Running gear
- Brake systems
- Technical data
- ABS, ADR, TCS, EDL, ESP
- General notes on anti-lock brake system
- Notes for repair work on anti-lock brake system
- Connecting VAS 5051 and selecting functions
- Electrical/electronic components and locations
- Fault display via warning lamps
- Assembly overview - hydraulic unit, brake servo/brake master cylinder
- Removing and installing parts of ABS system on front and rear axle
- Removing and installing parts of ESP system
- Brake, brake mechanics
- Repairing front brakes
- Repairing front brakes, FS III brake caliper
- Removing and installing brake pads/linings
- Removing and installing brake caliper
- Repairing front brakes, FN 3 brake caliper
- Removing and installing brake pads/linings
- Removing
- Installing
- Removing and installing brake caliper
- Removing
- Installing
- Repairing front brake, FNR-G brake caliper
- Removing and installing brake pads/linings
- Removing
- Installing
- Removing and installing brake caliper
- Removing
- Installing
- Repairing rear brakes
- Repairing rear brake CI 38
- Removing and installing brake pads/linings
- Removing and installing brake caliper
- Repairing rear brake CII 38
- Removing and installing brake pads/linings
- Removing
- Installing
- Removing and installing brake caliper
- Removing
- Installing
- Repairing rear brake CII 41
- Removing and installing brake pads/linings
- Removing
- Installing
- Removing and installing brake caliper
- Removing
- Installing
- Adjusting handbrake
- Assembly overview - handbrake lever
- Assembly overview - brake pedal
- Repairing front brakes
- Brakes, hydraulics, regulator, servo
- Repairing front brake caliper
- Repairing rear brake caliper
- Pressurised leak test
- Bleeding brake system
- Brake servo and brake master cylinder
- Assembly overview: brake servo/brake master cylinder (left-hand drive vehicle)
- Assembly overview: brake servo/brake master cylinder (right-hand drive vehicle)
- Overview - vacuum pump for brake servo (diesel vehicles)
- Checking non-return valve
- Removing and installing brake servo pressure sensorG294
- Vacuum pump for brakesV192
- Removing and installing brake light switchF as of week 45/05
- Removing and installing brake master cylinder
- Removing and installing brake servo
- Brake lines
- Running gear, axles, steering
- Technical data
- Front suspension, drive shafts
- Appraisal of accident vehicles
- Repairing front suspension
- Subframe, anti-roll bar, suspension links
- Assembly overview: subframe, anti-roll bar, suspension links
- Assembly overview: front left vehicle level senderG78
- Removing and installing front left vehicle level senderG78
- Repairing thread in longitudinal member
- Fixing position of subframe and brackets
- Lowering subframe
- Removing and installing subframe without steering box
- Removing and installing subframe with steering box
- Repairing subframe (front-wheel drive)
- Repairing subframe (four-wheel drive)
- 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)
- Removing and installing suspension link with mounting bracket (right side for vehicles with 6-cylinder engines)
- Renewing bonded rubber bush for suspension link
- Renewing mounting bracket with suspension link bush
- Removing and installing anti-roll bar
- Assembly overview: wheel bearing
- Assembly overview: suspension strut
- Removing and installing drive shafts
- Loosening and tightening drive shaft hexagon bolt
- 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 AAR2600i
- Removing and installing drive shafts with triple roller joint AAR3300i
- Removing and installing intermediate shaft
- Repairing drive shaft - overview of drive shafts
- Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
- Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
- Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
- Assembly overview: drive shaft with triple roller joint AAR2600i
- Assembly overview: drive shaft with triple roller joint AAR3300i
- Rear suspension, drive shaft
- Appraisal of accident vehicles
- Repairing rear suspension (front-wheel drive)
- Assembly overview: subframe, transverse link, track rod (front-wheel drive)
- Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
- Assembly overview: shock absorber, coil spring (front-wheel drive)
- Assembly overview: anti-roll bar (front-wheel drive)
- Assembly overview: attachment parts for subframe Golf BlueMotion, Golf Plus BlueMotion (front-wheel drive)
- Repairing rear suspension (four-wheel drive)
- Assembly overview: subframe made from aluminium, final drive (four-wheel drive)
- Assembly overview: subframe made from steel, final drive (four-wheel drive)
- Assembly overview: control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from ca
- Assembly overview: control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from alumin
- Assembly overview: wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housin
- Changing from wheel housing bearing made from cast steel to wheel bearing housing made from aluminium
- Removing and installing wheel bearing housing
- Renewing bonded rubber bush for wheel bearing housing
- Removing and installing wheel bearing/wheel hub unit
- Removing and installing trailing arm with mounting bracket
- Repairing trailing arm
- Assembly overview: wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing ma
