gear ratios, filling capacities (main reverse gear)
Front final drive marking
Rear final drive marking
General information about the gearbox
Electronic components and their installation locations on the transfer case
Removal and installation of the transfer case control E473
Removing and installing transfer case control unit J646
Removing the transfer case
Transfer box installation
Laying the ventilation tube on the transfer case
Replacing the rubber-metal support of the gearbox bracket
Checking the oil level in the transfer case
Removal and installation of sealing rings of the flange of the power take-off shaft / cardan shaft and the transfer case motor
Replacing the sealing ring of the flange of the PTO shaft / front propeller shaft (transfer box installed)
Replacing the sealing ring of the flange of the PTO shaft / rear propeller shaft (transfer box installed)
Removing the transfer case motor V253
Installing the transfer case motor V253
Checking the oil level in the final drive of the front axle
Cardan shaft
Cardan shaft and front final drive
Removal and installation of the front propeller shaft
Removal and installation of the rear propeller shaft
Checking the oil level in the rear final drive
Removing the front final drive
Installing the front final drive
Laying the ventilation tube of the front final drive
Replacing the O-ring on the left flanged shaft
Replacing the anther of the shaft with a flange
Replacing the rubber-metal support of the front final drive
Replacing the left flange shaft seal for vehicles without differential lock
Replacing the left flange shaft seal for vehicles with differential lock
Removal and installation of a power shaft
Drive shaft disassembly
Drive shaft assembly
Chassis
Wheels and tires
General information on wheels and tires
Specification for wheel and tire conversions
Tire speed indices
Disc markings
Compound disks
Tire wear and mileage
High speed tire wear
Tire service
Evenly worn tires
Tread Height Measurement
Unilateral wear
Diagonal uneven wear
Tire rolling noise
Wheel balancing
Radial and lateral runout of wheels and tires
Checking the radial and lateral runout of a wheel with a tire using a dial gauge for tires VAC 1435
Minimizing wheel runout
Side slip of the car
Side slip elimination
Tire damage
Loss of tire pressure
Tire damage due to tire fitting errors (installation damage)
Tire sidewall marking
Wheel swap
Used tires on Touareg from model year 2003
Tire pressure monitoring system repair
Crushing and installing the tire pressure monitoring system control unit J502
Repair of the clearance control system
Components of the clearance control system and their installation locations
Removing and installing a compressor without a solenoid valve block
Air duct repair
Front suspension
Subframe, stabilizer bar, lower control arm
Removal and installation of a stretcher
Switchable stabilizer
Removing the switchable stabilizer
Checking the level and topping up the oil of the hydraulic system of the switchable stabilizers
Pumping a switchable stabilizer
Front wheel suspension
Removal and installation of an amortization rack
Removing and installing body level sender G78/G289 on vehicles with suspension struts
Wheel support
Removing the coil spring
Installing the coil spring
Rear suspension
Removing and installing rear body level sender G76/G77
Rear wheel suspension
Removal and installation of an amortization rack
Wheel support
Removing wheel hub with bearing
Steering gear
Removal and installation of a steering column
Removal and installation of a sealing cuff
Removal and installation of a drive of the amplifier of a steering
Removal and installation of steering draft
Vane pump, 5-cyl. diesel engine
Removing and installing vane pump, 5-cyl. diesel engine
Removing and installing vane pump, 6-cyl. diesel engine
Removing and installing vane pump, 6-cyl. Gas engine
Bleeding the steering system and checking for leaks
Checking the steering system for leaks
Brake system
Example of a vehicle data plate
Front brakes
Rear brakes
Checking the brake system
Bleeding the brake system
Pumping (main)
Additional pumping
Removal and installation of brake booster membrane travel potentiometer G420
Removing and installing brake vacuum pump V192
Removing and installing brake booster pressure sender G294
Removal and installation of the main brake cylinder
Removal and installation of the brake booster
Repair of brake pipelines
Front wheel brake repair, Brembo 17 brake caliper (1LC)
Rear wheel brake repair, brake caliper FN 44
Parking brake adjustment
Adjustment of brake pads on two wheels
Checking the free travel of the pedal parking brake lever
Removal and installation of the lever of a pedal parking brake
Removal and installation of rear brake cables
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal, installation and adjustment of the switch of signals of braking
Anti-lock braking system (ABS)
Electrical and electronic components of the brake system
Body
Outdoor elements
Removal and installation of a cowl
Removing the gas stop
Release of gas from the gas stop
Removal and installation of insulation
Removal and installation of the lock of a cowl
Hood lock adjustment
Disconnecting the flexible cable
Removal and installation of a door of a luggage compartment
Tailgate adjustment with hinge
Lock loop adjustment
Removal and installation of the tailgate hinge
Removal and installation of a plug of a gas emphasis
Removal and installation of elements of locking and unlocking of a door
Removal and installation of the lock of a door of a luggage compartment
Removal and installation of a hinge of the lock with the closer
Removal and installation of the electric motor for opening the tailgate
Removed and installed rear spoiler
Removal and installation of elements for locking and unlocking the hatch of the fuel tank
Door adjustment
Removal and installation of the lock cylinder housing
Removal and installation of the door handle
Removal and installation of the door lock
Rear door adjustment
Removal and installation of the case of the cylinder of the lock of a back door
Sliding/tilting sunroof with glass panel
Removing the sliding/tilting sunroof glass panel
Installing the sliding/tilting sunroof glass panel
Sliding/tilting sunroof glass panel adjustment
Checking the Parallel Movement of the Glass Panel
Fitting the sunroof panel seal
Removing the sun shield
Removal and installation of facing of a forward bumper
Removal and installation of facing of a back bumper
Electrical equipment
Battery
General information about electrical equipment
Types of batteries
Checking the battery
Adding distilled water to the battery
Electrolyte Density Check
Checking the open circuit voltage of the battery
Disconnecting and connecting the battery, vehicles with one battery
Disconnecting and connecting the battery, vehicles with two batteries
Removal and installation of the battery located under the driver's seat
Removal and installation of the relay of disconnection of the storage battery
Generator and starter
Removal and installation of a starter (6-cyl. injection engine 3.2 and 3.6 l)
Removal and installation of a starter (8-cyl. injection engine 4.2 l)
Removal and installation of a starter (10-cyl. 4.9l TDI engine)
Three phase generator
Removing and installing three-phase alternator, 6-cyl. injection engine
Removing and installing three-phase alternator, 8-cyl. injection engine
Removal and installation of the voltage regulator
Instruments and wipers
Removal and installation of a combination of devices
Arrangement of contacts of sockets of a combination of devices
Front wiper
Removing the wiper arm from the driver's side
Removing the wiper arm on the passenger side
Removing the plenum box cover
Removing the wiper trapezoid with rods and the wiper motor V
Installation of wiper trapezium with rods and wiper motor V
Installing the plenum box cover
Setting the initial position of the wiper blades
Removal and installation of a screen wiper «aero»
Removal and installation of headlights
Headlight adjustment
Removal and installation of the headlight range control servo
Main headlights with gas discharge lamps
Climatronic air conditioner wiring diagram
Tiguan 1
General information
Characteristics
Vehicle identification
Overall dimensions and characteristics
Identification information
Dimensions of gaps between body parts
Vehicle overview
Vehicle appearance
Driver door overview
Driver side overview
Upper part of the center console
Lower part of the center console
Overview of the front passenger side
Signal and control lamps
Overview of control devices
Setting up and calibrating the compass
Maintenance indicator
Power unit
Petrol engine 1.4 BWK
Vehicle engine number
Characteristics of the gasoline engine 1.4 liters / 110 kW (BWK)
Removing the engine
Engine installation
Engine disassembly
Engine Assembly
Removal and installation of elements of the lubrication system
Removal and installation of elements of the cooling system
Draining and filling the coolant
Removing and installing radiator and radiator fan V7
Removal and installation of the pump of system of cooling
Relieve pressure in high pressure areas of the fuel system
Fuel tank device
Filmed and installed fuel tank
Removal and installation of elements of the power system
Turbocharger device
Removal and installation of a turbocharger
Removal and installation of the vacuum block of the turbocharger
Compressor device
Removal and installation of the compressor
Turbo air system
Removal and installation of the intercooler
Fuel injection system
Checking the functioning of the intake manifold flap
Removal and installation of control valve control unit and throttle control unit
High pressure fuel pump
Removal and installation of the high pressure pump
Removing and installing engine control unit J623
Theft-proof engine control unit
Catalyst and hinged parts of the exhaust system
Silencer with attachments
Removal and installation of a reception pipe
Repair of the ignition system
Petrol engine 1.4 CAVA
Vehicle engine number
Characteristics of the gasoline engine 1.4 liters / 110 kW (CAVA)
Removing the engine
Engine installation
Engine disassembly
Engine Assembly
Removal and installation of parts of the lubrication system
Removal and installation of components of the cooling system
Draining and refilling coolant
Fuel tank device
Removal and installation of the fuel tank
Removal and installation of elements of the fuel system
Turbocharger device
Removal and installation of a turbocharger
Compressor device
Removal and installation of the compressor (vehicles with all-wheel drive)
Turbo air system
Fuel injection system
Removal and installation of elements of system of release OG
Removal and installation of a reception pipe (vehicles with all-wheel drive)
Removal and installation of a reception pipe
Repair of the ignition system
Removal and installation of ignition coils with output stages
Engine 2.0 (petrol)
Vehicle engine number
Characteristics of the gasoline engine 2.0 liters / 125/147 kW
Removing the engine
Engine installation
Cylinder block — belt drive side
Cylinder block, gearbox side
Timing chain drive
Camshaft drive chain
Removal and installation of a chain of a drive of cam-shafts
Balance Shaft Drive Chain
Removal and installation of a chain of a drive of balancing shafts
Cylinder head
Removal and installation of the vacuum pump
Repair of the lubrication system
Oil filter, oil cooler and oil pressure switch
Removal and installation of the cooler
Connection plan for cooling system hoses
Draining and refilling coolant
Coolant pump and thermostat
Removal and installation of the thermostat
Removing and installing coolant temperature sensor G62
Coolant tubes
Coolant overrun pump V51
Radiator, fan rail and radiator fan
Safety regulations when working with the power system
Relieve pressure in high pressure areas (CAWA, CAWB, CCTA, CCTB)
Fuel tank device
Removal and installation of the fuel tank
Fuel system repair
Turbocharger device
Removal and installation of a turbocharger
Turbo air system
Fuel injection system
Air filter device
Intake manifold device
Fuel rail device (Rail)
Removing and installing intake manifold with fuel rail
Remove the fuel (Rail) intake manifold ramp
Removal and installation of nozzles
High pressure pump with fuel pressure control valve N276
Exhaust gas exhaust system
Removal and installation of catalysts with a downpipe
Repair of the ignition system
Engine 2.0 (diesel)
Vehicle engine number
Diesel engine specifications 2.0 liters / 100/103/120/125 kW
Removing and installing the engine cover
Removing the engine
