Leon Mk2: Running gear
Also for this vehicle: Leon Mk1.
Transmission
Steering & suspension
Body & interior
General
Engine
Heating & A/C
Diagnostics
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
Running gear, axles, steering1,267 pages
Technical data20 pages
- Check list to grade the running gear of an accident vehicle
- Checklist for evaluating running gear of accident vehicles
- General notes
General10 pages
Ecological disposal of parts containing oil5 pages
Shock absorber: verification4 pages
Front suspension, drive shafts402 pages
Front wheel suspension: repair (vehicles without stabilizer bar)25 pages
- Analytical assessment of collision vehicles
Front wheel suspension28 pages
- Front axle: overview
- I - Subframe, stabiliser bar, swinging arm overview
- Swinging arm ball joint: verification
- Swinging arm bonded rubber bearing: replacement
Bearing cap bolt on the longitudinal member: verification3 pages
- ll - Wheel attachment, shock absorber, half shaft
- General overview: telescopic arm: repairs
- Telescopic arm: Repairs
- Appraisal of accident vehicles
Front wheel suspension: repairing38 pages
I - Assembly overview of strut, stabilizer bar and swinging arm up to year 2000 models3 pages
- I - Assembly overview of strut, stabilizer bar and swinging arm from year 2001 models onwards
- Nut on longitudinal member/bodywork: repairing
- Modification to bolted connection of strut support to bodywork
- Strut support: aligning with bodywork
- II - Wheel bearing, suspension strut, driveshaft assembly: removing and fitting
Front wheel bearing: fitting and removing with mounted steering knuckle7 pages
- Front suspension strut: repairing
Front wheel suspension: repairs20 pages
- Front axle: overview
- I - Subframe, stabiliser bar, swinging arm overview
- Swinging arm bonded rubber bushes: replacement
Bearing cap bolt on the longitudinal member: verification2 pages
- II - Wheel bearing, suspension strut, driveshaft assembly: removing and fitting
- Front suspension strut: repairing
Repairing front wheel suspension3 pages
Articulated half shafts19 pages
Inner constant velocity joint: Verification4 pages
- Tripod joint: disassembly, repairs and assembly
Complete half shaft with tripod type joint: repairs4 pages
- Lifting suspension to unladen position
Driveshafts: repairing25 pages
Articulated half-shaft.11 pages
Front suspension5 pages
- Front axle - Assembly overview
Wheel hub assembly: lift when the vehicle is in unladen weight position3 pages
Front wheel suspension: repair (vehicles with a stabilizer bar)25 pages
- Front axle - Assembly overview
Support strut, stabiliser bar, swinging arms36 pages
- Subframe, transversal arm and track rods - Assembly overview
- Assembly overview: Front left vehicle level senderG78
- Removing and installing front left vehicle level senderG78
Fixing position of subframe and brackets3 pages
Subframe (front-wheel drive) - Repair3 pages
Subframe (all-wheel drive) - Repair3 pages
Removing and installing wishbone and mounting bracket5 pages
Renewing bonded rubber bush in wishbone3 pages
Replacing the bearing bracket with rubber-bonded metal mount of the control arm3 pages
IV Drive shafts11 pages
Sub-frame8 pages
- Removing and installing subframe
- To replace the bonded rubber bearing of the strut replace
- Stop wedges of the bonded rubber bearings: Removing and installing
- Cross-member of the gearbox: Removing and installing
Vehicle level sender for vehicles with automatic headlight range control3 pages
Subframe, stabiliser bar, traverse swinging arm24 pages
- Subframe, stabiliser bar, transverse swinging arm - Assembly overview
Sub-frame: securing3 pages
Removing and installing swivel joint4 pages
- Swinging arm bonded rubber bushes: replacement
- Removing and installing rubber bearing for stabilizer
- Tightening torques of the front axle
Wheel bearing - assembly overview7 pages
Wheel bearing housing and wheel bearing and wheel hub unit7 pages
Subframe: Assembly overview9 pages
- Front left vehicle level senderG78: Assembly overview
- Removing and installing front left vehicle level senderG78
- Repairing thread in longitudinal member
- Fixing position of subframe
- Lowering subframe
- Removing and installing subframe without steering box
- Removing and installing subframe with steering box
- Strut support: repairing
Wheel suspension: assembly overview7 pages
Front wheel suspension, suspension link: Assembly overview7 pages
- Checking swivel joint
- Removing and installing swivel joint
- Removing and installing suspension link with mounting bracket
- Removing and installing suspension link with mounting bracket (left side for vehicles with DSG or automatic gearboxes)
- Renewing bonded rubber bush for suspension link
- Renewing mounting bracket with suspension link bush
Wheel bearing assembly: Assembly overview3 pages
Complete half-shafts: repairs22 pages
Removing and installing drive shafts5 pages
- Drive shaft with constant velocity joint - Assembly overview
Dismantling and assembling drive shaft with constant velocity joint6 pages
- Drive shaft with tripod joint - Assembly overview
- Drive shaft with constant velocity joint VL107 - Assembly overview
- Dismantling and assembling drive shaft with VL107 constant velocity joint
Suspension strut: Assembly overview3 pages
Coil springs, shock absorbers and mounting bracket as one unit3 pages
Removing and installing drive shafts7 pages
- Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
- Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft
- Removing and installing drive shaft with constant velocity joint
- Removing and installing left drive shaft with (push-on) constant velocity slip joint
- Removing and installing right drive shaft with (push-on) constant velocity slip joint
- Removing and installing drive shafts with triple roller joint AAR3300i
Mounting bracket and top transverse link as unit4 pages
Assembly overview: Complete half-shaft with constant velocity joint VL1074 pages
Tripod type joint AAR?3300?i: Disassembling and assembling4 pages
Assembly overview for the VL107 constant velocity slip joint3 pages
Assembly overview: Drive shaft with triple roller joint AAR3300i2 pages
Servicing drive shaft (inner constant velocity joint with 100 mm dia.): repairs6 pages
Rear suspension, drive shaft285 pages