- Assembly overview: shock absorber, coil spring (four-wheel drive, subframe made from aluminium and wheel bearing housing made fr
- Assembly overview: shock absorber, coil spring (four-wheel drive, subframe made from steel and wheel bearing housing made from a
- Assembly overview: anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)
- Assembly overview: anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)
- Assembly overview: drive shaft
- Loosening and tightening drive shaft hexagon bolt
- 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
- Dismantling and assembling drive shaft
- Checking outer constant velocity joint
- Checking inner constant velocity joint
- Wheels, tyres. axle align
- Appraisal of accident vehicles
- Torque settings for wheel bolts
- Fitting wheel and tyre
- Removing and fitting tyres (wheels with tyre pressure monitoring)
- Removing and fitting tyres with run-flat properties to wheel rims
- Tyre monitor display
- Tyre pressure monitor (TPM)
- Wheel alignment
- Wheel alignment|General
- Test prerequisites
- Test preparations
- Wheel alignment specifications, Golf
- Overview - wheel alignment procedure
- Correcting front axle camber
- Adjusting camber on rear axle
- Adjusting toe at rear axle
- Adjusting front axle toe
- Basic setting for steering angle senderG85
- Vehicle data sticker
- Wheels, tyres
- Instructions for changing or fitting wheels
- Protecting wheel centring seat against corrosion
- Rough running due to wheels/tyres - causes and rectification
- Causes of rough running
- Balancing wheels
- Conducting a road test before balancing wheels
- Balancing wheels on stationary wheel balancing machine
- Vibration control systemVAS 6230 A
- Finish balancer
- Radial and lateral runout of wheels and tyres
- Checking radial and lateral runout on wheels and tyres with tyre gaugeV.A.G 1435
- Checking radial and lateral runout on wheel rim
- Matching
- Flat spots caused by storage or handling
- Steering
- Appraisal of accident vehicles
- General repair instructions
- Steering wheel
- Steering column, Golf
- Assembly overview: steering column
- Removing and installing steering column
- Basic setting for steering angle sensor G85 steering angle sender must be checked after the following repair work:
- Handling and transporting steering column
- Checking steering column for damage
- Removing and installing mounting bracket
- Removing and installing strut
- Electromechanical steering box up to model year 2008
- Assembly overview - electromechanical steering box, left-hand drive vehicle (1st and 2nd generations) up to model year 2008
- Assembly overview - electromechanical steering box, right-hand drive vehicle (2nd generation) up to model year 2008
- Removing and installing steering box, left-hand drive vehicle (1st and 2nd generations) up to model year 2008
- Removing and installing steering box, right-hand drive vehicle (2nd generation) up to model year 2008
- Electromechanical steering box from model year 2009
- Assembly overview - electromechanical steering box, right-hand drive vehicle (3rd generation) from model year 2009
- Removing and installing steering box, left-hand drive vehicle (3rd generation) from model year 2009
- Removing and installing steering box, right-hand drive vehicle (3rd generation) from model year 2009
- Distinguishing between steering boxes (1st and 2nd generations), Golf
- Differentiating between 2nd and 3rd generation steering boxes
- Exchanging 1st generation steering box for 2nd generation steering box, Golf
- Repairing electromechanical steering box (1st generation), Golf
- Repairing electromechanical steering box (2nd and 3rd generation)
- Wheels and Tyres Guide - Archive
- Wheels, tyres. axle align
- Recommended all-season tyres
- Recommended winter tyres
- Recommended summer tyres
- Golf model year 2004 to model year 2009
- Golf BlueMotion model year 2008 to model year 2009
- Golf GTI model year 2005 to model year 2009
- Pirelli Golf model year 2008 to model year 2009
- Golf R32 model year 2006 to model year 2009
- Wheels, tyres. axle align
- Body
- General body repairs, exterior
- Body front
- Bonnet, flaps, cab, central locking
- Bonnet, flaps, cab, central locking|Bonnet
- Bonnet, flaps, cab, central locking|Tools
- Assembly overview - bonnet
- Removing and installing bonnet
- Removing gas strut
- Releasing gas from gas strut
- Removing and installing flap hinge
- Removing and installing insulation
- Assembly overview - bonnet latch and release components
- Removing and installing bonnet lock
- Separating Bowden cable
- Adjusting bonnet
- Removing and installing release lever
- Rear lid
- Rear lid|Tools
- Assembly overview - rear lid
- Removing and installing rear lid
- Removing gas strut
- Releasing gas from gas strut
- Removing and installing rear lid hinges
- Removing and installing striker pin
- Adjusting lid
- Assembly overview - rear lid latch and release components
- Removing and installing release element
- Removing and installing lid lock
- Rear lid seal
- Removing and installing rear lid seal
- Tank flap unit
- Bonnet, flaps, cab, central locking|Bonnet
- Front door, central locking
- Front door
- Front door|Tools
- Materials
- Assembly overview - door assembly
- Assembly overview - door hinges
- Removing and installing door
- Adjusting door
- Removing and installing door outer panel