Engine installation
V-ribbed belt drive
Removal and installation of an accessory bracket
Toothed belt drive
Cylinder block device
Removal and installation of covers and flywheel
Cylinder head
Removal and installation of Hall sensor G40
Carved versions of the rear toothed belt guard
Valve cover device
Cylinder head cover, removal and installation
Removal, installation and tension of a toothed belt
Engine oil
Oil pump, oil pan, balancer shaft block
Removing and installing oil level and temperature sensor G266
Removal and installation of the oil pump
Removing the balancer shaft block
Oil filter bracket, oil pressure switch, oil cooler and oil pressure line
Removing and installing oil filter bracket with oil cooler
Removal and installation of a pressure head oil pipeline to a turbocharger
Rules for working with the cooling system
Parts and assemblies of the cooling system mounted on the body
Parts and components of the cooling system installed on the engine
Cooling system hose connection diagram
Draining and filling the coolant
Procedure for incorrect filling of the fuel system
Fuel tank device
Removal and installation of the fuel tank
Removal and installation of the fuel level sensor
Fuel filter device
Removal and installation of the top part of the fuel filter
Removal and installation of the fuel filter
Removal and installation of additional fuel pump V393
Flying and accelerator drive units
Turbocharger with attachments
Removal and installation of a turbocharger
Charge air cooling system
Vacuum hose connection diagram
Diesel fuel injection system
Fuel system device
Removal and installation of nozzles (piezo injectors)
Checking fuel pressure regulator N276
Removal and installation of the high pressure fuel pump (injection pump)
Intake manifold with attachments
Removal and installation of an inlet collector
Air filter device
Front section of exhaust system with diesel particulate filter
Removal and installation of the particulate filter
Removal and installation of the particulate filter (vehicles with front wheel drive)
Silencer device
Exhaust gas recirculation system
Removal and installation of a pin glow plug
Transmission
6-speed manual gearbox 0A6
Marking location on the MCP
Marking, gear ratios, filling capacities
The location of the marking on the transfer case
Clutch pedal assembly
Removing and installing the support bracket
Removing and installing clutch pedal servo spring
Removal and installation of the clutch master cylinder
Details and components of the hydraulic clutch
Repair of the clutch release mechanism
Clutch repair
Gear shift mechanism repair
Repair of the shift lever and gear shift housing
Removal and installation of drive cables
Removing the gearbox (vehicles with front wheel drive)
Installing the gearbox (vehicles with front wheel drive)
Checking the oil level in a manual transmission
Removing the transfer case (vehicles with turbocharged diesel engine)
Transfer box installation (vehicles with turbocharged diesel engine)
Checking the oil level in the transfer case
6-speed automatic gearbox 09M
Marking on the gearbox
Letter designation, compatibility of units
Electrical and electronic components and parts and their installation locations
Removing the multifunction switch F125
Drive changeover overview
Cable pull test
Selector lever emergency release
Check of a drive of a gear change
Gearbox Removal — Vehicles with 2.0L Engine — 147kW TSFI
ATF radiator
Removal and installation of a radiator ATF
Draining and filling ATF
Electro-hydraulic gearbox
Removing and installing wiring harness for solenoid valves and sensors
Drive shafts
Cardan shaft device
Removal and installation of cardan shaft
Removal and installation of the rear final drive
Silent blocks
Locations for installation of electrical/electronic components and parts
All-wheel drive control unit J492
Removal and installation of the Haldex coupling
Assembly and disassembly of the Haldex coupling (generation IV)
Checking the oil level in the rear final drive or adding oil
Adding oil to the Haldex coupling
Chassis
Front suspension
Subframe, stabilizer, wishbone
Removal and installation of a subframe with a steering mechanism
Checking the state of the ball joint
Removal and installation of a spherical support
Removal and installation of triangular lever and its support bracket
Details and assemblies of the bearing assembly of the wheel hub
Damper strut device
Removal and installation of an amortization rack
Loosening and tightening of the hub bolt with a twelve-sided head
Removal and installation of a drive shaft with a ball inner CV joint
Removal and installation of a drive shaft with an internal hinge type tripod AAR3300I (put on the semi-axial shaft of the gearbox)
Removal and installation of a drive shaft with an internal hinge type tripod AAR3300I (inserted into the CP)
Applicable drive shafts
Heat shields for drive shafts
Drive shaft with ball joint VL107
Drive shaft with tripod joint AAR3300I
Drive shaft with tripod joint AAR3300I for vehicles with automatic transmission 09M
Rear suspension (2x4)
Subframe device
Removal and installation of the subframe assembly with the nodes installed on it
Details and assemblies of transverse levers and transverse thrust
Parts and assemblies, rear left ride height sender G76
Removal and installation of the upper transverse arm
Removal and installation of the lower transverse arm
Removal and installation of transverse draft
Details and assemblies of the wheel bearing housing and trailing arm
Removal and installation of the wheel bearing housing
Shock absorber and coil spring
Removal and installation of a twisted spring
Removal and installation of the shock absorber
Shock Absorber Repair
Stabilizer transverse stability
Rear suspension (4x4)
Parts and assemblies of the subframe, final drive
Removal and installation of the subframe assembly with the nodes installed on it
Details and assemblies of transverse levers and transverse thrust
Removal and installation of the upper transverse arm
Removal and installation of the lower transverse arm
Details and assemblies of the wheel bearing housing and trailing arm
Shock absorber and coil spring
Shock Absorber Repair
Stabilizer transverse stability
Drive shaft device
Removal and installation of a power shaft
Air suspension
Components of the adaptive chassis control system DCC and their installation locations
Damping adjustment key E387
Components, front left/right ride height sender G78/G289
Parts and assemblies, rear left ride height sender G76 (front-wheel drive)
Parts and assemblies, rear left ride height sender G76 (4x4)
Front suspension cable routing, left
Right front suspension cable routing
Rear suspension cable routing
Details and assemblies of the shock absorber strut of the adaptive chassis control system DCC
Parts and assemblies of the shock absorber of the adaptive suspension control system DCC (front wheel drive)
Removal and installation of damper for adaptive chassis control DCC (front-wheel drive)
Repair of the shock absorber of the adaptive suspension control system DCC (front-wheel drive)
Parts and assemblies of the shock absorber of the adaptive suspension control system DCC (4x4)
Removal and installation of damper for adaptive chassis control DCC (4x4)
Wheels and rims
Wheel bolt torque
Tire pressure indicator
Tire pressure monitoring system
Tire pressure sensor device
Removal and installation of the tire pressure sensor
Brake system
General information about the brake system
Electrical/electronic components and installation locations
General information regarding the anti-lock braking system
Details and units of the hydraulic block
Connecting the brake pipes from the GTZ to the hydraulic unit
Removing the control unit and hydraulic unit
Removal and installation of components of system ABS of a forward axis
Removal and installation of components of system ABS of a back axis (front-wheel drive)
Removal and installation of components of system ABS of a back axis (4x4)
Removal and installation of components of the ESP system
Front brake repair, brake caliper FN 3
Removal and installation of front brake pads FN 3
Removal and installation of the front brake caliper FN 3
CII41 rear brake repair
Removal and installation of rear brake pads CII41
Removal and installation of the rear brake caliper CII41
Electromechanical parking brake
Removal and installation of the parking brake motor
Brake pedal
FN 3 brake caliper repair
Rear brake caliper repair
Parts and assemblies of the brake booster / brake master cylinder
Vacuum pump for brake booster
Removing and installing vacuum sensor G608
Removing and installing brake light switch F
Removal and installation of the main brake cylinder
Removal and installation of the brake booster
Steering gear
Steering column
Removal and installation of a steering wheel
Removal and installation of a steering column
Steering gear with electromechanical booster
Removal and installation of the steering mechanism
Differences in steering gears 2 and 3 generations
Removing and installing the bellows
Removal and installation of steering draft
Body
External equipment
Front carrier
Service position
Removal and installation of the forward bearing panel assy
Removal and installation of wings
Soundproof casing
Device, removal and installation of the hood
Disconnecting the hood cable
Hood adjustment
Hood release lever
Luggage compartment door
Removal and installation of loops of a door of a luggage compartment
Tailgate locking mechanism
Removal and installation of the lock of a door of a luggage compartment
Removal and installation of a cover of the handle with a key for opening
Tailgate adjustment
Lock shackle adjustment
Stop adjustment
Gas stops
Filler cap and actuator
Front door device
Door hinges
Removal and installation of door hinges
Upper door hinge bolt
Door adjustment
Carrier door panel with attachments
Removal and installation of the carrier panel with attachments
Door opening limiter
Door handle and lock
Removal and installation of a roof of a larva of the lock
Removal and installation of a stammering larva
Removing and installing the cover (without larva)
Removal and installation of the external door handle
Removal and installation of a door stutter
Removal and installation of the case of the external handle
Removal and installation of an arm of the lock of a door
Door soundproofing
Central locking
Removal and installation of a battery of a folding key of ignition with remote control
Backdoor
Rear door hinges
Lubrication of new door hinges
Installing the hinges after replacing the B-pillar
Rear door adjustment
Carrier panel with attachments
Removal and installation of the carrier panel with attachments
Tailgate handle and lock
Removing and installing the lock cover
Removal and installation of the rear door handle
Removal and installation of the lock of a back door
Removing and installing the handle housing
Removal and installation of an arm of a back door
Panoramic sunroof control
Sunblind motor initialization
Removal and installation of a forward glass section of the hatch
Removal and installation of back glass section of the hatch
Height adjustment of the front and rear sunroof sections
Replacing the hatch seals
Removal and installation of a fairing of the hatch
Removal and installation of a sun-protection blind
Removal and installation of the mechanism of a raising and a cable of a drive of forward section of the hatch
Hatch frame device
Sunroof Maintenance
Opening and closing the hatch in the absence of electrical power
Cleaning the drain hoses
Front bumper cover
Removal and installation of facing of a forward bumper
Hinged details of facing of a forward bumper
Internal details of fastening of facing of a forward bumper
Details and components of the front bumper
Front bumper cover, off-road version
Removal and installation of facing of a forward bumper
Hinged details of facing of a forward bumper
Details and components of the front bumper
Rear bumper cover
Removal and installation of facing of a back bumper
Hinged details of facing of a rear bumper
Rear bumper lining inner fittings
Rear bumper beam
Drawbar hitch
Glued glass
Front door glass
Removal and installation of the electric motor of a window regulator
Removal and installation of glass guide
Rear door glass
Removal and installation of glass of a back door
Removal and installation of the electric motor of a window regulator of a back door
Details and assemblies of fender liner
Exterior mirrors
Removal and installation of a radiator grille
Roof rails
Moldings and trims
Removal and installation of overlays of wheel arches