Rear wheel suspension (Front wheel drive): repairs2 pages
General overview, wheel bearing: repairs19 pages
- Analytical assessment of collision vehicles
- Appraisal of accident vehicles
Rear wheel suspension: repairing13 pages
Rear axle: repairs13 pages
Repair the rear axle (vehicles with brake drums)15 pages
Rear wheel suspension (front-wheel drive)5 pages
Rear wheel suspension19 pages
- Rear axle: removing and fitting
Wheel bearing assembly: removing and fitting4 pages
- Rear axle in unladen position
Rear wheel bearing assembly: repairing7 pages
Rear wheel bearing: removing and fitting with V.A.G?1459?B6 pages
Repair the wheel bearing assembly (vehicles with brake drums)6 pages
- Rear axle: Assembly overview
Rear subframe bracket6 pages
- Removing and installing subframe
- To replace the bonded rubber bearing of the strut replace
Vehicle level sender for vehicles with automatic headlight range control3 pages
Repair the rear axle (vehicles with brake disc)14 pages
Subframe, control arm and track rod (front-wheel drive) - Assembly overview13 pages
Assembly overview: Subframe (front-wheel drive)5 pages
Shock absorber and coil spring (front-wheel drive) - Assembly overview9 pages
Assembly overview: Transverse link, track rod (front-wheel drive)6 pages
Steering knuckle and trailing arm (front-wheel drive) - Assembly overview6 pages
Shock absorber and coil spring (all-wheel drive) - Assembly overview5 pages
Rear wheel suspension (four-wheel drive)3 pages
Stabiliser (front-wheel drive) - Assembly overview2 pages
Wheelhouse bearing housing with wheel bearing/wheel hub unit3 pages
- Rear axle in unladen position (four-wheel drive)
Cross beam, connecting rod (all-wheel drive) - Assembly overview14 pages
- Rear axle (all-wheel drive): Assembly overview
Wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast st17 pages
- Changing from wheel housing bearing made from cast steel to wheel bearing housing made from aluminium
Renewing bonded rubber bush for wheel bearing housing5 pages
- Repairing trailing arm
Wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium):4 pages
Subframe, final drive (all-wheel drive) - Assembly overview5 pages
Assembly overview: Transverse link, track rod (all-wheel drive)6 pages
Steering knuckle and trailing arm (all-wheel drive) - Assembly overview6 pages
Assembly overview: Shock absorber, coil spring (all-wheel drive)5 pages
Drive shaft (all-wheel drive) - Assembly overview18 pages
Stabiliser (all-wheel drive) - Assembly overview2 pages
Wheels, tyres. axle align156 pages
- Evaluation of accident vehicles
- Appraisal of accident vehicles
Wheel alignment11 pages
- General aspects
- Test requirements
Preparation for measurement2 pages
- Wheel alignment specifications
- ?Zero? vehicle inclination
- Adjust the camber of the front wheels
- Front axle convergence: adjustment
- Steering wheel rotation left and right limits: verification
- Determining by calculation of the direction of the turn
- Tightening torque for wheel bolts
- Specified torque for fitting wheels
Permitted tyre and rim combinations3 pages
Tyre damage34 pages
Damage to the tread13 pages
- Flattening on the tyres: correction
- Diagonal wear: correction
- Significant side wear: correction
- Centre wear: correction
- Tyre wall wear: correction
- Localised wear: correction
- Uneven wear: correction
- Tears in the tyre rubber: correction
- Tread wear: correction
- Max-min wear: correction
- Rupture due to a cut: correction
- Deformation of the tread: correction
Ripples in sidewall10 pages
Damage to the bead4 pages
Damage to the inside of the cover4 pages
Wheels and tyres8 pages
- Position of the anti-theft wheel bolts with steel rims
- Instructions for changing/fitting wheels
- Instructions for changing and fitting wheels
- Centred housing of the wheel: Protect it from corrosion
Wheels and tyres: fitting5 pages
Removing and installing the wheels8 pages
- Centred housing of wheel: protect from corrosion
Wheel balance10 pages
Conventional tyres: Removing and installing.5 pages
Conventional tyres: removing and fitting6 pages
Tyre with emergency running features (SST-Runflat-System): Removing and installing7 pages
- Tyre pressure monitoring display (RKA Function)
Conventional tyres: Removing and installing6 pages
Imbalance when driving due to the rims and tyres: Cause and remedy14 pages
- Causes of imbalance when driving
- Balancing
- Test drive prior to balancing
- Balancing on a static wheel balancer
- Vibration control system VAS 6230
- Balancing with a Finish Balancer
- Radial run-out and axial run-out of the wheel rim / tyre
- Radial and axial wheel eccentricity: Check
- Radial and axial rim eccentricity: Check
- Match balancing
Self-sealing tyre ?ContiSeal?3 pages
- Tyre pressure monitoring display (RKA and RKA+ Function)
- Tyre pressure control indicator (RKA+ function)
Front camera for driver assistance systemsR2422 pages
Steering404 pages
Steering22 pages
- Steering wheel with airbag, steering column
- Multiple cog adaptor for the steering column: disassembly and assembly
- Steering column, steering mount: assembly overview
- Steering column, steering mount: assembly overview
Steering mount and steering column: disassembly and assembly3 pages
- Removing
- Fitting the steering column: from 05/99
- Fitting the steering column: from 05/99
Airbag, steering wheel and steering column24 pages
Removing and fitting the airbag unit on the driver?s side (Vehicles up to 08.00)3 pages
Removing and fitting the steering wheel (vehicles with airbag until 08.00)3 pages
Removing and fitting the steering wheel (vehicles with airbag until 09.00)3 pages
- Steering column, steering mount: assembly overview
Dismantle and assemble the steering mount and the steering column4 pages
- Instructions for diagnostic using the VAS?505X
- Analytical assessment of collision vehicles
- Evaluation of accident vehicles
Steering wheel with airbag6 pages
- Safety precautions when working on airbags
- Steering wheel with airbag: Assembly overview
Steering wheel: removing and installing3 pages
Steering mount and steering column up to year 2000 models: removing and fitting9 pages
Steering mount and steering column: removing and fitting4 pages
- Assembly overview of steering mount and the steering column
Electrical/electronic components and fitting locations6 pages