- Installing new outer panel for door
- Removing and installing retaining rail on door outer panel
- Installation instructions for bonding in new door outer panel
- Minimum curing period
- Cleaning off excess adhesive sealing material
- Assembly overview - door inner part
- Assembly overview - door handle and door lock
- Removing and installing housing
- Removing and installing door handle
- Removing and installing mounting plate
- Removing and installing door lock
- Assembly overview - side impact protection
- Door inner seal
- Removing and installing door inner seal
- Removing and installing door outer seal
- Central locking
- Front door
- Rear door,sliding door,wing doors,central locking
- Rear door
- Rear door|Tools
- Materials
- Assembly overview - door assembly
- Assembly overview - door hinges
- Removing and installing door
- Adjusting door
- Removing and installing door outer panel
- Installing new outer panel for door
- Removing and installing retaining rail on door outer panel
- Installation instructions for bonding in new door outer panel
- Minimum curing period
- Cleaning off excess adhesive sealing material
- Assembly overview - door inner part
- Assembly overview - door handle and door lock
- Removing and installing housing
- Removing and installing door handle
- Removing bearing bracket
- Removing and installing door lock
- Assembly overview - side impact protection
- Door inner seals
- Removing and installing door inner seal
- Removing and installing door outer seal
- Rear door
- Sliding roof
- Sliding/tilting sunroof with glass panel (Meritor)
- Sliding/tilting sunroof with glass panel (Meritor)|Tools
- Function
- Assembly overview - sliding/tilting sunroof with glass panel
- Removing and installing bellows
- Removing glass panel of sliding/tilting sunroof
- Installing glass panel of sliding/tilting sunroof
- Adjusting height of glass panel of sliding/tilting sunroof
- Adjusting panel seal
- Renewing panel seal
- Removing and installing wind deflector
- Removing and installing sliding headliner
- Removing and installing sliding/tilting sunroof glass panel drive
- Adjusting drive for sliding/tilting sunroof glass panel (0 position)
- Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
- Checking parallel running
- Adjusting parallel running
- Assembly overview - carrier unit
- Removing and installing carrier unit
- Operating without electrics
- Removing and installing guide plate
- Removing and installing sliding gate
- Cleaning water drain hoses
- Sliding/tilting sunroof with glass panel (Meritor)
- Bumper
- Front bumper
- Front bumper for GTI, GTI special models, GT, R32
- Front bumper for GTI, GTI special models, GT, R32|Tools
- Repairing bumper cover
- Assembly overview - bumper cover for GTI, GT
- Removing and installing front bumper cover for GT, GTI
- Front bumper attachments for GT, GTI
- Assembly overview - bumper cover for R32
- Removing and installing front bumper cover for R32
- Front bumper attachments for R32
- Assembly overview - front bumper cover for GTI special models
- Removing and installing front bumper cover for GTI special models
- Front bumper attachments for GTI special models
- Front bumper substructure
- Assembly overview - bumper carrier
- Rear bumper
- Rear bumper for R32 and GTI special models
- Rear bumper for R32 and GTI special models|Tools
- Repairing bumper cover
- Assembly overview - bumper cover for R32
- Removing and installing bumper cover for R32
- Rear bumper attachments for R32
- Assembly overview - rear bumper cover for GTI special models
- Removing and installing rear bumper cover for GTI special models
- Rear bumper attachments for GTI special models
- Rear bumper substructure
- Assembly overview - bumper carrier
- Glazing/window mechanism
- Flush bonded windows
- Flush bonded windows|Tools
- Materials
- Repairing windscreen
- Assembly overview - windscreen
- Assembly overview - plenum chamber cover
- Removing windscreen
- Installing windscreen
- Assembly overview - rear window
- Removing undamaged rear window
- Removing broken rear window
- Installing rear window
- Assembly overview - rear side window
- Removing undamaged rear side window
- Removing damaged rear side window
- Installing rear side window
- Preparing old undamaged window for glazing
- Preparing new window without precoating for glazing
- Preparing new window with precoating for glazing
- Preparing body flange for glazing
- Installation instructions
- Minimum curing period
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Front door windows
- Front door windows|Tools
- Assembly overview - front door window
- Removing and installing door window
- Adjusting door window
- Assembly overview - window regulator motor
- Removing and installing window regulator motor
- Assembly overview - window guide
- Removing and installing window guide
- Assembly overview - window regulator
- Removing and installing window regulator
- Rear door windows
- Rear door windows|Tools
- Assembly overview - rear door window
- Removing and installing door window
- Assembly overview - fixed door window with window guide
- Removing and installing fixed door window with window guide
- Assembly overview - window regulator motor
- Removing and installing window regulator motor
- Assembly overview - window regulator
- Removing and installing window regulator