Add-on parts for vehicles with Volkswagen Individual special equipment
Nameplates
Internal equipment
Interior rear view mirror
Linings, casings and decorative shields
Removal and installation of the center console without armrest
Removal and installation of the center console with armrest
Removal and installation of brackets of the center console
Replacing the rear cup holder
Removal and installation of the central decorative overlay of the forward panel
Removal and installation of a ware box
Removal and installation of facing of the block of understeering switches
Removal and installation of an overlay of the control panel of a heater and air conditioner
Removal and installation of the left facing from the driver's side
Removal and installation of the bottom facing of the forward panel
Removal and installation of the ceiling console
Removing and installing sun visors
Removal and installation of rear overlays of thresholds
Removal and installation of facing of a back wheel arch
Removal and installation of forward seat belts
Removal and installation of the seat belt height adjustment mechanism
Removal and installation of the lock of a forward seat belt
Removal and installation of rear side seat belts
Removal and installation of a 3-point central seat belt
Safety regulations for working with airbags
Removing and installing the airbag control unit
Removal and installation of the driver's airbag
Removal and installation of a pillow of safety of the forward passenger
Checking the need for laying an additional ground wire in the car
Front passenger and driver seats
Removal and installation of a back lateral pillow of safety
Removal and installation of the upper airbag on the driver / passenger side
Removing and installing seat occupancy sensor
Procedure after an accident with deployment of pretensioners and/or airbags
Seat occupied recognition (USA)
Seat occupancy detection repair kit
Removing Seat Occupancy Detection Components
Shock sensors
Removing and installing the front panel
Removal and installation of the supporting frame
Putting the Front Panel in the Correct Position
Front panel adjustment
Removal and installation of an upholstery of a forward door
Removal and installation of an upholstery of a back door
Rack trims
Luggage compartment door linings
Luggage compartment trims
Ceiling lining
Removal and installation of a forward seat
Removal and installation of elements of a forward seat
Front seat with manual height adjustment
Driver's seat with electric controls
Rear seats
Cushions and upholstery front seats
Rear seat upholstery and cushions
Electrical equipment
Power devices
Disconnecting and connecting the battery
Removing and installing the battery
Starter (vehicles with 1.4l TSI engines and MQ500 manual gearbox)
Starter (vehicles with 2.0l TDI engines and MQ500 manual gearbox)
Starter (vehicles with 2.0l TDI engines and AQ450 automatic transmission)
Generator (1.4 l TSI engine)
Removal and installation of the generator (1.4 l TSI engine)
Generator (2.0l TDI engine)
Removal and installation of the generator (2.0 l TDI engine)
Generator (2.0 l TSI engine)
Removal and installation of the generator (2.0 l TSI engine)
Appliances and lighting
Instrument cluster
Symbols for warning lights in the instrument cluster
Front wiper
Removal and installation of a forward screen wiper
Removing the wiper motor from the wiper trapezoid
Adjustment of the extreme position of the wiper blades
Removal and installation of frameless wiper blades
Removing and installing rain and light sensor G397
Windshield washer
Removal and installation of the windshield washer reservoir and headlight washer
Removal and installation of the windshield and rear window washer pump
Removal and installation of the liquid level sensor in the windshield washer reservoir
Removal and installation of nozzles of a washer of a windshield
Rear window wiper
Removal and installation of a back screen wiper
Rear window washer
Headlight cleaning system
Main headlight with halogen lamps
Removal and installation of the main headlight with halogen lamps
Correction of the installation position of the headlight
Replacing the Low Beam Bulb
High Beam Bulb Replacement
Parking light bulb replacement
Replacing the front turn signal bulb
Main headlights with gas discharge lamps
Headlamps with gas discharge lamps and adaptive lighting
Removal and installation of a headlight with discharge lamps and adaptive lighting
Replacing the discharge lamp
Replacing the cornering light bulb
Replacing the front turn signal bulb
Parking light bulb replacement
Removal and installation of the device of inclusion of a headlight with a discharge lamp
Removal and installation of the power module of the AFS system
Control unit for cornering light and headlight range control
Vehicle ride height sensor
Fog lights
Turn signal lamp in the side mirror for easy entry and illumination
Back light (SBBR) in the side of the body
Rear lights (SBBR) in the tailgate
Additional brake lights
License plate light
Reversing lights in bumper cover
Side marker lights
Understeering's shifter
Ignition and starter switch and lock cylinder
Rear parking aid (PDC)
Front parking aid (PDC)
Gap parking assistant (PLA)
Rear View Camera
Lamps and switches internal
Lights and switches in the front doors
Lights and switches in the rear doors
Lighting and switches in the trunk
Lighting and switches in the upholstery of the ceiling
Lights and switches in the center console
Sound signal
Inmobilizer
Anti-theft alarm (DWA)
Fuse and relay boxes
Switching blocks
Control units
U1 cigarette lighter
Communication systems
RCD 300 audio system
RCD 500 audio system
Radio navigation system RNS 300
Radio navigation system RNS 510
Audio system amplifier
CD changer
Digital satellite radio tuner, vehicle for USA and Canada
Apple iPod Player Socket
Multimedia system control unit
Acustic systems
Telephony systems
Antenna systems
Multifunction steering wheel
Heating and air conditioning
Heater device
Removal and installation of heater elements
Removal and installation of the heat exchanger
Checking the heating element of the additional air heater
Exhaust ventilation check
Removal and installation of inlet ventilation grilles
Removal and installation of a heater
Parts and components of the heater
Heater and climate control system Climatic
Functions of the control buttons for the heater and Climatic
Removal and installation of the block of rotary regulators of a heater and air conditioner Climatic
Electrical connectors for the block of rotary controls of the heater and the Climatic air conditioner
Checking the drain hose for the condensate water of the heater and air conditioner module
Removal and installation of the executive electric motor of the damper of recirculation of air
Removing and installing the temperature control damper actuator
Removing and installing footwell duct temperature sensor
Removal and installation of the temperature sensor of the central deflector
Outside temperature sensor
Climate control system with automatic control Climatronic
Location of parts and assemblies of the Climatronic air conditioning system in the passenger compartment
Electrical connectors for the Climatronic control unit
Removal and installation of the control panel and display of the Climatronic air conditioning system
Removal and installation of the supply fan control unit
Climatronic evaporator housing
Removal and installation of the temperature sensor of the left footwell air duct
Removal and installation of the temperature sensor of the right footwell air duct
Removal and installation of the evaporator temperature sensor
Description of the operation of the air pollution sensor
Removal and installation of the air pollution sensor (vehicles from calendar week 22/08)
Removing the temperature sensor of the left and right deflectors
Removing light sensors G107 and G134
Removal and installation of the actuating motor of the intake ventilation dampers
Removal and installation of the control mechanism for the supply ventilation dampers
Removal and installation of the executive electric motor of the right temperature control flap
Removal and installation of the executive electric motor of the central shutter
Air conditioning fluids
Safety instructions for working with the Thermo Top V auxiliary heater
Repair of additional heater Thermo Top V
Nameplates on the Thermo Top V heater
Removal and installation of system of release OG of a heater
Removal and installation of the device of reception of a radio signal of a heater
Crushing and installing an additional heater Thermo Top V
Removal and installation of hinged units of additional heater Thermo Top V
Disassembly and assembly of the additional heater Thermo Top V
Scheme for connecting an additional heater to the cooling circuit
Removal and installation of the additional heater control unit
Removing and installing glow plugs with flame sensor
Removal and installation of the temperature sensor and overheating sensor
Heater supply system Thermo Top V
Removal and installation of the metering pump heater Thermo Top V
Additional heater control Thermo Top V
Description of the operation of the heater when controlled by radio
Electrical circuits
Control units in the luggage compartment
Control units in the engine compartment
Control units in the cabin
Electrical connector blocks
Location of fuses
Relay location
List of ground connections in the engine compartment
List of ground connections in the cabin
List of ground connections in the luggage compartment
Battery, terminal 15 power supply relay 2, terminal 50 power supply relay, fuses
Fuses, ABS control unit, electromechanical parking brake control unit
Contact X unloading relay, fuses
Ignition key removal lock solenoid
Steering wheel angle sensor, horn switch
Multifunction display call key, multifunction display memory switch
Left fog lamp, left headlight, left headlight range control motor
Headlight range control, dual tone horn relay
Right fog lamp, right headlight, right headlight range control motor
Lighting switch backlight lamps, lighting switch
Rear direction indicators, left and right brake lights, reversing lights
License plate lighting, turn signal lamps in exterior mirrors
Washer jet heating resistors, brake light switch
Wiper motor, rain and light sensor, ASR and ESP deactivation button
Footwell lighting, glove compartment light
Rear dome light, front dome light, reading lights
Vanity mirror lighting limit switches, cigarette lighters, 12 V socket
Rear window heating element, rear window heating relay
Diagnostic socket, data bus diagnostic interface
Data bus diagnostic interface, bonnet warning light, instrument cluster
Brake pad wear indicator, instrument cluster immobilizer control unit
Fuel gauge, temperature and coolant level control system
Steering column control unit, fuse SB16, starter/ignition switch
Cruise control switch, sound signal switch
Multifunction buttons on the steering wheel on the left
Multifunction buttons on the steering wheel on the right
Diagnostic socket, data bus diagnostic interface, instrument cluster
Sharan 1
General information
Introduction to guide
Minivan VW Sharan — abstract
Vehicle identification
General recommendations for car repair
Working conditions and tools used
Proper vehicle lifting
Lubricants and sealants
Rules for handling threaded connections, bolts, nuts
Appendix 1. Technical data and characteristics
Annex 2. Basic data for adjustments and control
Appendix 3. Torques for threaded connections
Maintenance
Repair and maintenance work
Checking the engine oil level and changing it
Checking the brake fluid level
Checking the operation of brake lights
Checking the operation of the lighting system
Tire pressure check
Checking the air filter
Checking the coolant level
Checking the fluid level in the power steering
Regular maintenance operations
Maintenance every 12 months or every 15,000 km
Maintenance every 12 months
Maintenance every 24 months or every 30,000 km
Maintenance every 60,000 / 120,000 km
Petrol engines
Engine repair 2.8 l (AAA)
VR6 engine — design description
Removal and installation of the engine
Removal and installation of a transmission from the engine
Additional operations on an air-conditioned vehicle
Engine Mount
General recommendations for disassembly and assembly of the engine
Removing the cylinder head
Dismantling of a head of the block of cylinders
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic pusher — removal and installation
Removing pistons and connecting rods
Measuring the inner diameter of a cylinder