- Power assisted steering box components
Steering servo: structure and operation4 pages
General repair instructions6 pages
Power steering: repairs21 pages
Repair the steering box11 pages
Airbag, steering wheel and steering column for year 2001 models onwards13 pages
- Four arm steering wheel: repairing
Steering mount and steering column: removing and fitting4 pages
- Ignition key withdrawal lock: checking
- Assembly overview of steering mount and the steering column
- Steering mount and steering column: removing
- Steering mount and steering column: fitting
Repairing the power steering14 pages
Steering column: assembly overview14 pages
General assembly overview: Hydraulic pump, reservoir, hydraulic lines6 pages
Assembly overview: Steering column, left-hand drive4 pages
Assembly overview: Steering column made from sheet metal14 pages
Power Steering21 pages
- Power steering box TWR brand: removing and fitting
- Power steering box Koyo brand: removing and fitting
- Power steering box TWR brand: dismantling and assembling
- Power steering box Koyo brand: dismantling and assembling
- Play, attachment and dustguard of the link bar heads: Check
- Length of the tie rod: verification and adjustment
- Steering rack centring: determine
- Power steering box: setting
Power steering: repairing13 pages
Assembly overview: steering column, right-hand drive4 pages
Electromechanical steering gear (2nd generation) in models Altea 2004, Altea XL 2007, Altea XL Freetrack 2008, Leon 2006 and Tol4 pages
- Electromechanical steering gear (2nd generation) in models Altea 2004, Altea XL 2007, Altea XL Freetrack 2008, Leon 2006 and Tol
Electromechanical steering gear (2nd generation) in models Altea 2004, Altea XL 2007, Altea XL Freetrack 2008, Leon 2006 and Tol2 pages
Hydraulic pump, tank, hydraulic lines13 pages
- Electro-hydraulic pump unit, Koyo brand removing and fitting
- Electro-hydraulic pump unit, TRW brand : removing and fitting
- Electro-hydraulic pump unit, Koyo brand removing and fitting
- Power steering box: bleeding
- Leaks on the power steering box: Check
- Hydraulic pump pressure delivery: Check
- Oil level: Check
Vane pump, filling reservoir, hydraulic piping13 pages
- Vane pump supply pressure: checking
- Vane pump, hydraulic piping and reservoir up to year 2000 models: assembly overview
Vane pump with hydraulic piping from year 2001 models onwards: assembly overview2 pages
- Power steering fluid: level checking
- Power steering vane pump in vehicles with 4-cylinder engines: assembly overview
- Vane pump: fitting
- Poly-V belt: tightening
- Power steering vane pump in vehicles with VR6 engines: assembly overview
Electromechanical steering gear for the model Leon 2009 Cupra R5 pages
- Electromechanical steering gear for the model Leon 2009 Cupra R: Assembly overview
Electromechanical steering gear for the model Leon 2009 Cupra R: Removing and installing3 pages
Power steering box: repairs4 pages
Repairing power steering box4 pages
- Equivalence table according to applicability
- Understood as:
Electromechanical steering box, LHD vehicle3 pages
Graphical information of equivalent tools and equipment at VW14 pages
Electromechanical steering box, RHD vehicle3 pages
Electromechanical steering gear (3rd generation) in models Altea 2009, Altea XL 2009, Altea XL Freetrack 2009, Leon 2009 and To4 pages
- Electromechanical steering gear (3rd generation) in models Altea 2009, Altea XL 2009, Altea XL Freetrack 2009, Leon 2009 and Tol
Electromechanical steering gear (3rd generation) in models Altea 2009, Altea XL 2009, Altea XL Freetrack 2009, Leon 2009 and Tol2 pages
Engine oil level: Check- Steering system: bleeding - leaks: check4 pages
Equivalency table according to usability25 pages
Graphical information of equivalent tools and equipment at VW24 pages
- Spanner T20165
- Support equipment T20198
- Tappet U-40002
- Securing tool T20169
- Spanner T20180A
- Pulling device T20147
- Centring pin T20150
- Adapter T20172/2
- Engine and gearbox jack T20172/4A
- pressure tool T20072A
- Pliers A-81124
- Pliers T20029
- Open-end 32. SAT 8010/32A
- Torque wrench SAT 8010/18A
- Tappet T20027
- Torque wrench SAT 8010
- Engine and gearbox jack SAT 1040
- Pulling device T20078
- Tool set U-40450A
- Spanner T20160
- Hot-air blower VAG 1416
- Oil extraction unit V.A.G 1782
- Tray T20173
Repairing electromechanical steering box, LHD vehicle8 pages
- Assembly overview: electromechanical steering box, LHD vehicle
- Renewing bonded rubber bushes for power-assisted steering box
- Removing and installing track rod
- Removing and installing track rod ball joint
- Removing and installing rubber boot
- Checking play, tightness and bellows of track rod ball joints
- Allocation of track rod ball joints
- Differences between 2nd and 3rd generation steering gears
Vane pump, hydraulic lines on petrol engines5 pages
Repairing electromechanical steering box, RHD vehicle7 pages
- Replacing a 2nd generation steering gear with a 3rd generation steering gear
Vane pump, reservoir, hydraulic lines on diesel engines5 pages
Electromechanical steering gear (2nd generation) in models Altea 2004, Altea XL 2007, Altea XL Freetrack 2008, Leon 2006 and Tol21 pages
Adjustable power steering pump, reservoir, hydraulic lines on petrol engines (from 05.2010)5 pages
- Adjustable power steering pump, reservoir, hydraulic lines on petrol engines (from 05.2010): Assembly overview
Adjustable power steering pump on petrol engines (from 05.2010): Removing and installing3 pages
Electromechanical steering gear for the model Leon 2009 Cupra R: Repairing7 pages
Adjustable power steering pump, reservoir, hydraulic lines on Common Rail diesel engines (from 11.2011)5 pages
- Adjustable power steering pump, reservoir, hydraulic lines on Common Rail diesel engines (from 11.2011): Assembly overview
Adjustable power steering pump on Common Rail diesel engines (from 11.2011): Removing and installing3 pages
Electromechanical steering gear (3rd generation) in models Altea 2009, Altea XL 2009, Altea XL Freetrack 2009, Leon 2009 and Tol8 pages
- Vane pump supply pressure: checking
Suction hose: installation position3 pages
Brake systems313 pages
Technical data25 pages
Technical data, brakes13 pages
Front brakes6 pages
Rear brakes6 pages
Brake test9 pages
- General
- Test for vehicles with front-wheel drive.