- Flush bonded windows
- Exterior equipment
- Wheel housing liner
- Exterior mirror
- Radiator grille
- Radiator grille|Tools
- Assembly overview - radiator grille
- Removing and installing radiator grille
- Assembly overview - radiator grille for GTI, GTI special models and GT
- Removing and installing radiator grille for GT, GTI special models and GT
- Radiator grille for GTI, GTI special models, GT and R32 - number plate carrier
- Assembly overview - radiator grille for R32
- Removing and installing radiator grille for R32
- R32 radiator grille - company emblem
- Mouldings and trims
- Mouldings and trims|Tools
- Assembly overview - water deflector
- Removing and installing water deflector
- Assembly overview - protective side strips
- Renewing side protective mouldings
- Removing and installing stone-chip protection trim
- Assembly overview - side member extension for GTI, GTI special models and R32
- Removing and installing side member extension for GTI, GTI special models and R32
- Retaining strip for side member extension
- Roof edge spoiler
- Roof edge spoiler|Tools
- Materials
- Assembly overview - roof spoiler for GTI, GTI special models and R32
- Removing and installing roof spoiler for GTI, GTI special models and R32
- Retaining strip
- Preparing body kit component for bonding
- Installation instructions
- Minimum curing period
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Protective backing
- Lettering
- Vermin repellent system
- General body repairs, interior
- Interior equipment
- Interior mirror
- Compartments, covers and trims
- Compartments, covers and trims|Tools
- Removing and installing basic centre console (Golf 2004 ?)
- Removing and installing basic centre console (Golf 2009 ?)
- Loosening and securing basic centre console (Golf 2009 ?)
- Removing and installing Highline centre console (Golf 2004 ?)
- Removing and installing Highline centre console (Golf 2009 ?)
- Loosening and securing Highline centre console (Golf 2009 ?)
- Removing and installing mounting bracket for centre console (Golf 2004 ?)
- Removing and installing mounting bracket for centre console and mounting bracket for footwell trim (Golf 2009 ?)
- Removing and installing cup holder in Highline centre console
- Repairing drinks holder in Highline centre console
- Removing and installing storage compartment / ashtray (Golf 2004 ?)
- Removing and installing storage compartment / ashtray (Golf 2009 ?)
- Removal and installation of dash panel centre vents (vehicles without Climatronic) (Golf 2004 ?)
- Removing and installing dash panel centre vents (vehicles with Climatronic, Golf 2004 ?)
- Removing and installing centre compartment in dash panel (Golf 2009 ?)
- Removing and installing spectacles holder in moulded headliner
- Removing and installing frame in moulded headliner
- Removing and installing dash panel centre vent (Golf 2009 ?)
- Removing and installing dash panel centre trim (Golf 2004 ?)
- Removing and installing dash panel centre trim (Golf 2009 ?)
- Removing and installing air conditioner control panel trim / heater control panel trim (Golf 2009 ?)
- Removing and installing dash panel end trims
- Removing and installing steering column trim
- Removing and installing left trim panel on driver side
- Removing and installing right trim panel on driver side
- Removing and installing centre cover (Golf 2004 ?)
- Removing and installing centre cover (Golf 2009 ?)
- Removing and installing glove compartment
- Removing and installing glove compartment lock cylinder
- Removing and installing footwell cover on driver side
- Removing and installing decorative trim on dash panel (Golf 2004 ?)
- Removing and installing decorative trim on dash panel (Golf 2009 ?)
- Removing and installing sun visor
- Sill panel mouldings
- Grab handles
- Passenger protection
- Seat belts
- General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components)
- Special instructions for belt tensioners
- Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)
- Removing and installing front seat belt (2-door models)
- Removing and installing front seat belt (4-door models)
- Removing and installing front belt height adjuster
- Removing and installing front seat belt buckle (2-door)
- Removing and installing front seat belt buckle (4-door)
- Removing and installing rear outer seat belts
- Removing and installing rear middle three-point seat belt
- Removing and installing middle rear seat lap belt
- Removing and installing rear double belt buckle
- Inspecting seat belts
- Checking child seat anchors (ISOFIX) after an accident
- Passenger protection|Airbag
- Overview of locations - airbag systems
- General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components)
- Special instructions for driver and front passenger airbag
- Special instructions for curtain airbag modules
- Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)
- Deactivating the airbag
- Renewing airbag units following an accident
- Removing and installing airbag control unitJ234
- Removing and installing driver airbag (Golf 2004 ?)
- Removing and installing driver airbag (Golf 2009 ?)
- Removing and installing airbag coil connector and return spring with slip ringF138
- Removal and installation of key operated switch to deactivate front passenger airbagE224
- Removing and installing knee airbag (Golf 2009 ?)