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Cylinder block — check
Removing the crankshaft
Checking the crankshaft
Installing the crankshaft
Crankshaft seals
Flywheel — removal and installation
Timing mechanism drive — design description
Removal of details of a drive of the gas-distributing mechanism
Installing the timing drive
Intermediate shaft — removal and installation
Checking compression in the engine cylinders
Additional air supply system
Removal and installation of a final collector
Removal and installation of system of release of the fulfilled gases
Engine repair 2.0 l (ADY)
Removal and installation of the engine
General engine disassembly
Engine Assembly
Cylinder head and valves — general information
Removing the cylinder head
Dismantling of a head of the block of cylinders
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic pusher
Camshaft oil seal replacement
Removing pistons and connecting rods
Measuring the inner diameter of a cylinder
Checking pistons and connecting rods
Connecting rod clearance measurement
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Cylinder block — design description
Removing the crankshaft
Checking the parts of the crankshaft
Installing the crankshaft
Crankshaft seals — removal and installation
Removal and installation of a flywheel (car with manual gearbox)
Torque converter drive pulley (for vehicles with automatic transmission)
Timing mechanism drive — design description
Removing the toothed drive belt
Installing the toothed drive belt
Ignition installation
Adjusting the tension of the drive belt of engine assemblies
Intermediate shaft — removal and installation
Lubrication system
Engine lubrication system — design description
Removal and installation of the oil pan
Removal and installation of the oil pump
Oil pump repair
Oil filter — removal and installation
Oil pressure check
Oil cooler — removal and installation
Engine oil change
Cooling system
Engine Cooling System — Design Description
Coolant replacement
Antifreeze — General Information and Precautions
Radiator cap and radiator check
Removal and installation of a radiator
Checking the cooling fan
Checking the temperature sensor of the remote thermometer
Removal and installation of the water pump
Removal and installation of the water pump of the VR6 engine
Water pump repair
2.0 liter engine thermostat
Engine thermostat VR6
V-ribbed belt
Coolant circulation pump
Fuel injection system
VR6 engine fuel injection system
Precautions when carrying out repair work on the injection system
The principle of operation of the ECM under various conditions
Electronic control unit — general information
Throttle body
Fuel pressure regulator
Fuel Injection System Malfunctions
Removal and installation of fuel injectors
Checking the Mass Air Flow Sensor
Throttle drive cable
Electric fuel pump — general information
Checking the performance of the fuel pump
Removal and installation of the fuel pump
Fuel filter — removal and installation
Fuel level sensor in the tank
Description and operation of the Simos injection system (engine 2.0 l)
Simos system idle mode (engine 2.0 l)
Ignition system
General description and operation of the ignition system
Distributor. Ignition coil
Ignition output stage
Engine crankshaft speed sensor
Knock sensor. Detonation adjustment
Precautions when carrying out work on the repair of the ignition system
Repair and maintenance of the ignition system
General check of the ignition system
Checking the ignition coil
Hall sensor and knock test
Ignition distributor 2.0-liter engine
Maintenance of the ignition distributor
Removal and installation of the distributor of ignition
Ignition distributor repair
2.0-litre ignition timing adjustment
Spark plugs — removal, installation and adjustment
Diesel engines
Engine repair
Diesel engine — general information
Removal and installation of the engine
Engine disassembly
Engine Assembly
Cylinder head — removal on installed engine
Dismantling of a head of the block of cylinders
Cylinder head repair
Cylinder head assembly
Installing the cylinder head
Hydraulic tappets — removal and installation
V-ribbed and timing belts
Removing the toothed belt
Installing a toothed drive belt and adjusting the timing drive
Connecting rod and piston group — design description
Removal and disassembly of the connecting rod and piston group
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Removing the intermediate shaft
Installation of an intermediate shaft
Flywheel — removal and installation
Camshaft and oil seal
Removing the camshaft
Camshaft oil seal
Installing the camshaft and oil seal in the cylinder head
Determination of the axial clearance of the crankshaft
Crankshaft seals — removal and installation
Checking the parts of the crankshaft
Measuring cylinder bores
Checking the mating surface of the cylinder block
Lubrication system
Diesel engine lubrication system — general information
Removal and installation of an oil crankcase
Removal and installation of the oil pump
Oil pump repair
Oil filter — removal and installation
Checking oil pressure and changing it
Oil cooler — removal and installation
Cooling system
Diesel engine cooling system — general information
Filling the cooling system with coolant
Radiator cap and radiator check
Removal and installation of a radiator
Checking the cooling fan
Removal and installation of the water pump
Coolant Pump Repair
V-ribbed belt — removal and installation
Thermostat — removal, installation and inspection
Supply system
Diesel engine power system and turbocharger
Injection System Repair Precautions
Diesel fuel — general information
Fuel filter — removal and installation
High pressure fuel pump — general information
Removal and installation of the high pressure fuel pump
Nozzles — removal and installation
Removal and installation of a turbocharger
Glow plugs — check
Charge air cooler — removal and installation
Transmission
Clutch
Clutch — design description
Removing the clutch
Checking the technical condition and checking the clutch
Clutch installation
Clutch Release Actuator — Design Description
Removal and installation of the clutch slave cylinder
Removal and installation of the clutch master cylinder
Removal of air from the hydraulic clutch
Possible clutch malfunctions
Manual gearbox and shafts
Manual 5-speed gearbox
Removing the gearbox
Installing the gearbox
Gear shift mechanism
Replacing shift cables
Checking the operation of the gear shift mechanism
Checking the oil level in the gearbox
Wheel drive shafts — design description
Removal and installation of a power shaft (manual transmission)
Removal and installation of a power shaft (automatic transmission)
Drive shaft repair
Chassis
Steering
Removal and installation of the steering mechanism
Tie Rod Replacement
Tie Rod Head Replacement
Replacing the entire tie rod
Filling and bleeding the hydraulic system
Checking the hydraulic system for leaks
Adjusting the tension of the V-belt of the hydraulic booster pump
Removal and installation of the power steering pump
Power steering hoses and lines
Car suspension
Front suspension — general information
Removal and installation of a forward suspension bracket
Front suspension repair
Coil spring and shock absorber
Wheel bearing replacement
Removal and installation of transverse levers
Stabilizer transverse stability
Front wheel alignment
Rear suspension — design description
Removal and installation of a back suspension bracket
Trailing Arm / Suspension Springs
Removal and installation of shock absorbers
Rear wheel bearings
Brake system
Brake system — general information
Service brake adjustment
Parking brake adjustment
Checking the thickness of the front brake pads
Removal and installation of front brake pads
Disassembly and assembly of the brake mechanism of the front wheel
Removal and installation of a brake support of forward wheels
Checking the thickness of the rear brake pads
Replacing the rear brake pads
Dismantling and assembly of the brake mechanism of a back wheel
Brake disc processing
Master brake cylinder — general information
Removal and installation of the main brake cylinder
Repair of the main brake cylinder
Checking the vacuum brake booster
Bleeding hydraulic brakes
Parking brake — general information
Removal and installation of a cable of a drive of a parking brake
Removal and installation of the parking brake lever
ABS system (anti-lock braking system)
Removal and installation of the vacuum booster on a car with ABS
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Wipers — design description
Wiper Arm Replacement
Replacing the rubber band of the brush and the wiper blade itself
Replacing the wiper motor
Headlights — general information
Replacing headlight bulbs
Removal and installation of a headlight
Disassembly and assembly of the headlight
Headlight adjustment
Rear lights — removal and installation
Replacing front turn signal bulbs
Power devices
Battery — general information
Checking the condition of the battery
Generator — general information
Precautions when working with the power supply system
Generator check
Removal and installation of the generator
Generator repair
Starter — general information and malfunctions
Starter check
Removal and installation of a starter
Disassembly and assembly of the starter
Electrical circuits
Symbols for electrical diagrams
Wiring diagrams for Volkswagen Sharan, basic equipment
Wiring diagrams for Volkswagen Sharan with 2.8L VR6 engine
Wiring diagrams for Volkswagen Sharan with turbodiesel
Transporter T3
General information
Maintenance
Checking brake hoses and pipelines
Lubrication of moving joints
Lubrication and maintenance of vehicles with a diesel engine
Lubricants
Checking the smoke formation
Oil change for gearbox and final drive
Installing the car on the goats
Maintenance plan (diesel, release up to 8.85)
Maintenance plan (diesel, release from 9.85)
Maintenance plan (gasoline, release up to 8.85)
Maintenance plan (gasoline, release from 9.85)
Petrol engines
Engine repair
General description of gasoline engines
Basic technical data of a gasoline engine
Engine identification number
Removal and installation of the engine
Engine disassembly and assembly
Removal and installation of a head of cylinders
Basic valve clearance adjustment
Removal and installation of a protective tube of a pusher
Cylinder head with valves
Removal, installation and check of valves
Lapping of valve seats
Valve processing
Checking the valve guides
Valve seat processing
Checking the tightness of valve seats
Cylinder compression check
Cylinders, pistons and piston rings — design description
Removal and installation of cylinders, pistons and piston rings
Piston check
Checking cylinder bores
Removal and installation of the flywheel, replacement of the crankshaft oil seal
Checking and adjusting the axial play of the crankshaft
Disassembly and assembly of the engine crankcase
Removal and installation of a camshaft
Removal and installation of the crankshaft
Removal and installation of connecting rods
Removal and installation of an epiploon of a cranked shaft
Removal and installation of a belt pulley
Engine Troubleshooting
Removal and installation of the engine beam
Lubrication system
Purpose of engine oil
Engine oil change
Oil filter replacement
Oil pump, oil filter and pressure reducing valve
Removal and installation of the oil reducing valve
Check, removal and installation of the oil switch with a hydraulic drive
Automatic oil pressure control
Oil switch test, oil pressure test
Removal and installation of the oil pump
Diagnostics of malfunctions of the engine lubrication system
Cooling system
Description of the design of the engine cooling system
Engine cooling circuit
Coolant — general information
Draining and filling coolant
Removal and installation of a radiator
Removal and installation of the thermostat
Thermostat check
Removal and installation of the gauge of the index of temperature of a cooling liquid
Removal, installation and check of the temperature switch of the electric fan
Removal and installation of the water pump
Water hose connection diagram
Diagnostics of malfunctions of the engine cooling system
Power and exhaust system
Carburetor / fuel injection device
Maintenance of the carburetor device
Carburetor adjustment
Fuel supply problems
Air filter and carburetor vacuum connections 34 PICT
Air filter and carburetor vacuum connections 2E3
Intake air heating control
Thermostat check
Removal and installation of the fuel pump
Removal and installation of the fuel filter
Cable gas drive — design description
Removal and installation of a cable of gas