Test for vehicles with four-wheel drive via a viscous clutch.3 pages
Test for vehicles with four-wheel drive via a Haldex clutch.3 pages
ABS, ADR, TCS, EDL, ESP99 pages
- Connect vehicle diagnosis, testing and information system VAS 5051 and select functions
Antiblock system (ABS) ITT Mark 20 GI/IE and ITT Mark 30 IE4 pages
Anti-locking brake system (ABS) ITT Mark 20 IE4 pages
ABS and ABS/EDL Mark 04 GI11 pages
- General information on this ABS, ABS/EDL
- Notes for repair work on ABS, ABS/EDL
- Electrical/electronic components and fitting locations
Fault indication via the Dual curcuit brake/handbrake warning lamp K7 and ABS warning lamp K472 pages
- Assembly overview - hydraulic unit, brake servo/brake master cylinder
Removing and installing control unit and hydraulic unit4 pages
- Electric/electronic components and locations for ABS ITT Mark 20 GI/IE
Electrical/electronic components and fitting locations3 pages
Faults displayed by warning lamps K14 , K47 and K1182 pages
- Fault warnings through warning lamps K47 and K118 of ABS ITT Mark 20 GI/IE
- Assembly overview - hydraulic unit, brake servo/ brake master cylinder (left-hand drive)
ABS Mark 20 IE up to model year 200012 pages
- Notes for repair work on ABS
- Electrical/electronic components and fitting locations
- Fault indication via the ABS warning lamp K47 and brake system warning lamp K118
Assembly overview - hydraulic unit/control unit2 pages
Removing and installing control unit and hydraulic unit4 pages
Assembly overview - Hydraulic unit, right-hand drive4 pages
ABS Mark 20 IE as of model year 2001 and Mark 25 as of model year 200313 pages
General information on this ABS2 pages
- Notes for repair work on ABS
- Electrical/electronic components and fitting locations
- Fault indication via the ABS warning lamp K47 , brake system warning lamp K118 and stabilising program warning lamp K155
Assembly overview - hydraulic unit, brake servo/brake master cylinder2 pages
Removing and installing control unit and hydraulic unit5 pages
- Electric/electronic components and locations for ABS ITT?Mark 30 IE
- Fault warnings through warning lamps K47 and K118 of ABS ITT Mark 30 IE
Removing and installing parts of ABS system on front and rear axle12 pages
Removing and installing parts of ABS system on front axle, VW ll brake caliper4 pages
Removing and installing parts of ABS system on front axle, Lucas brake caliper4 pages
Removing and installing parts of ABS system on rear axle (vehicles with drum brakes)3 pages
Removing and installing parts of ESP system9 pages
Removing and installing yaw rate sender G202 , lateral acceleration sender G200 and ESP sensor unit G4193 pages
Assembly diagram: Brake servo / Master brake cylinder, hydraulic unit4 pages
Components of the ABS system on front and rear axles: removing and installing17 pages
- I - ABS system components on the front axle: removing and installing
- Revolution sensor for front axle: removing and installing
- Removing and fitting revolution sensor cables at the front
- Revolution sensor rotor, front axle: checking
- II - ABS system components on the rear axle: removal and fitting (vehicles with drum brakes up to 08.00)
- Revolution sensor, rear axle: removal and fitting (vehicles with drum brakes up to 08.00)
- Rear revolution sensor cables: removal and fitting (vehicles with drum brakes up to 08.00)
- Check the revolution sensor rotor on the rear axle (vehicles with drum brakes up to 08:00)
- III - ABS system components on the rear axle: removal and fitting (vehicles with drum brakes from 09.00)
- Revolution sensor, rear axle: removal and fitting (vehicles with drum brakes up to 09.00)
- Rear revolution sensor cables: removal and fitting (vehicles with drum brakes up to 09.00)
- Check the revolution sensor rotor on the rear axle (vehicles with drum brakes up to 09.00)
- IV - ABS system components on the rear axle: removal and fitting (vehicles with disc brakes)
- Revolution sensor, rear axle: fitting and removal (vehicles with disc brakes)
- Rear revolution sensor cables: fitting and removal (vehicles with disc brakes)
- Check the revolution sensor rotor on the rear axle (vehicles with disc brakes)
Brake, brake mechanics101 pages
Repairing front brakes8 pages
- Repairing front brakes, Teves/Ate up to model year 2000
- Repairing front brakes, FN3 brake caliper, model year 2001
Removing and installing brake pads0 pages
- Removing
- Installing
- Repairing front brakes, FN3 brake caliper, as of model year 2002
Removing and installing brake pads0 pages
- Removing
- Installing
- Repairing front brakes, FNR brake caliper as of model year 2001
Removing and installing brake pads0 pages
- Removing
- Installing
Front wheel brake: repairing7 pages
- I - Front wheel brake: repairing (brake caliper VW I)
- Brake pads/caliper: removing and installing (VW I caliper)
- II - Front wheel brake: repairing (brake caliper VW I)
- Brake pads/caliper: removing and installing (VW II caliper)
- III - Front wheel brake: repairing (Lucas and Girling brake calipers)
- Brake pads: fitting and removing (Lucas and Girling brake calipers)
Servicing front brakes14 pages
Repairing rear brakes7 pages
- Repairing 15" rear brakes
- Repairing 16" rear brakes
Removing and installing brake pads0 pages