- Removing and installing knee airbag bracket (Golf 2009 ?) LHD models
- Removing and installing knee airbag bracket (Golf 2009 ?) RHD models
- Removing and installing front passenger airbag unit
- Removing and installing side airbags on driver and front passenger sides
- Removing and installing rear side airbag (4-door)
- Removing and installing curtain airbag on driver and passenger side
- Removing and installing driver/front passenger curtain airbag, 4-door, (Golf 2009 ?)
- Removing and installing seat occupied sensor, front passenger sideG128
- Adapting components
- Seat occupied recognition (USA)
- Safety precautions for when working on seat occupied recognition
- Procedure after an accident when belt tensioner and/or airbag was triggered
- Assembly overview - seat occupied recognition (USA)
- Components of repair kit for seat occupied recognition
- Removing components of seat occupied recognition (vehicles with manually operated seats)
- Installing repair kit for seat occupied recognition (vehicles with manually adjusted seats)
- Removing components of seat occupied recognition (vehicles with electrically operated seats)
- Installing repair kit for seat occupied recognition (vehicles with electrically operated seats)
- Importers reporting obligation
- Crash sensors
- Removing and installing front door crash sensors (Golf 2004 ?)
- Removing and installing side airbag crash sensor on driver sideG179 (Golf 2009 ?)
- Removing and installing side airbag crash sensor on front passenger sideG180 (Golf 2009 ?)
- Removing and installing rear wheel housing crash sensors (2-door) (Golf 2004 ?)
- Removing and installing rear wheel housing crash sensors (4-door) (Golf 2004 ?)
- Removing and installing rear side airbag crash sensor on driver sideG256 (Golf 2009 ?)
- Removing and installing rear side airbag crash sensor on front passenger sideG257 (Golf 2009 ?)
- Seat belts
- Trim, noise insulation
- dash panel
- Door trim (Golf 2004 ?)
- Door trim (Golf 2009 ?)
- Pillar and side trims
- Removing and installing upper A-pillar trim
- Removing and installing centre A-pillar trim
- Removing and installing lower A-pillar trim on driver side
- Removing and installing lower A-pillar trim on front passenger side
- Removing and installing upper B-pillar trim
- Removing and installing lower B-pillar trim
- Removing and installing C-pillar trim
- Removing and installing sill panel moulding (2-door model)
- Rear lid trim (Golf 2004 ?)
- Rear lid trim (Golf 2009 ?)
- Luggage compartment trim
- Roof trims
- Floor covering
- Seat frames
- Front seats
- Front seats|Tools
- Removing and installing front seat
- Removing and installing left side trim on seat
- Removal and installation of left bucket seat trim
- Removing and installing backrest trim of front bucket seat
- Removing and installing trims on left side of electrically adjustable seat
- Removing and installing left trim (seat with through-load aperture)
- Removing and installing right trim (seat with through-load aperture)
- Removing and installing slider (2 door models)
- Removing and installing seat drawer mounting
- Removing and installing front seat bar and operating lever
- Removal and installation of front bucket seat bar and operating lever
- Removing and installing bar and operating lever on electrically adjustable seat
- Removing and installing right side trim on seat
- Removal and installation of right side trim on bucket seat
- Removing and installing lumbar support adjusting lever (Golf 2009 ?)
- Removing head restraint guides
- Removing and installing front seat backrest
- Removal and installation of front bucket seat backrest
- Removing and installing front bucket seat pan
- Removing and installing backrest release Bowden cable on bucket seat
- Removing and installing backrest release (seat with through-load aperture)
- Removing and installing backrest release Bowden cable (2-door)
- Removing and installing manual lumbar support frame (Golf 2004?)
- Removing and installing manual lumbar support frame (Golf 2009 ?)