Cable throttle on vehicles with automatic transmission
Fuel tank — design description
Removal and installation of the fuel tank
Carburetor Troubleshooting
Exhaust system of the 1.9 l engine
2.1L engine exhaust system with catalytic converter
Removal and installation of the muffler
Cars with a catalyst — general information
Operation of vehicles with a catalyst
Carburetor 34 PICT
Carburetor 34 PICT — design description
Removal and installation of the carburetor 34 PICT
Carburetor adjustment 34 PICT
Removing and installing the float needle valve
Checking the Air Circulation Shutoff Valve
34 PICT carburetor cable adjustment
Checking the throttle and air damper shafts
Checking and adjusting idle speed and CO content
Engine start automatic system
Removal and installation of a heating coil
Adjustment of the automatic engine start system
Checking the automatic engine start system
Checking and adjusting the injection quantity of the accelerator pump
Checking and adjusting the size of the air damper gap
Checking and adjusting idle speed of a cold engine
Checking and adjusting the shut-off damper and delay valve
Removal and installation of an inlet pipe with a carburetor
Checking and replacing the intake pipe heater
Basic data of the 34 PICT carburetor
Carburetors 2E3 and 2E4
Carburetor 2E3 — design description
Throttle control test
Removal and installation of the carburetor 2E4
Checking and adjusting the idle speed and CO content
Engine start automatic system
Partial load duct heating test
Checking and adjusting idle speed of a cold engine
Checking and adjusting the size of the air damper gap
Checking and adjusting the injection quantity of the accelerator pump
Checking the Pulldown Device
Checking the idle shutoff valve
Carburetor inlet pipe 2E3 and 2E4
Basic data of the carburetor 2E3 and 2E4
Checking the thermostat housing and vacuum diaphragm
Fuel injection system
Fuel injection device for petrol engines
Digijet and Digifant injection systems
Adjustment of idle speed and CO content (Digijet)
Adjustment of idle speed and CO content (Digifant)
Checking the operation of the catalyst
Replacing the air filter insert
Removal and installation of the fuel filter
Ignition system
Ignition system — general information
Safety measures when working with the ignition system
Operation of the TSZ-H transistorized ignition system
Digifant ignition and fuel injection system
Checking the ignition coil
Checking high voltage wires and spark plug tips
Removal and installation of the distributor of ignition
Removal and installation of a power shaft of the distributor of ignition
Checking and adjusting the ignition timing
Connecting the switching unit of the idle stabilization system
Checking the ignition switching unit TSZ-H
Hall sensor test
Diesel engines
Engine repair
Main technical data of the engine
The principle of operation of a diesel engine
The principle of operation of a gas turbine supercharger
Removal and installation of the engine
Additional vibration damper
Sealed toothed belt guard
Removal and installation of a toothed belt
Toothed belt drive — design description
Checking and adjusting the toothed belt tension
Cylinder head — design description
Removal and installation of the cylinder head, gasket replacement
Valve Actuator — Design Description
Dismantling and installation of the camshaft
Dismantling and installation of valves
Valve seat finishing
Checking the valve guides
Replacement of rod seals
Valve clearance adjustment
Cylinder compression check
Emergency engine start
Diesel Engine Malfunction Table
Gas turbine supercharger — design description
Rules for maintaining cleanliness when working with a gas turbine supercharger
Removal and installation of a gas turbine supercharger
Lubrication system
Description of the design of the engine lubrication system
Changing the oil and oil filter
Engine oil consumption
Engine Oil Pressure Check
Dismantling and installation of the oil bath
Dismantling and installation of the oil pump
Dynamic oil pressure control
Table of malfunctions of the oil circulation system
Cooling system
Description of the design of the engine cooling system
Connection diagram of the cooling system hoses
Antifreeze — general information
Coolant replacement
Radiator — design description
Dismantling and installation of the radiator
Dismantling and installation of the valve-regulator
Checking the Regulator Valve
Dismantling and installation of the cooling pump
Dismantling and installation of the temperature indicator sensor
Installing and dismantling the fan thermostat and checking it
Dismantling and installation of the cooling pump V-belt, belt tension
Coolant circulation pump
Engine cooling system 1.7 liters
Table of malfunctions of the cooling system
Power and exhaust system
General description of the fuel system
Repair of the fuel injection system
Removing water from the fuel filter, replacing the filter
Installing the Fuel Filter Preheat System
Features with all-wheel drive Syncro
Checking and adjusting the maximum speed
Dismantling and installation of gas draft
Throttle adjustment
Cold start thrust adjustment
Checking and adjusting the idle speed
Cleaning and replacing the air filter insert
Checking the preheat system
Checking glow plugs
Dismantling and installation of nozzles
Table of malfunctions at idle
Checking and adjusting the start of delivery of the fuel pump
Troubleshooting table for too much fuel consumption
Checking and adjusting gas distribution
Table of faults with reduced engine power
Fuel tank — design description
Dismantling and installation of the fuel tank
Removal and installation of the fuel tank sensor
Dismantling and installation of the exhaust system
Fault table. excessively black exhaust gases
Transmission
Clutch
The principle of operation of the clutch
Description of the clutch design
Dismantling and installation of the clutch
Hydraulic clutch control
Clutch fault table
Car gearbox
General description of the gearbox
Dismantling and installation of transmission
All-wheel drive system
Gear shifting — design description
Installing the gearshift mechanism
Chassis
Front suspension
Description of the design of the front suspension and steering
Dismantling and installation of the spring (knuckle) and guide rod
Front wheel suspension — design description
Dismantling and installation of the shock absorber
Shock absorber check
Removal and installation of the upper guide rod / bearing check
Front wheel support
Dismantling and installation of the brake disc and wheel bearings
Checking the clearance in bearings and its adjustment
Car suspension measurement
Checking and adjusting the toe-in of the front wheels
Checking and adjusting the camber of the front wheels
Check and installation of a longitudinal inclination of a kingpin
Adjustable toe, camber and kingpin caster
Adjustable toe-in values for front wheels for vehicles with all-wheel drive
Car wheels and tires
Rear suspension
Rear axle — general description
Rear suspension — design description
Dismantling and installation of the shock absorber
Dismantling and installation of the spring
Dismantling and installation of the brake drum
Dismantling and installation of the cardan shaft
Disassembly of the cardan shaft, replacement of the protective cover and articulation
Checking and adjusting the convergence of the rear wheels
Checking and adjusting the camber of the rear wheels
Steering
Description of the steering structure
Dismantling and installation of the steering wheel
Hydraulic booster — design description
Checking the servo control for tightness
Servo oil level check
Steering check
Removal and installation of the tie rod
Steering gear and tie rod
Brake system
General description of the braking system
Checking the Thickness of Disc Brake Linings
Dismantling and installation of brake pads
Rear wheel brake — design description
Checking the thickness of the brake disc
Rear drum brake, brake lining control
Disabling the rear wheel brake
Removal and installation of brake pads
Rear wheel brake adjustment
Replacement of brake pads
Brake lines and hoses
Dismantling and reassembly of the wheel brake cylinder
Brake Hose Replacement
Brake fluid reservoir
Removal of air from the brake system
Hand brake — design description
Handbrake adjustment
Dismantling and installation of hand brake rods
Anti-lock braking system (PBS)
Table of malfunctions of the brake system
Body
Body and interior elements
Dismantling and installation of the front bumper
Dismantling and installation of the rear bumper
Removing and installing the driver's seat
Camping Equipment — Precautions
Checking the indicator lamps of the camping equipment indicator
Camping Equipment Water Pump Test
Dismantling and installation of a water tap
Dismantling and installation of the central locking servomotor
Description of the design of the interior heating system
Adjustment of drafts for fresh air and heating
Doors, locks and windows
Dismantling and installation of door trim
Exterior mirror glass replacement
Dismantling and installation of the front door
Dismantling and installation of a door window
Dismantling and installation of the power window
Dismantling and installation of corner glass
Dismantling and installation of the lock cylinder
Front door adjustment
Removal and installation of sliding door trim
Dismantling and installation of a sliding door
Sliding door adjustment
Adjustment of the sliding doors of buses with increased cabin height
Dismantling and installation of the lock with remote control
Dismantling and installation of the central lock
Replacement of worn parts of the swivel device
Side windshield replacement
Electrical equipment
Lighting system
Headlight Bulb Replacement
Parking light bulb replacement
Headlight adjustment
Dismantling and installation of the interior lighting lamp
Dismantling and installation of the front direction indicator
Dismantling and installation of a license plate light
Dismantling and installation of the rear light
Dismantling and installation of the headlight
List of used lamps
Equipment and devices
Control devices — design description
Dismantling and installation of the control panel
Dismantling and installation of the speedometer shaft
Switches on the steering column
Removal and installation of switches on the steering column
Dismantling and installation of the antenna
Windshield washer and headlight washer
Windshield washer nozzle adjustment
Replacing the rubber nozzles of the wiper blade
Dismantling and installation of the wiper brush holder
Table of malfunctions of wiper blades
Dismantling and installation of the wiper
Wiper malfunction table
Power devices (diesel)
Electrical system of vehicles with a diesel engine
Dismantling and installation of the battery
Checking the battery
Charging the battery
The battery is self-discharging
List of fuses
Removal and installation of the relay
Battery malfunction table
Dismantling and installation of the generator
Tensioning and changing the V-belt
Checking the W terminal of the generator
Replacing the voltage regulator
Generator Fault Table
Dismantling and installation of the starter
Starter malfunction table
Power devices (petrol)
Fuse table
Removal and installation of the relay
Removal and installation of the generator
Replacing the voltage regulator
Removal and installation of a starter
Diagnostics of malfunctions of the generator
Starter Troubleshooting
Wiring diagrams (diesel)
Working with circuit diagrams
Current flow diagrams (diesel and turbodiesel, 1990 model)
Preheating system (V.A.G 1466), cooling pump (turbodiesel)
Battery, starter, alternator, ignition switch
Control panel, optical and acoustic oil level control
Control panel, water temperature and water shortage indicator (V.A.G 1466), sensor
Cigarette lighter, radio, interior lighting
Light switches, license plate light, parking light, instrument lighting
Headlight, tail lamp, light and signal switch
Direction indicator with flashing light and signal light
Stop light, reverse light, signal horn
Fog lamp, rear fog light, heated rear window
Supply air fans, radiator (450 or 500 watts) and warm air
Windshield wiper and washer (V.A.G 1466)
Rear window wiper and washer (V.A.G 1466), handbrake and brake fluid control
Wiring diagrams (petrol)
Wiring diagrams for cars with gasoline engines
Starter, battery, alternator, ignition switch
Ignition system
Heated intake pipe, automatic engine start
Instrument kit, visual and acoustic oil pressure control
Instrument kit, coolant temperature gauge, sensors...
Cigarette lighter, radio, interior lighting
Light switch, license plate lights...