- Removing
- Installing
- Adjusting handbrake
Rear brake: repairing (vehicles with drum brakes)7 pages
- I - Rear brake, removal and fitting (vehicles with drum brakes up to 08.00)
- Revolution sensor rotor: removal and fitting (vehicles with drum brakes up to 08.00)
- II - Rear brake, removal and installing (vehicles with drum brakes from 09.00)
- Rear brake: repairing
- Brake shoes: removal and installation
- Hand brake: adjustment
Servicing rear wheel brakes (drum brakes)9 pages
Rear brake: repairing (vehicles with disc brakes)3 pages
Removing and installing handbrake cable (drum brakes)4 pages
Assembly overview - handbrake lever10 pages
- Handbrake lever - Assembly overview
Assembly overview - brake pedal up to model year 20004 pages
- Hand brake cable: removal and fitting (vehicles with drum brakes)
Assembly overview - brake pedal as of model year 20016 pages
- Hand brake cable: removal and fitting (vehicles with disc brakes)
Brake pedal - Assembly overview7 pages
Removing, installing and adjusting brake light switch7 pages
- Assembly diagram: Hand brake lever
Brake/servo pedal: removing and installing4 pages
Brakes, hydraulics, regulator, servo88 pages
Servicing VW II front brake caliper4 pages
Repairing front brake calipers9 pages
Front brake caliper: repairing (brake caliper VW I and VW II)2 pages
Servicing Lucas front brake caliper4 pages
Repairing rear brake caliper5 pages
Front brake caliper: repairing (Lucas and Girling brake calipers)2 pages
Servicing Cupra -R- front brake caliper4 pages
Assembly overview: brake pressure regulator, delay dependent2 pages
- Assembly overview: Brake pressure regulator
- Fluid tightness under pressure: checking
Checking and adjusting brake pressure regulator2 pages
Bleeding brake system7 pages
Bleeding brake system using brake filling and bleeding unit VAS 5234 or V.A.G?18694 pages
Assembly diagram: Braking force regulator (vehicles without ABS)2 pages
Bleeding braking system on vehicles with and without ABS3 pages
Assembly overview: Brake servo/brake master cylinder up to model year 20002 pages
Bleed brake system (vehicles with and without ABS)3 pages
- Assembly overview: Brake servo/brake master cylinder as of model year 2001
Assembly diagram: Brake servo / Master brake cylinder:4 pages
Assembly overview: brake master cylinder/brake servo4 pages
Removing and installing vacuum pump for brake servo (Diesel vehicles)3 pages
Removing and installing brake master cylinder4 pages
- Understood as:
Assembly overview: Brake servo /brake master cylinder for vehicles with ABS/EDL/TCS/ESP as of model year 20016 pages
Removing and installing brake pressure sender 1 G201 and brake pressure sender 2 G2143 pages
Removing and installing brake servo4 pages
- Definitions
Removing and installing brake master cylinder, right-hand drive vehicles3 pages
Brake system409 pages
Technical data13 pages
ABS, ADR, TCS, EDL, ESP123 pages
Anti-lock brake system ABS) - General Instructions3 pages
- Indications regarding repairs to the anti-lock brake system (ABS)
- Hydraulic unit, servo brake/main brake cylinder - assembly overview, left-hand drive vehicles
- Central diagnosis systemVAS 505X : connect and select functions
- Hydraulic unit - assembly overview, right-hand drive vehicles
- Central diagnosis system VAS 505X : connect and select functions
Viewing the faults indicated by the control warning lamps3 pages
Electrical / electronic components and their fitting locations4 pages
Control unit and hydraulic unit4 pages
ABS/ESP system components: removing and fitting15 pages
Brake light switchF and Brake pedal position senderG100: installation and removal3 pages
ESP sensor unitG419 :removing and installing4 pages
- Vacuum transmitter of the brake servo G483 : installation and removal
- Faults indicated by the control warning lamps
ABS system components in front and rear axles: removal and installation8 pages
ABS system components in front axle: removing and installing Lucas brake clips4 pages
BS system components in rear axle: removal and installation3 pages
Hydraulic unit, brake servo/ brake master cylinder - exploded view16 pages
ABS Bosch 5.7 (ABS/EDS/ASR/ESP)7 pages
Hydraulic unit, brake servo/brake master cylinder: Assembly overview25 pages
ABS Mark 70 -ABS/ASR- (until week 22.08)6 pages
- Connection of the tandem master cylinder brake lines to the hydraulic unit
- ABS control unit J104 and ABS control unit and ABS hydraulic unitN55 : removal.
- Unscrew the ABS control unitJ104 from the ABS hydraulic unit N55
- Fitting a new control unitJ104
- ABS control unitJ104 and ABS hydraulic unitN55 : installation
ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08)6 pages
- Connection of the tandem master cylinder brake lines to the hydraulic unit
- ABS control unit J104 and ABS control unit and ABS hydraulic unitN55 : removal.
- Unscrew the ABS control unitJ104 from the ABS hydraulic unit N55
- Fitting a new control unitJ104
- ABS control unitJ104 and ABS hydraulic unitN55 : installation
ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08)6 pages
- Connection of the tandem master cylinder brake lines to the hydraulic unit
- ABS control unit J104 and ABS control unit and ABS hydraulic unitN55 : removal.