- Removing and installing Easy Entry unit Bowden cable
- Removing and installing electric longitudinal seat adjustment
- Removing and installing seat pan on electrically adjustable seat
- Removing and installing rake adjustment on electrically adjustable seat
- Removing and installing height adjustment on electrically adjustable seat
- Removing and installing (electric) seat lumbar support
- Removing and installing drive for (electric) backrest adjustment
- Rear seats
- Front seats
- Seat padding, covers
- Front seat covers and padding
- Front seat covers and padding|Tools
- Removing and installing front seat cushion cover and padding
- Removal and installation of front bucket seat cushion cover and padding
- Removing and installing front seat backrest cover and padding
- Removal and installation of front bucket seat backrest cover and padding
- Rear seat covers and padding
- Front seat covers and padding
- Interior equipment
- General body repairs, exterior
- Vehicle electrics
- Electrical system
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Checking battery
- Charging battery
- Disconnecting and reconnecting battery
- Removing and installing battery
- Specified torques: battery
- Battery isolation igniterN253
- Jump start point with suppression filterC24
- Specified torques: jump start point
- Starter-current supply-CC|Starter
- Checking starterB
- Removing and installing starter, automatic gearbox
- Removing and installing starter, dual clutch gearbox (DSG)
- Vehicles with 1.4 l TSI engine and dual clutch gearbox (DSG), 90 kW
- Vehicles with 1.4 l TSI engine and dual clutch gearbox (DSG), 103 kW and 125 kW
- Vehicles with 2.0 l FSI turbocharged engine and dual clutch gearbox (DSG)
- Vehicles with 3.2 l injection engine and dual clutch gearbox (DSG)
- Vehicles with 1.9 l TDI engine and dual clutch gearbox (DSG)
- Vehicles with 2.0 l TDI engine and dual clutch gearbox (DSG)
- Removing and installing starter, manual gearbox
- Vehicles with 1.4 l TSI engine and manual gearbox
- Vehicles with 1.4 l injection engine, 1.4 and 1.6 l FSI engine, manual gearbox
- Vehicles with 1.6 l injection engine and manual gearbox
- Vehicles with 2.0 l FSI engine and manual gearbox
- Vehicles with 2.0 l FSI turbocharged engine and manual gearbox
- Vehicles with 2.5 l injection engine and manual gearbox
- Vehicles with 3.2 l injection engine and manual gearbox
- Vehicles with 2.0 l SDI engine and manual gearbox
- Vehicles with 1.9 l TDI engine and manual gearbox
- Vehicles with 2.0 l TDI engine and manual gearbox
- Specified torques: starter
- Alternator
- Securing B+ (battery positive) wire to alternator
- Checking poly V-belt
- Checking alternatorC
- Alternator, 1.4 l injection engine
- Alternator, 1.4 l FSI engine
- Alternator 1.4 l TSI
- Alternator, 1.6 l injection engine
- Alternator, 1.6 l FSI engine
- Alternator, 2.0 l FSI engine
- Alternator, 2.0 l FSI turbocharged engine
- Alternator, 2.5 l injection engine
- Alternator, 3.2 l injection engine
- Alternator, 2.0 l SDI engine
- Alternator, 1.9 l TDI engine
- Alternator, 1.9 l TDI engine with diesel particulate filter
- Alternator, 2.0 l TDI engine
- Removing and installing poly V-belt pulley on alternator
- Voltage regulator for alternator
- Cruise control system (CCS)
- Instruments, GCI
- Windscreen wipe/wash system
- Windscreen wiper system
- Windscreen washer system
- Assembly overview - windscreen washer system
- Removing and installing washer fluid reservoir
- Removing and installing windscreen and rear window washer pumpV59
- Removing and installing windscreen washer fluid level senderG33
- Removing and installing windscreen washer system spray jets
- Adjusting windscreen washer system spray jets
- Rear window wiper system
- Rear window washer system
- Headlight washer system
- Washer fluid line hose couplings
- Hose repair
- Specified torques: windscreen wash/wipe system
- Lights, lamps, switches outside
- Headlight
- Assembly overview - headlight
- Removing and installing headlight
- Adjusting headlight installation position
- Renewing headlight bulbs
- Removing and installing headlight range control motor
- Repairing headlight retaining tabs
- Converting headlights for use when driving on the left or right
- Adjusting headlights
- Headlights with gas discharge bulbs
- Assembly overview - gas discharge headlights
- Removing and installing gas discharge headlights
- Adjusting headlight installation position
- Renewing headlight bulbs
- Removing and installing headlight range control motor
- Removing and installing gas discharge bulb control unit
- Headlight range control unitJ431
- Vehicle level sender
- Repairing headlight retaining tabs
- Converting headlights for use when driving on the left or right
- Adjusting headlights
- Headlights - Golf GT, GTI, R32
- Assembly overview
- Removing and installing headlight GT, GTI and R32
- Adjusting headlight installation position
- Renewing headlight bulbs
- Removing and installing headlight range control motor
- Removing and installing gas discharge bulb control unit
- Headlight range control unitJ431
- Vehicle level sender
- Repairing headlight retaining tabs
- Converting headlights for use when driving on the left or right
- Adjusting headlights
- Fog lights
- Bulb for mirror turn signal and entry light in exterior mirror
- Side marker lights
- Tail lights
- Assembly overview - tail light in side panel, vehicles ? 11.05
- Assembly overview - tail light in side panel, vehicles 11.05 ?
- Removing and installing tail light in side panel
- Renewing tail light, vehicles ? 11.05
- Renewing tail light, vehicles 11.05 ?