Low beam switch and high beam alarm
Direction indicators and alarms
Stop lights, reversing lights, horn
Fog lights, rear fog lights, heated rear window
Fresh air fan, radiator fan, warm air fan
Radiator fan (200/300/450W)
Windshield wiper and washer
Headlamp washer, wiper and rear window washer
Starter, battery, alternator, ignition switch (engine 2.1 l)
Ignition system (engine 2.1 l)
Heated intake pipe, automatic engine start (engine 2.1 l)
Ignition system, Digifant control unit, crankcase ventilation electric heating
Digifant control unit, lambda probe, digital fuel injection system
Idle speed stabilization circuit
Permanent all-wheel drive, blocker, flashing relay, warning lamp
Transporter T4
General information
User manual
Bulkhead modifications
Vehicle dimensions
Replacing the rubber blades of the wipers
Glass washing jets — removal, installation and adjustment
Headlight cleaning system
Wiper drive device
Wiper motor — removal and installation
Glass washing water pump — check and replacement
Diagnostics of malfunctions of janitors
Car wash
Care of the lacquer coating
Care of plastic parts
Glass cleaning
Caring for rubber seals
Caring for aluminum rims
Seat belts
Bottom protection and preservation of axle shafts
Upholstery care
Starting the engine from another source
Towing a car
Putting the machine on stands
Vehicle identification
Maintenance
Service oil change
Maintenance Schedule
Machine maintenance work
Engine and exhaust system
Engine oil change
Draining engine oil
Engine oil fill
Checking oil leakage by external inspection
Checking the engine oil level
Checking the coolant level
Checking the tightness of the cooling system by external inspection
Frost resistance test
Adding VW Concentrate to the Cooling System
Replacing spark plugs
Checking the electrical connections
Replacing the air filter element
Draining water from the fuel filter
Fuel filter replacement
V-belt check
Tensioning and replacing the toothed belt
Checking the exhaust gas system by external inspection
Brakes, tires, wheel rims
Checking the brake fluid level
Checking the thickness of the brake linings
Checking the brake pipelines by external inspection
Brake Fluid Replacement
Tire pressure check
Checking the tread profile
Tire valve check
Steering and front axle
Dust caps for tie rods and axle joints
Steering play check
Checking the oil level in the power steering
Body and interior equipment
Gearbox and wheel drive
Checking the tightness of the transmission with an external osmotor
Checking the rubber cuffs of the drive shafts
Checking the oil level in an automatic transmission
Checking the electrical system
Checking the battery
Power unit
Engine repair
Engine device
General engine data
Removal and installation of the engine
Removing the radiator
Removal and installation of a mudguard of the engine
Toothed belt — design description
Toothed belt adjustment (petrol 4-cylinder)
Toothed belt adjustment (diesel 4-cylinder)
Toothed belt adjustment (petrol 5-cylinder)
Toothed belt adjustment (diesel 5-cylinder)
Removal and installation of a gear belt (petrol 4-cylinder)
Removal and installation of a gear belt (diesel 4-cylinder)
Removal and installation of a gear belt (petrol 5-cylinder)
Removal and installation of a gear belt (diesel 5-cylinder)
Cylinder head — design description
Removal and installation of a head of the block of cylinders (petrol 4-cylinder)
Removal and installation of a head of the block of cylinders (diesel 4-cylinder)
Removal and installation of a head of the block of cylinders (petrol 5-cylinder)
Removal and installation of a head of the block of cylinders (diesel 5-cylinder)
Removal and installation of the camshaft
Hydraulic Poppet Pushers
Replacement of oil seals
Removal and installation of valves
Checking the valve guides
Finishing the valve seat in the cylinder head
Valve seat lapping
Cylinder compression check
V-belt alternator or alternator and water pump
Power Steering Pump V-Belt
Removal, installation and tension of the wedge toothed belt
Engine Troubleshooting
Ignition system
Ignition system — general information
Operation of the ignition system
Safety Precautions When Handling the Electronic Ignition System
Ignition distributor — design description
Removal and installation of the distributor of ignition
Checking the high voltage transformer
Hall sensor test
Checking and adjusting the ignition timing
Spark plugs — general information
Installing spark plugs
Selection of spark plugs for gasoline engines
Diagnostics of malfunctions of system of ignition
Lubrication system
Engine lubrication system — design description
Engine oil operating conditions
Oil dilution in a gasoline engine
Engine oil viscosity
All-weather and easy-flowing oil
Scope of oil and viscosity grades
Engine oil specification
Engine oil consumption
Engine oil circulation
Dynamic oil pressure control
Checking sensors and oil pressure
Diagnostics of malfunctions of the lubrication system
Cooling system
Checking the pressure in the engine cooling system
Coolant circulation
Radiator and antifreeze — design description
Removal and installation of a radiator
Coolant replacement
Coolant thermostat — removal, inspection and installation
Water pump — removal and installation
Fan motor temperature sensor — check
Coolant circulation temperature sensor
Diagnosis of malfunctions of the cooling system
Fuel system (petrol)
Engine power system — general information
Rules for maintaining cleanliness when working with the power system
Remote control connection
Checking for voltage at the fuel pump
Checking the amount of fuel supply
Checking the fuel pump check valve
Checking the fuel pump relay
Removal and installation of the fuel pump and pump sensor
Activated carbon system
Throttle cable
Cold start acceleration cable
Fuel system (diesel)
Working principle of diesel engine
Fuel filter heating system
Checking and adjusting idling and speed limits
Sealing of connecting fittings of injection pump
Nozzles — removal, inspection and installation
Checking the start of injection pump supply
Operation of machines equipped with a catalyst
Turbocharging system — design description
Diagnosis of malfunctions of the diesel fuel injection system
Injection system (petrol)
Gasoline injection system — general information
Checking idling and CO content
Idle stabilization
Throttle damper
Injection valves — removal and installation
Checking injection valves
Idling switch
Temperature sensor resistance value
Checking the intake air heating
Technical data of the Digifant system
Diagnostics of malfunctions of the fuel injection system Digifant
Exhaust system
Exhaust System — Design Description
Removal and installation of system of removal of exhaust gases
Replacing spring plates
Exhaust muffler and exhaust pipe — removal and installation
Lambda probe — removal and installation
Transmission
Clutch
Clutch — design description
General clutch data
Removal, installation and clutch check
Exhaust air from the clutch drive
Clutch cable replacement
Clutch Troubleshooting
Car gearbox
Removal and installation of a transmission
Engine-gearbox mount
Full automatic transmission
Transmission shift system
Shift Actuator Adjustment and Operation Check
Chassis
Car suspension
Front suspension — design description
General information about the front suspension
Support of the top rotary fist
Shock absorber — removal and installation
Removal and installation of forward leading semiaxes
Disassembly and assembly of the front drive semi-axes
Rear suspension — design description
General information about the rear suspension
Removal and installation of the rear shock absorber
Checking the rear shock absorber
Rear shock coil spring
Steering
Steering — design description
General steering information
Steering wheel — removal and installation
Ball joint and tie rod — removal and installation
Checking the tightness of the control system
Bleeding air from the control system
Elimination of vibration of the steering wheel and the front of the machine
The main parameters of the chassis adjustment
Convergence, transverse tilt of the kingpin, longitudinal tilt of the kingpin back
Brake system
General information about the brake system
Brake system technical data
Brake pads front disc brakes (14 inch wheels)
Brake pads front disc brakes (15 inch wheels)
Eliminate squeaky disc brakes
Checking the thickness of the brake discs
Brake disc and brake mechanism — removal and installation
Brake drum — removal and installation
Brake pads — removal and installation
Basic rear wheel brake adjustment
Handbrake adjustment
Brake fluid
Bleeding air from the brake system
Brake Fluid Replacement
Working brake cylinder — removal and installation
Brake pipeline and brake hose
Brake force regulator
Stoplight switch
Anti-lock braking system (ABS)
Brake fault diagnosis
Wheels and tires
General information about wheels and tires
Rim designation
Tire designation
Wheel replacement
Tire care rules
Snow chains (anti-slip chains)
Spare wheel — removal and installation
Incorrect tire wear
Diagnosis of wheel failures
Body
Exterior
General information about the car body
Bumpers — removal and installation
Front closing beam — removal and installation
Bonnet cover — removal and installation
Bonnet cover — removal and installation
Radiator grill — removal and installation
Protective bar for license plate light
Outside mirror — removal and installation
Replacement of exterior mirrors
Interior
Interior mirror — removal and installation
Front seat — removal and installation
The middle row of seats in the cabin — removal and installation
Rear seat bench — removal and installation
Glove box — removal and installation
Doors and windows
Rear door — removal and installation
Fitting tailgate
Removal and installation of a gas shock-absorber of a door of a luggage carrier
Front door device
Removal, installation and adjustment of the front door
Front door lining
Door glass — removal and installation
Window regulator — removal and installation
Handle and door lock — removal and installation
Door seal — removal and installation
Sliding door device
Removal and installation of a sliding door
Removal and installation of the guide rail of the sliding door
Rear double door — removal and installation
Heating system
Heating system device
Inlet pipes — removal and installation
Heater motor — removal and installation
Air deflectors — removal and installation
Heating regulator — removal and installation
Heater control cables — removal and installation
Additional heat exchanger — removal and installation
Additional heating system on the model «Caravel»
Diagnosis of malfunctions of the heating system
Electrical equipment
Equipment and devices
Electrical system — general information
Voltage measurement
Current measurement
Resistance measurement
Installing additional electrical accessories
Troubleshooting in electrical equipment
Incandescent lamp test
Checking electric motors
Checking switches
Checking lamp and motor switches
Checking sensors
Relay — description and test
Wiper motor — description and verification
Direction indicator system — description and verification
Stoplight — check
Sound signal — description and verification
Heated rear window — description and check
Replacing fuses
Control lamps — removal and installation
Checking the LEDs
Voltage stabilizer — removal, inspection and installation
Control devices — removal and installation
Speedometer roller — removal and installation
Instrument panel — design description
Instrument visor (torpedo) on the instrument panel
Combination steering switch — design description
Removal and installation of the combined switch of a wheel
Connections on steering wheel combination switch and steering lock
Digital clock backlight
Radio receiver — removal and installation
Entering the radio code for radios
Lighting and signaling
Lighting and signaling system — general information
Lamp table
Lamp replacement
Turn signal housing — removal and installation
Headlight adjustment
Servo motor for beam adjustment
Fog lamp — removal and installation
Rear light — removal and installation
Power devices
Battery — general information
Removing and installing the battery
Checking the battery
Charging the battery
Storage of the battery
Battery self-charging
Diagnostics of battery malfunctions
Generator — design description
Alternator voltage test
Removal and installation of the generator
Replacing the graphite brushes of the generator and checking the voltage regulator
Diagnostics of malfunctions of the generator
Starter — general information
Removal and installation of a starter
Starter magnetic relay — removal, inspection and installation
Starter Troubleshooting
Electrical circuits
General information about electrical circuits
Letter designation of the most important devices
Deciphering the color of the conductors
Fuse kit and ratings
Identification of wiring diagrams depending on the engine
Instructions for using the wiring diagram
Designation of elements in electrical circuits
Alternator, battery, starter, ignition switch
Ignition system, Digifant injection system control unit
Digifant fuel injection control unit, self-diagnosis unit
Digifant fuel injection control unit
Instrument panel: control instruments
Instrument panel: speedometer, turn signal and brake lamps
Instrument panel: tachometer, brake sensor
Fan (150W, 250W) and additional coolant pump
Connecting the radio, cigarette lighter and engine compartment lamp
Interior lighting
Headlight wiring diagram
Headlight adjustment system
Switches for turning, alarm, parking lights
Direction indicators, rear lights
Light switch, license plate light
Fog lights, reversing lights
Cooling system fans (150, 250W), heating and ventilation
Heated rear window and horn
Windshield wiper and washer
Rear window wiper and washer
Diesel: pre-heating system, fuel cut-off valve
Diesel: instrument panel, warning lamps
Diesel: instrument panel, tachometer, indicator lamps
Diesel: radio, cigarette lighter and engine compartment lamp
Diesel: fog lights, reversing lights
Diesel: heating fan, additional cooling pump
Diesel: cooling fans (2x350W)