- Unscrew the ABS control unitJ104 from the ABS hydraulic unit N55
- Fitting a new control unitJ104
- ABS control unitJ104 and ABS hydraulic unitN55 : installation
ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR- (from week 22.08)6 pages
- Connection of the tandem master cylinder brake lines to the hydraulic unit
- ABS control unit J104 and ABS control unit and ABS hydraulic unitN55 : removal.
- Unscrew the ABS control unitJ104 from the ABS hydraulic unit N55
- Fitting a new control unitJ104
- ABS control unitJ104 and ABS hydraulic unitN55 : installation
ABS components on the front axle: Assembly overview4 pages
Removing and installing parts of ABS system on front and rear axles13 pages
ABS system components on the front axle: removing and fitting5 pages
Parts of the ABS system on the rear axle: remove and install (vehicles with drum brakes)3 pages
Parts of the ABS system on the rear axle: remove and install (vehicles with disc brakes)4 pages
ABS system components in rear axle:5 pages
ABS components on the rear axle (front-wheel drive): Assembly overview2 pages
ABS components on the rear axle (4-wheel drive): Assembly overview2 pages
Brake, brake mechanics129 pages
Front wheel brake: repairs29 pages
Front brake: repair5 pages
Rear wheel brake: repairs29 pages
Rear brake: repairs - drum brake7 pages
Rear brake: repair9 pages
- Hand brake cable: removal and installation
Handbrake7 pages
Brake pedal9 pages
- Hand brake lever: general assembly diagram
Brake pedal: repairs13 pages
- Brake pedal - assembly overview
Removing, installing and adjusting the brake light switch F and brake pedal switch F473 pages
Pedal gear, brake pedal: general assembly diagram3 pages
Brakes, hydraulics, regulator, servo144 pages
Repairing: Lucas front brake clips4 pages
Front brake calliper: repairs7 pages
Front brake calliper: repair11 pages
- FS 3 brake calliper: Assembly overview
- Brake caliper FN 3: assembly overview
- FNR G brake calliper (Model Leon 2006 Cupra):
- FNR G brake calliper (Model Leon 2009 Cupra and Cupra R): Assembly overview
Piston for FNR-G brake calliper (Leon 2009 Cupra and Cupra R model): removal and installation3 pages
Brake servo / Master brake cylinder: general assembly diagram4 pages
Servo brake vacuum pump (diesel vehicles): removal and installation3 pages
Rear brake calliper: repairs6 pages
- Lucas rear brake calliper - general assembly overview
Removing and installing piston for rear brake calliper4 pages
- Brake servo: removal and installation
Rear brake caliper: repairs11 pages
- Rear brake calliper: assembly overview
Piston for rear brake caliper: removing and fitting4 pages
- Rear brake calliper ZOH 38 BIR III Bosch: assembly overview
Piston for back brake calliper ZOH 38 BIR III Bosch: installation and removal4 pages
Brake pressure regulator7 pages
- Braking force regulator - general overview
Brake pressure regulator: verification and adjustment5 pages
- Master brake cylinder: removal and installation
Brake servo and brake master cylinder19 pages
- Brake servo/brake master cylinder, LL: Assembly overview
- Brake servo/brake master cylinder, RL: Assembly overview
Vacuum pump for brake servo: removal and installation5 pages
- Vacuum pump for brake servo for 4 cylinder diesel motors (2 valve) : removal and installation
- Vacuum pump for brake servo for 4 cylinder diesel motors (4 valve) : removal and installation
- Vacuum pump for brake servo for 4 cylinder petrol motor, BYT-BZB: removal and installation
- Vacuum pump of brake servo for common rail motors: removal and installation
- Checking non-return valve
- Assembly diagram: Braking force regulator
Braking force regulator: check and adjust2 pages
Brake servo / Master brake cylinder: repairs14 pages
- Brake servo/brake master cylinder - general overview
Vacuum pump for brake booster (diesel vehicles) - Assembly overview5 pages
- Checking the retention valve
Brake pipes and brake hoses:10 pages
Removing and installing brake lines and brake hoses9 pages
- Brake pipes on the master brake cylinder
- Brake pipes to the hydraulic unit
- Brake pipes/hoses on the front wheels
- Brake hose connection with anti-twist protection
- Brake pipe connection on the brake calliper
- Brake pipe connections on the underbody of the vehicle
- Brake pipes / rear axle hoses
- Brake pipe coupling
Brake system: air bleeding, vehicles with and without ABS3 pages
Equivalency table according to usability9 pages
Graphic information on tool and equipment equivalents VW / SEAT8 pages
- Glossary
Equivalence table according to applicability13 pages
Graphical information of equivalent tools and equipment at VW12 pages
- Filling and bleeding apparatus for brakes -VAS 5234-
- Filling and bleeding apparatus for brakes -V.A.G 1869-
- Torque wrench -V.A.G 1331-
- Torque wrench -V.A.G 1332-
- Torque wrench -V.A.G 1410-
- Pliers -VAG 1921-
- Piston retraction device -T10145-
- Tool to insert and remove the piston -3272-
- Removal tool -T10006 A
- Clamps for hoses up to ? 25 mm -3094-
- Wedge -3409-
Running gear, axles, steering - front and four-wheel drive124 pages
Technical data2 pages
Front suspension, drive shafts31 pages
- Appraisal of accident vehicles
- Repairing front suspension
I - Assembly overview - subframe, anti-roll bar, lower wishbone up to model year 20003 pages
I - Assembly overview - subframe, anti-roll bar and wishbone from model year 20019 pages
- Removing and installing swivel joint
- Removing and installing wishbone
- Removing and installing subframe
- Removing and installing front anti-roll bar to model year 2000
- Removing and installing front anti-roll bar from model year 2001
- Repairing nut in longitudinal member/body
- Modified subframe connection to body
- Aligning subframe to body
II - Removing and installing wheel bearing, suspension strut, drive shaft5 pages
Removing and installing drive shafts6 pages