- Adjusting tail light
- Removing and installing tail light setting element
- Removing and installing tail light bulb carrier in side panel
- Assembly overview - tail light in rear lid
- Removing and installing tail light in rear lid
- Removing and installing tail light bulb carrier in rear lid
- Number plate light
- Additional brake light
- Steering column switch
- Assembly overview - steering column switch
- Removing and installing steering column switch
- Removal and installation sequence of components of steering column switch
- Removing and installing steering column electronics control unitJ527
- Removing and installing airbag coil connector and return ring with slip ringF138
- Removing and installing steering angle senderG85
- Removing and installing turn signal switch
- Removing and installing windscreen wiper switchE
- Removing and installing steering column switch base
- Steering column electronics control unitJ527
- Steering angle senderG85
- Ignition/starter switch and lock cylinder
- Parking aid
- Specified torques: lights, bulbs, switches - exterior
- Headlight
- Lights, lamps, switches inside, anti-theft system
- Interior lights and switches
- Lights and switches in engine compartment
- Lights and switches in dash panel
- Removing and installing light switchE1
- Removing and installing glove compartment lightW6
- Removing and installing glove compartment light switchE26
- Removing and installing headlight range control regulatorE102 and switch and instrument illumination regulatorE20
- Removing and installing front passenger side airbag deactivated warning lampK145
- Removing and installing hazard warning light switchE3
- Removing and installing left footwell lightW9 and right footwell lightW10
- Removing and installing key-operated switch to deactivate front passenger side airbagE224
- Lights and switches in front doors
- Removing and installing window regulator switch in front passenger doorE107
- Removing and installing switch element for mirror adjustment on driver side
- Removing and installing driver side interior locking button for central locking systemE308
- Components - front door locks
- Removing and installing driver side window regulator switch element
- Removing and installing fuel tank flap release buttonE319
- Lights and switches in rear doors
- Lights and switches in luggage compartment
- Lights and switches in roof trim
- Front interior light and reading light (vehicles with no sliding sunroof)
- Front interior light and reading light (vehicles with sliding sunroof)
- Rear interior light and reading light (vehicles with no anti-theft alarm)
- Rear interior light and reading light (vehicles with anti-theft alarm system (ATA))
- Removing and installing front passenger side illuminated vanity mirrorW14 and driver side illuminated vanity mirrorW20
- Garage door opener
- Lights and switches in centre console
- Lights, lamps, switches inside, anti-theft system|Horn
- Immobiliser, vehicles up to 05/2007
- Immobiliser, vehicles as of 06/2007
- Anti-theft alarm (ATA) to 05/2006
- General description
- Activating and deactivating anti-theft alarm
- Removing and installing interior monitoring deactivation switchE267 and deactivation button for vehicle inclination senderE360
- Removing and installing interior monitoring sensor
- Removing and installing vehicle inclination senderG384
- Central locking and anti-theft alarm system aerialR47
- Alarm hornH12
- Anti-theft alarm (ATA) from 06/2006
- General description
- Activating and deactivating anti-theft alarm
- Removing and installing interior monitoring deactivation switchE267 and deactivation button for vehicle inclination senderE360
- Removing and installing interior monitoring sensor and vehicle inclination sender
- Central locking and anti-theft alarm system aerialR47
- Alarm hornH12
- Wiring
- Vehicle diagnosis, testing and information systems
- Main fuse holder, Golf R32 only
- Specified torques: main fuse box
- Removing and installing fuse holder
- Removing and installing relay carrier
- Electronics boxes
- Control units
- Specified torques: wiring
- Wiring harness and connector repairs
- Starter-current supply-CC
- Communication
- Infotainment
- Communication Systems
- Radio units and radio navigation systems in general
- Radio system "RCD 500"
- Radio system "RCD 300”
- Radio system RCD 310
- Radio system "RCD 500”
- Radio system RCD 510
- General notes
- Overview of radio system "RCD 510”, Golf saloon
- Activating/deactivating transport lock for CD changer in "RCD 510”
- Overview of connectors on radio "RCD 510”
- Multi-pin connector 1, 8-pin, loudspeaker outputs
- Multi-pin connector 2, 8-pin, voltage supply, CAN bus, telephone mute switch
- Multi-pin connector 3, 12-pin, AUX audio output, telephone signal input
- Multi-pin connector 4, 12-pin, AUX audio input, CD changer control and CD audio input signals
- Multi-pin connector 5, audio and video, 26-pin
- Anti-theft coding
- Radio system "Premium Sound System”, for vehicles for USA and Canada
- Radio navigation system "RNS 300”