Diesel (ABL): exhaust aftertreatment system
Diesel (ABL): glow plugs, auxiliary cooling pump
Diesel (ABB): pre-heating system, fuel cut-off
Diesel (ABB): additional cooling pump
Central door locking system
Rear door lock motors
Connecting an additional battery from November 1990
Beetle
General information
Maintenance
Car body wash
Paintwork care
Care of chrome parts, glass and rubber bands
Seat upholstery care
Basic and additional set of tools
Engine oil — general description
Gear oil — general description
Engine oil change
Changing the oil in the gearbox and final drive housing
Front suspension lubrication
Lubrication of door hinges
Lubrication of door locks and latches
Cleaning the Paper Air Filter Element
Cleaning drain holes
Vehicle maintenance work
Power unit
Engine repair
General description of engines
Vehicle lifting
Removal and installation of the engine
Engine disassembly and assembly
Removal and installation of cylinder heads
Removal, check and installation of valves
Valve grinding
Lapping of valves
Checking valve seats for tightness
Checking the valve guides
Valve seat processing
Valve clearance adjustment
Cylinder compression check
Removal and installation of cylinders, pistons and piston rings
Piston check
Checking piston rings
Checking the inner diameter of the cylinders
Removal and installation of a back protective cover of the engine
V-belt pulley replacement
Removal and installation of a flywheel
Replacing the crankshaft seal
Checking and adjusting the axial play of the crankshaft
Inlet piping and preheating ducts
Main engine attachments
Disassembly, inspection and assembly of the crank mechanism
Removal, check and installation of a camshaft
Removal, disassembly, assembly and installation of the crankshaft
Removal, check and installation of connecting rods
Engine malfunctions and solutions
Cooling and lubrication system
General description of the engine lubrication system
The main elements of the lubrication system
Removal and installation of the safety valve
Removing, installing and checking the oil pressure sensor
Removal, check and installation of the oil pump
Removal and installation of an oil filler neck
Removal and installation of an oil cooler
Malfunctions of the engine lubrication system
Engine Cooling System — Design Description
Removal and installation of a casing of the fan
Removal, installation, adjustment and check of the thermostat
Supply system
Power system maintenance
Carburetor — design description
Carburetor adjustment
Fuel supply problems
Removal and installation of the carburetor
Air-fuel mixture cut-off valve check
Accelerator drive adjustment
Dismantling the carburetor
Removing, checking and installing the float needle valve
Checking and adjusting idle speed
Checking and adjusting the CO content in the exhaust gases
Throttle damper adjustment
Throttle adjustment
Checking and adjusting the air damper gap
Checking the thermal switch
Checking and adjusting the fuel supply by the accelerator pump
Automatic start — general description
Removing, installing, adjusting and checking the heating coil
Replacing the accelerator cable
Removal and installation of the fuel pump
Removal, cleaning and installation of the strainer of the fuel pump
Air filter replacement
Removal and installation of the fuel tank
Removal and installation of the fuel level sensor
Carburetor technical data
Carburetor malfunctions and solutions
Exhaust system
Exhaust System — Design Description
Exhaust system replacement
Removal and installation of levers of gates of system of heating and ventilation
Exhaust pipe replacement
Removal and installation of the heat exchanger
Transmission
Clutch
Description of the clutch design
How the clutch works
Removal, check and installation of coupling
Removal and installation of the clutch cable
Checking and adjusting the deflection of the clutch cable guide
Clutch pedal free play adjustment
Clutch problems and how to fix them
Car gearbox
Description of the design of the gearbox
Removal and installation of a transmission (rear axle with diagonal balancer)
Replacing the front rubber-metal support
Removal and installation of a transmission (with independent wheel suspension)
Replacement of protective covers of semiaxes
Replacement of epiploons in covers of bearings of semiaxes
Removal and installation of the gear lever
Removal and installation of a mobile bar
Adjustment of the mechanism of a gear change
Chassis
Front suspension
Front suspension on shock absorbers
Shock absorber strut — design description
Removal and installation of shock absorber struts
Removing, installing and checking shock absorbers and coil springs
Front torsion bar suspension
Removal and installation of steering knuckles
Replacing shock absorbers
Removal and installation of brake drums, discs and wheel bearings
Front wheel brakes
Checking and adjusting wheel bearing play
Rear suspension
Rear suspension (independent) — design description
Replacing the brake drums of the rear wheels
Replacing the rear wheel bearing seals
Replacing torsion bars (rear axle with independent suspension)
Adjustment of elastic levers
Removal and installation of balancers
Rear suspension parts
Removal and installation of shock absorbers
Replacing wheel bearing seals
Rear brake elements (suspension with diagonal balancer)
Removal and installation of axle shafts, hinges and their protective covers
Steering
Description of the steering structure
Removal and installation of a steering wheel
Removal and installation of the steering column switch
Steering elements
Removal, check and installation of the steering damper
Removal and installation of transverse steering rods
Checking and adjusting the roller steering gear
Adjustment and check of the rack and pinion steering mechanism
Roller Steering Malfunctions
Brake system
General description of the braking system
Checking the thickness of the friction linings of disc brakes
Removal and installation of friction linings of disc brakes
Checking the thickness of the friction linings of drum brakes
Drum brake adjustment
Removal and installation of front brake pads
Details of front suspension brakes on torsion bars
Details of front suspension brakes on shock absorber struts
Rear wheel brake — design description
Removal and installation of rear brake pads
Removal, disassembly, assembly and installation of wheel brake cylinders
Replacement of brake pipelines and hoses
Brake fluid reservoir
Bleeding the brake system
Removal and installation of the parking brake lever
Replacing the parking brake cable
Parking brake adjustment
Brake system malfunctions
Wheels and tires
General description of wheels and tires
Wheel balancing
Tire wear
Uneven tire wear
Wheel replacement
Geometric parameters of wheel installation
Checking and adjusting the camber of the front wheels (torsion bar suspension)
Adjustment of a convergence of forward wheels
Rear camber adjustment (rear axle with independent suspension)
Front camber adjustment (suspension with shock absorbers)
Adjustment of a convergence of forward wheels (suspension with shock absorbers)
Setting values for toe and camber angles
Abnormal tire wear
Body
Exterior
Removal and installation of front fenders
Removal and installation of rear fenders
Removing and installing the trunk lid
Removal and installation of the trunk lid lock
Removal and installation of a cowl
Removal and installation of the lock of a cowl
Checking the drains of the sliding roof (cabriolet)
Sliding roof seal replacement (cabriolet)
Removal and installation of doors
Door fixing plate adjustment
Removal and installation of a covering of doors
Removal and installation of windows
Removal and installation of door handles and lock cylinders
Replacement of windshield and side windows
Electrical equipment
Equipment and devices
General description of onboard electrical equipment
Maintenance of electrical equipment
Removal and installation of headlights and their lamps
Replacing parking light bulbs
Replacing bulbs in the rear lights
Removal and installation of plafonds of illumination of salon
Front direction indicators and license plate light
Headlight range adjustment
Replacing fuses
Instrument panel — removal and installation
Removal and installation of clocks (Kafer 1303)
Removal and installation of a speedometer (Kafer 1303)
Removal and installation of a speedometer (Kafer 1200)
Removal and installation of a cable of a speedometer
Check and replacement of brake light switches
Removal and installation of the washer switch
Steering wheel lock and ignition lock replacement
Removal and installation of levers of screen wipers (Kafer 1200)
Replacing wiper blades
Removal and installation of the electric motor of screen wipers (Kafer 1200)
Removal and installation of levers of screen wipers (Kafer 1303)
Removal and installation of the electric motor of screen wipers (Kafer 1303)
Possible malfunctions of wipers
Power devices
Removing and installing the battery
Battery check
Possible battery problems
Generator — design description
Removal and installation of the generator
Removing, installing and tensioning the alternator drive V-belt
Possible generator malfunctions
Ignition system — general information
Maintenance of the ignition system
Checking the ignition coil
Capacitor check
Ignition distributor parts
Removal and installation of the distributor of ignition
Removal and installation of a drive of the distributor of ignition
Replacing breaker contacts
Checking and adjusting the angle of the closed state of the contacts
Adjustment of the gap between the contacts of the breaker and the angle of their closed state
Ignition timing adjustment with instruments
Adjustment of the moment of ignition by means of a control lamp
Ignition Timing Adjustment Data
Spark plug
Maintenance and inspection of spark plugs
Electrical circuits
Use of electrical diagrams
Symbols of elements of electrical circuits
Wiring diagram for Kafer 1200/1200L vehicles from August 1975
Wiring diagram of a Kafer 1303 from August 1974
Wiring diagram of a Kafer 1200 from August 1974
Additional wiring diagram for Kafer 1300/1303 from August 1974
Fog lights and rear fog lights
Changes in the electrical circuit (generator and voltage regulator)
Caddy 3
General information
User manual
Governing bodies
Instrument cluster
Instrument cluster indicator lights
Multifunction indicators in the instrument cluster
Multifunction display control (IFD)
Indication of the total, daily mileage or mileage remaining until MOT
Odometers
Ambient temperature indicator
Warning and informational texts in MFD
Warning indicator lights
Main menu of the multifunction display
Car keys
Central locking switch
Remote control battery health indicator
Anti-theft alarm
Device that prevents children from opening the sliding door
Exterior car lighting
Car interior lighting
Wiper control
Exterior mirrors
Seat heating
Warning triangle and dressing box
Interior heating and cooling control
Steering wheel adjustment
ESP stabilization system and ASR traction control
Key switch for ignition and instrumentation with anti-theft device
Description and location of fuses (until 2005)
Vehicle Specifications
Daily care
Location of relays and fuses (since 2005)
Incandescent lamps used in the car
General information about maintenance
Periodicity of maintenance work
Vehicle Inspection Service
Raising the car on a lifting platform and a jack
Visual check of the battery
Battery electrolyte level check
Checking battery voltage at no load
Tire wear condition check
Checking the brake fluid level
Visual inspection of the brake system for leaks and damage
Checking the thickness of the brake pads for disc brakes
Visual inspection of anthers of constant velocity joints (SHRUS)
Checking the tie rod ends
Checking the oil level in the power steering reservoir
Visual inspection of axle joints
Visual inspection of parts in the engine compartment and on the bottom
Checking the engine oil level
Checking the condition of antifreeze and coolant level
V-ribbed belt — condition check
Checking the position of the power windows
Checking the antifreeze content in the washer fluid concentrate
Windshield washer jet adjustment
Adjustment of headlight cleaner nozzles
Carrying out a test drive
Maintenance
Disconnecting and connecting terminals from the battery
Removing and installing the battery
Removing the wheel center cap
Brake Fluid Replacement
Changing engine oil and oil filter
Removal and installation of the protective pallet of a motor compartment
Removal and installation of the top casing of the engine
Replacing the fuel filter in a diesel engine
Replacing the air filter element
Checking the camshaft timing belt (4-cyl. gasoline engines)
Checking the camshaft timing belt (SDI and TDI diesels)
Replacing the timing belt for 1.4L BCA and BUD petrol engines
Replacing the timing belt for the timing drive of gasoline engines 1.6 l BGU, ALL and BCF
Replacing the timing belt in TDI and SDI diesel engines
Removal and installation of a gear belt (with motor support mounted remotely)
Replacing spark plugs
Changing the oil and filter in a 6-speed dual clutch transmission 02E
Headlight adjustment check
Petrol engines 1.4 l
Engine repair
Technical characteristics of gasoline engines 1.4 l BCA, BUD and 1.6 BGU, BSE, BSF
Removal and installation of the engine 1.4 l (BCA and BUD)
Engine disassembly and assembly (BCA and BUD)
Removal and installation of poly V-belt
The block of cylinders of petrol engines of 1,4 l (BCA and BUD)
Removal and installation of front and rear covers of the crankshaft
Removal and installation of a back cover of the block of cylinders
Pressing the flange with the ring gear onto the crankshaft
Disassembly and assembly of pistons and connecting rod
Checking the thermal gap at the joints of the piston rings
Checking clearance between piston ring and groove in axial direction
Checking pistons and cylinders
Removal and installation of a head of the block of cylinders
Dismantling and assembly of a head of the block of cylinders
Check of deformation of a plane of contact of a head of the block of cylinders
Notes on the features of the work on disassembling and assembling the cylinder head