- Removing and installing drive shafts on vehicles with manual gearbox 006
- Removing and installing drive shafts on vehicles with automatic gearbox 099
- Removing and installing drive shafts on vehicles with automatic gearbox 099 and four-wheel drive
- Removing and installing drive shafts on vehicles with manual gearbox 02N
- Removing and installing drive shafts on vehicles with automatic gearbox 09B
Rear suspension, drive shaft16 pages
- Appraisal of accident vehicles
Repairing rear suspension8 pages
Wheels, tyres. axle align36 pages
- Appraisal of accident vehicles
Wheel alignment11 pages
- Protecting wheel centring seat against corrosion
Rough running due to wheels/tyres - causes and rectification12 pages
- Causes of rough running
- Balancing wheels
- Conducting a road test before balancing wheels
- Balancing wheels on stationary wheel balancing machine
- Vibration control system VAS 6230
- Finish balancer
- Radial and lateral runout of wheels and tyres
- Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435
- Checking radial and lateral runout on wheel
- Matching
- Flat spots caused by storage or handling
Steering39 pages
- Appraisal of accident vehicles
Column tube with steering column to model year 20004 pages
Airbag, steering wheel, steering column from model year 20019 pages
- Driver side airbag unit
- Removing and installing driver's airbag unit
- Repairing 4 spoke steering wheel
- Removing and installing column tube with steering column
- Checking ignition key lock
- Assembly overview - steering column, column tube
- Dismantling column tube and steering column
- Assembling column tube and steering column
Repairing power assisted steering7 pages
- Removing and installing power assisted steering box to model year 2000
- Removing and installing power assisted steering box from model year 2001
- Assembly overview - power assisted steering box
- Assembly overview - power assisted steering box (RHD)
- Removing and installing track rod when steering box is installed
- Checking and adjusting track rod length
Vane pump, reservoir, hydraulic pipes11 pages
- Checking vane pump delivery pressure
- Assembly overview - vane pump, hydraulic lines and reservoir to model year 2000
- Assembly overview - vane pump with hydraulic lines from model year 2001
- Dismantling and assembling reservoir
- Checking hydraulic fluid level of power-assisted steering
- Assembly overview - power assisted steering vane pump, vehicles fitted with 4-cyl. engines
- Installing vane pump
- Tensioning V-belt
- Assembly overview - power assisted steering vane pump, vehicles fitted with VR6 engine
- Removing and installing vane pump for vehicles with VR6 engines
Wheel rims and tyres › Wheels, tyres. axle align138 pages
- General information about wheel rims and tyres
Legal and technical conditions for modifying wheel rim and tyre combinations4 pages
Facts about tyres15 pages
- Markings on tyre sidewall
- Explanation of tyre markings
- Percent of speed-dependent loading capacity
- Speed symbol on tyres
- Tyres with speed code letter V
- V-tyres with extra load (XL) specification/reinforced
- Ripples in sidewall
- Tyre storage
- Ageing of tyres
- Tyres with different tread
- Tyres with special bead for starting
- Winter tyres
- All-season tyres
- Snow chains
Wear/performance characteristics of tyres (passenger cars)16 pages
Imbalance when driving due to the wheels / tyres11 pages
- Causes of rough running
- Balancing wheels
- Test drive prior to balancing
- Balancing on a static wheel balancer
- Vibration control systemVAS 6230
- Balancing with a Finish Balancer
- Wheel (rim and tyre) radial and axial runout
- Radial and axial rim eccentricity:
- Match balancing
- Flat spots caused by storage or handling
Tyre damage13 pages
- General notes
- Structure of a radial tyre
- Damage from impacts
- Cuts
- Damage from foreign bodies
- Damage due to age
- Scraping:
- Inflation pressure loss on the tyre
- Check the tyre inflation pressure
- Damage to tyres as a result of underinflation
- Increase in temperature of an underinflated tyre
- Tyre damage resulting from mounting errors
Run flat tyres (tyres with emergency running characteristics)6 pages
Self-sealing tyre ?ContiSeal?3 pages
Alternative systems for spare tyre4 pages
- Technical data on wheels for SEAT vehicle models
- Technical wheel data for Alhambra 1996
- Technical wheel data for Alhambra 2001
- Technical wheel data for Alhambra 2011
- Technical data on wheels for Arosa 1997
- Technical data of the wheels for Ibiza 1999, Cordoba 1999, Cordoba Vario 1999
- Technical data on wheels for Ibiza 2002
- Technical data on wheels for Ibiza 2008, Ibiza ST 2010
- Technical data on wheels for Cordoba 2003
- Technical data on wheels for Altea 2004
- Technical data on wheels for Altea 2009
- Technical data on wheels for Altea XL 2007
- Technical data on wheels for Altea XL 2009
- Technical data on wheels for Altea XL Freetrack 2008
- Technical data on wheels for Altea XL Freetrack 2009
- Technical data on wheels for Leon 2006
- Technical data on wheels for Leon 2009
- Technical data on wheels for Toledo 2005
- Technical data on wheels for Toledo 2009
- Technical data on wheels for Exeo 2009, Exeo ST 2009
- Technical data on wheels for Mii 2012
- Emergency tyres and rim for SEAT vehicles
Recommended conventional tyres or summer tyres for SEAT vehicle17 pages
- Conventional tyres or summer tyres for Alhambra 2011
- Conventional tyres or summer tyres for Ibiza 2002
- Conventional tyres or summer tyres for Ibiza 2008, Ibiza 2010
- Conventional tyres or summer tyres for Cordoba 2003
- Conventional tyres or summer tyres for Altea 2004
- Conventional tyres or summer tyres for Altea 2009
- Conventional tyres or summer tyres for Altea XL 2007
- Conventional tyres or summer tyres for Altea XL 2009
- Conventional tyres or summer tyres for Altea XL Freetrack 2008
- Conventional tyres or summer tyres for Altea XL Freetrack 2009