Valve mechanism repair
Fixing both toothed camshaft pulleys
Cylinder head seating surface treatment
Camshaft — checking end play
Valve seat processing
Cooling and lubrication system
Elements of the lubrication system
Removal and installation of parts of the lubrication system
Removal and installation of an oil filler neck
Removal and installation of the pallet of an oil crankcase
Removing and installing the oil pump
Connection diagram of the cooling system
Details and units of the hydraulic part of the cooling system
Parts and assemblies of the thermostat, radiator and expansion tank
Parts and assemblies of the cooling fan unit
Precautions when working with the cooling system
Elements of the cooling system installed on the body
Elements of the cooling system associated with the thermostat
Elements of the system associated with the coolant pump
Removal and installation of the fan, radiator (V7) and radiator fan 2 (V177)
Removal and installation of a radiator
Removal and installation of the pump of a cooling liquid
Power and exhaust system
General information about removing and installing elements of the power system
Parts and components of the power system
Collision fuel cut-off system
Checking the performance of the fuel pump
Details of the fuel manifold with injectors
Air filter housing for engines with BCA designation
Air filter housing for engines with the designation BUD
Air filter housing for BCA engines — removal and installation
Air filter housing for BUD engines — removal and installation
Cleaning the throttle control unit (J338)
Removal and installation of fuel injectors
Checking the preheating of the intake air
Checking the amount of injected fuel
Checking the tightness and quantity of injected fuel (from 2006 release)
Fuel pressure regulator and residual pressure
Removal and installation of the anti-theft engine control unit
Parts and components of the exhaust system (BCA motors)
Parts and components of the exhaust system (BUD engines)
Petrol engines 1.6 l
Engine repair
1.6L petrol engines (BGU, BSE and BSF) — design description
Removing the petrol engine
Gasoline engine installation
Disassembly and assembly of a gasoline engine
Removing the upper part of the casing of the toothed belt
Removal and installation of poly V-belt
Cylinder covers and flywheel
Removal and installation of a back cover of the block of cylinders
Installation of a forward cover of the block of cylinders
Removal and installation of the master rotor
Marking of the upper shells of the main bearings of the crankshaft
Parts and assemblies of the cylinder-piston and connecting rod-piston groups
Mounting position of bearing shells
Checking cylinders, pistons and piston rings
Parts and assemblies of the cylinder head
Checking the cylinder head for warping
Removal and installation of cylinder head
Removal, installation and tension of a toothed belt
Checking the semi-automatic toothed belt tensioner
Parts and assemblies of the valve mechanism
Processing of the attached cylinder head plane
Valve sizes
Valve seat processing
Checking the valve guides
Removal and installation of a camshaft
Cooling and lubrication system
Lubrication system — design description
Oil filter with heat exchanger — design description
Removed and installed oil pan
Removal and installation of the oil pump
Parts and components of the cooling system installed on the engine
Cooling system hose connection diagram
Draining and refilling coolant
Removal and installation of the pump of a cooling liquid
Installing a thermostat in the cylinder block
Power and exhaust system
Air supply and fuel injection system
Parts and assemblies of the air supply system of BGU, BSE, BSF engines
Details of the fuel manifold with injectors of engines 1.4 and 1.6 l
Parts and components of the air supply and filtration system
Removal and installation of the lower part of the intake manifold (BGU)
Removal and installation of the lower part of the intake manifold (BSE, BSF)
Removing and installing injectors
Switching in the control system to check the parameters of the injection system
Details and knots of a reception pipe with the catalyst
Details and assemblies of the additional and main mufflers
Exhaust gas recirculation system (BGU)
Secondary air supply system (BGU, BSE)
Diesel engines
Engine repair
Technical characteristics of diesel engines 1.9 l and 2.0 l
Components and parts of the timing drive
Drive of auxiliary units
Cylinder block and related units
Removal and installation of poly V-belt
Removal and installation of sealing flange and flywheel
Cylinder block of diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
Removal and installation of the crankshaft speed sensor (G28)
Crankshaft and main bearings
Details of the crank mechanism
Connecting rod and piston group
Checking the thermal seal of the piston rings
Checking the height clearance between the groove and the ring
Checking the cylinder diameter
Mounting position and assignment of pistons to cylinders
Measurement of piston protrusion from the cylinder block at TDC
Cylinder head gasket marking
Cylinder head for diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
List of parts and assemblies of the cylinder head
Checking the cylinder head for warping
Installing the valve cover
Removal and installation of a head of the block of cylinders
Camshaft, valves and pump injector drive
List of components and parts of the valve mechanism
Checking the axial run of the camshaft
Valve sizes
Removal and installation of a camshaft
Cooling and lubrication system
List of units and parts of the lubrication system
Parts list for oil filter and heat exchanger
Pressure oil line for lubrication of turbocharger bearings
General information about the engine cooling system
Parts and assemblies of the cooling system mounted on the body
Parts and components of the cooling system installed on the engine
Cooling system hose connection diagram
Cooling system for diesel engines 1.9 l BJB
2.0L BDJ Diesel Engine Cooling System
Engine cooling system 2.0 l BDJ with auxiliary heater
2.0L BST Diesel Engine Cooling System
Cooling system for diesel engines 2.0 l BST with auxiliary heater
Cooling system for diesel engines 1.9 l BLS, BSU
Cooling system for diesel engines 1.9 l BJB with auxiliary heater
Power and exhaust system
Fuel supply system
Fuel filter parts and assemblies
Removal and installation of the fuel supply module
Removal and installation of the fuel level sensor
Removal and installation of the dual pump
Fuel and vacuum pump
Quick Hose Couplings
1.9L BJB turbocharged air supply system
Components and parts of the intake tract of the diesel engine 1.9 l VJB
1.9L BJB Intercooler Components and Parts
1.9L BLS and BSU turbocharged air supply system
Specification of components and parts of the intake tract of the engine 1.9 l BJB
Removal and installation of a turbocharger
Non-turbo air supply system
Fuel injection system — description
Specification of unit injectors for diesel engines
Vacuum hose connection diagram
Removal and installation of an accelerator pedal
Details and components of the exhaust system with a catalyst for BJB, BSU engines
Details and components of the exhaust system with a particulate filter of the BLS engine
Particulate Filter Related Parts
Correction of the position of the elements of the exhaust system
Parts and components of the exhaust gas recirculation system
Vacuum hose connection diagram (BJB, BSU and BLS)
Silencer with mounts — design description
Details of the exhaust gas recirculation system
Transmission
Mechanical gearbox 0AH
Manual transmission identification data
Types and device manual transmission
Description of the clutch design
Repair of the clutch release mechanism
Gearshift Mechanism — Design Description
Gearbox — removal
Gearbox — installation
Checking the oil level in the manual transmission
Parts and assemblies of manual transmission type 0AH
Removal and installation of a cover of a crankcase of a box and gear wheels of 5th transfer
Removal and installation of the manual transmission housing
Removal and installation of input shaft, output shaft, differential
Gearbox disassembly
Gearbox Assembly
Internal shift mechanism manual transmission
Dismantling and assembly of the internal mechanism of inclusion of transfers
Dismantling and assembly of the input shaft
Disassembly and assembly of the hub with a sliding sleeve of the synchronizer of 3rd and 4th gears
Checking the synchronizer ring for wear
Determining the thickness of the thrust ring
Disassembly and assembly of the hub with a sliding sleeve synchronizer 5th gear
Dismantling and installation of the secondary shaft
Dismantling and assembly of a secondary shaft
Installation position of 3rd and 4th gears
Checking the inner ring of the synchronizer of 1st and 2nd gears for wear
Checking the blocking ring of the synchronizer of the 1st and 2nd gears for wear
Installation position of the outer, inner and blocking rings of the 2nd gear
Disassembly and assembly of the hub with a sliding sleeve of the synchronizer of 1st and 2nd gears
Differential — design description
Dismantling and assembling the differential
Mechanical gearbox 0A4
0A4 mechanical transmission design description
Gear shift mechanism
Checking the operation of the gear shift mechanism
Removal and installation of the mechanism of a gear change
Adjustment of the mechanism of a gear change
Disassembly and assembly of the gear shift mechanism
Dismantling and assembly of a secondary shaft
The position of the inner, intermediate and blocking ring synchronizer 1st gear
Disassembly and assembly of the clutch with the synchronizer hub of 1st and 2nd gears
Pressing on the clutch and hub of the synchronizer of 1st and 2nd gears
Disassembly and assembly of the clutch with the synchronizer hub 3rd 4th gear
Drive shafts
General description of drive shafts
Removing the drive shaft
Installing the drive shaft
Parts and assemblies of the drive shaft with CV joint VL100
Parts and assemblies of the drive shaft with CV joint VL107
Drive shaft disassembly
Drive shaft assembly
Chassis
Car suspension
Front wheel suspension — design description
Removal and installation of a stretcher
Setting the suspension to the position corresponding to the curb weight
Checking the condition of the ball joints
Removal and installation of a spherical support
Tightening torques for fasteners of parts and assemblies of the front suspension
Swivel fist assembly with hub
Removal and installation of a rack of the shock-absorber
Rear suspension repair
Tightening torques for threaded connections in the rear suspension
Steering
Removal and installation of a steering wheel
Removal and installation of a multipurpose steering wheel
Steering column — design description
Steering column — removal and installation
Removal and installation of steering draft
Hydraulic Power Steering — Design Description
The steering mechanism with hydraulic strengthening — removal and installation
Removing air from the steering system
Steering gear repair
Power Steering Rotary Pump
Steering gear with electromechanical booster
Repair of the steering mechanism with an electromechanical amplifier
Removal and installation of steering draft (electromechanical amplifier)
Tightening torques for threaded fasteners of steering parts
Brake system
Specifications of the brake system
FS III Front Brake Parts List
Removal and installation of brake pads (FS III)
Removal and installation of a brake caliper (FS III)
Brake Caliper Repair (FS III)
Removal and installation of the brake caliper piston (FS III)
List of parts and assemblies of the front brake FN 3
Removal and installation of brake pads (FN 3)
Removal and installation of a brake caliper (FN 3)
Brake Caliper Repair (FN 3)
List of parts and assemblies of the rear brake
Removal and installation of rear brake pads
Removal and installation of a support of back brakes
Parking brake adjustment
Rear brake caliper repair
Brake booster, brake master cylinder
Details and knots of the vacuum pump of the amplifier of brakes (diesel)
Stoplight switch (F), since 2007
Removal and installation of the main brake cylinder
Removal and installation of the brake booster
Electronic Stability Program (ESP)
List of elements of the ABS Mark 70 system (ABS/ASR)
List of elements of the ABS Mark 60 system (ABS/EDS/ASR/ESP)
Fault indication with indicator lamps
List of parts and assemblies of the main brake cylinder
Installation of ABS system components
Body and wiring diagrams
Interior and exterior
Removal and installation of the front of the center console (van)
Removal and installation of the front of the center console (station wagon)
Removal and installation of the center console (van)
Removal and installation of the center console (station wagon)
Removing storage compartments and compartments
Removing and installing trims in the footwell
Removal and installation of the central decorative overlay of the forward panel
Removal and installation of lateral overlays of the forward panel
Removal and installation of facing of the block of understeering switches
Compartments, linings and facings of interior elements
Mounting front and rear seats
Control dimensions of the body
Dimensions of gaps between body parts
Electrical circuits
Rules for the use of electrical circuits
List of electrical equipment elements shown in the diagrams
Motronic injection system for 1.4l 55kW BCA petrol engine
Simos injection system for engines 1.6 l, 75 kW, BGU, BSE, BSF since May 2005
Diesel injection system 1.9L BSU and BLS
Diesel injection system 2.0 l 51 kW, BDJ, BST
Infinitely adjustable 350W heatsink fan (200W and 150W) from 05.2005
Infinitely adjustable 500W heatsink fan (300W and 200W) from 05.2005
Radiator fan for cooling system, 1-speed from 05.2005
Anti-Lock Braking System (ABS) with ASR from 05.2005
Anti-lock braking system ABS with EDS, ASR and ESP from 05.2005
Electromechanical power steering from 05.2005
Schemes of the basic configuration of electrical equipment from 05.2005
Sockets (12 V) from 05.2005

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