- Conventional tyres or summer tyres for Leon 2006
- Conventional tyres or summer tyres for Leon 2009
- Conventional tyres or summer tyres for Toledo 2005
- Conventional tyres or summer tyres for Toledo 2009
- Conventional tyres or summer tyres for Exeo 2009, Exeo ST 2009
- Recommended conventional tyres or summer tyres for the Mii 2012
- Recommended all-season tyre) for SEAT vehicles
Brake system:312 pages
Technical data30 pages
Brake specifications7 pages
Technical data › Brake specifications4 pages
Brake testing5 pages
- Brake fluid › General notes
ABS, ADR, TCS, EDL, ESP43 pages
- General indications regarding the antilock braking system
- Notes for repair work on anti-lock brake system
- Central diagnosis systemVAS 505X : connect and select functions
Control unit and hydraulic unit3 pages
- Connecting VAS?5051 and selecting functions
- Faults indicated by the control warning lamps
Sensors7 pages
- Assembly overview - speed sensor on front axle
- Removing and installing speed sensor on front axle
- Assembly overview - speed sensor on rear axle
- Removing and installing speed sensor on rear axle
- Removing and installing steering angle sender
- Removing and installing yaw rate sender and lateral acceleration sender
- Electrical/electronic components and locations › ABS TRW (ABS/EDL/TCS/ESP)
ABS/ESP system components: removing and fitting3 pages
Assembly overview - hydraulic unit5 pages
Hydraulic unit, brake servo / brake master cylinder: Assembly overview2 pages
Removing and installing parts of ABS system on front and rear axles2 pages
- ABS system components on the front axle: removing and fitting › Removing and installing speed sensor on front axle
Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive)2 pages
Removing and installing parts of ESP system3 pages
ABS components on the front axle: Assembly overview › Front axle speed sensor: Removing and installing.4 pages
ABS system components on the front axle: removing and fitting2 pages
Removing and installing ABS system components on rear axle2 pages
Brake, brake mechanics129 pages
Front wheel brake: repairs33 pages
- FS III front wheel brake: Assembly overview
- FS-III brake heat shield: Removing and installing.
- FN 3 (15??) front wheel brake: Assembly overview
- Brake heat shield FN3 (15??): Removing and installing.
- Front wheel brake AP Racing (16??)): Assembly overview
- Brake heat shield AP Racing (16??): Removing and installing.
Repairing front brakes9 pages
- FN 3 front wheel brake - general assembly overview
- Assembly overview- front brakes C60
brake calliper, removing and installing0 pages
- Removal:
- Installation
Installing and removing the brake calliper0 pages
- Removal:
- Installation
Rear wheel drum brake: repairing7 pages
Repairing rear brakes8 pages
Rear wheel disc brake: repairing12 pages
Rear brakes C38 and C38HR6 pages
Overview of electromechanical parking brake components3 pages
Rear brakes CII41HR6 pages
Brake pedal4 pages
- Assembly overview - brake pedal
- Separating brake pedal from brake servo
- Connecting brake pedal to brake servo
- Removing and installing brake pedal
Assembly overview - brake pedal6 pages
Brake pedal: Assembly overview, left-hand drive5 pages
- Hand brake cables: Removing and installing
Brake pedal and mounting bracket9 pages
- Brake pedal and mounting bracket (vehicles with manual gearbox) Assembly overview
- Brake pedal and mounting bracket (vehicles with automatic gearbox): Assembly overview
- Brake pedal and servo brake: separating and fitting
- Brake pedal (vehicles with manual gearbox): Removing and installing
- Brake pedal (vehicles with automatic gearbox): Removing and installing
- Removing and installing mounting for brake servo push rod
- Bearing bracket for the brake pedal (vehicles with manual gearbox): Removing and installing
- Bearing bracket for the brake pedal (vehicles with automatic gearbox): Removing and installing
Brakes, hydraulics, regulator, servo110 pages
High and low pressure testing0 pages
- High pressure test
- Low-pressure test
Front brake calipers3 pages
Repairing front brake calipers9 pages
Brake calliper FN33 pages
Front brake calliper: repairs1 page
- FS III brake calliper - general assembly overview
- FN 3 brake calliper - general assembly overview
Removing and installing pistons for front brake calliper1 page
- Removal:
- Installation
Repairing rear brake calipers6 pages
Brake calliper FNRG603 pages
Vacuum system7 pages
Rear brake calliper: repairs1 page
- Servicing brake callipers
- Removing and installing piston for rear brake calliper
Brake system: bleeding of air5 pages
Bleeding brake system with the brake filling and bleeding equipmentVAS 52344 pages
- Changing brake fluid
Brake servo / Master brake cylinder: repairs9 pages
- Brake servo/brake master cylinder - general overview
- Checking the retention valve
- Brake servo pressure sensorG294 : Removing and installing.
Removing and installing brake master cylinder1 page
- Removal:
- Installation
Removing and installing brake servo1 page
- Removal:
- Installation
Assembly overview: Brake servo / Master brake cylinder12 pages
- Brake servo / Master brake cylinder: Assembly overview (left-hand drive)
- Vacuum pump for brake servo (vehicles with diesel engine)
- Vacuum pump for brake servo (vehicles with petrol engine)
Checking the brake servo vacuum system5 pages
- Checking non-return valve
- Removing and installing vacuum senderG608
- Removing and installing brake light switchF
Hydraulic system7 pages
Brake servo / Master brake cylinder: Assembly overview5 pages
Brake lines5 pages
Brake pipes and brake hoses: › Brake pipes and brake hoses: Removing and installing8 pages
Brake pipe repairs0 pages
- Flaring tool: Assembly overview
- Work instructions
- Equivalency table according to usability
Graphic information on tool and equipment equivalents VW / SEAT6 pages