- Radio navigation systems "RNS MFD 2” and "RNS MFD 2 DVD”
- General description
- Overview of "radio navigation system 2” with multifunction display (MFD)
- Overview of "radio and navigation system 2” with multifunction display (MFD), Golf Plus
- Overview of connectors on "radio and navigation system 2” with multifunction display (MFD)
- Multi-pin connector 1, 18-pin, for video and low frequency input
- Connector 2
- Multi-pin connector 3, 8-pin, for loudspeaker outputs
- Multi-pin connector 4, 8-pin, for voltage supply wires and CAN bus
- Multi-pin connector 5, 12-pin, for telephone signals and pre-amplifier output signals
- Multi-pin connector 6, 12-pin, for CD changer control and CD audio input signals
- Connectors 7 and 8, aerial connections
- Anti-theft coding
- Radio navigation system "RNS MFD 2 DVD”, for models for USA and Canada
- General description
- Overview of radio navigation system "RNS MFD 2 DVD”
- Overview of connectors on radio navigation system "RNS MFD 2 DVD”
- Multi-pin connector 1, 18-pin, for video and low frequency input
- Connector 2
- Multi-pin connector 3, 8-pin, for loudspeaker outputs
- Multi-pin connector 4, 8-pin, for voltage supply wires and CAN bus
- Multi-pin connector 5, 12-pin, for telephone signals and pre-amplifier output signals
- Multi-pin connector 6, 12-pin, for CD changer control, CD audio input signals and satellite digital radio tuner
- Connectors 7 and 8, aerial connections
- Anti-theft coding
- Radio navigation system "RNS 510”
- General notes
- Overview of radio navigation system "RNS 510”, Golf saloon
- Overview of connectors on radio navigation system "RNS 510”
- Multi-pin connector 1, 8-pin, for loudspeaker outputs
- Multi-pin connector 2, 8-pin, for voltage supply lines and CAN bus
- Multi-pin connector 3, 12-pin, for telephone and microphone signals
- Multi-pin connector 4, 12-pin, for CD changer control and CD audio input signals
- Multi-pin connector 5, audio and video, 26-pin
- Connectors 6, aerial connectors
- Anti-theft coding
- Radio navigation system "DX-R4” (Blaupunkt)
- Sound system amplifier
- CD changer
- Satellite digital radio tuner for vehicles for USA and Canada
- "Apple” "iPod player” holder
- USB connection for USB sticks and MP3 player
- Multimedia system control unit
- Connection for external audio sources
- Loudspeaker systems
- Removing and installing front bass loudspeakers
- Removing and installing rear bass loudspeakers (4-door)
- Removing and installing rear bass loudspeakers (2-door)
- Removing and installing front mid-range loudspeakers
- Removing and installing front treble loudspeakers
- Removing and installing rear treble loudspeakers (4-door)
- Removing and installing rear treble loudspeakers (2-door)
- Telephone systems
- General notes
- Fault finding
- Overview of telephone system
- Removing and installing telephone bracket, Golf saloon ? 06/2006
- Removing and installing telephone bracket, Golf saloon 06/2006 ?
- Removing and installing telephone operating electronics control unit (interface box), Golf saloon ? 06/2006
- Removing and installing telephone operating electronics control unit (interface box), Golf saloon, Golf Plus 06/2006 ?
- Removing and installing telephone system microphone
- Aerial systems
- General notes
- Overview - aerial system ? 05.05
- Overview - aerial system 06.05 ? for radio units without telephone/auxiliary heater telestart equipment
- Overview - aerial system 06.05 ? for radio units or radio/navigation systems (with telephone/auxiliary heater telestart equipmen
- Overview of aerial system with digital satellite tuner for vehicles for USA and Canada
- Removing and installing aerial amplifier in rear lid, Golf saloon
- Removing and installing amplitude modulation (AM) frequency filter
- Removing and installing aerial selection control unit
- Roof aerial
- Renewal of aerial wiring
- Multifunction steering wheel
- Notes on operating mobile telephones and two-way radios
- Suppression measures
- Infotainment
- Electrical System, General Information
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Checking battery
- Charging battery
- Battery chargerVAS 5095 A
- Battery chargerVAS 5900
- Description of battery chargerVAS 5900
- Charging battery with battery chargerVAS 5900
- Charging battery in service mode with battery chargerVAS 5900
- Charging totally discharged batteries with battery chargerVAS 5900
- Charging battery in support mode with battery chargerVAS 5900
- Charging battery in maintenance mode with battery chargerVAS 5900
- Battery chargerVAS 5903
- Description of battery chargerVAS 5903
- Charging battery with battery chargerVAS 5903
- Charging battery in refresh charge mode with battery chargerVAS 5903
- Charging totally discharged battery with battery chargerVAS 5903
- Charging battery in support mode with battery chargerVAS 5903
- Charging battery in maintenance mode with battery chargerVAS 5903
- Battery chargerVAS 5906
- MidtronicsINC 940 battery charger only for USA/Canada
- Solar panelVAS 6102A
- Totally discharged batteries
- Cruise control system (CCS)
- Windscreen wipe/wash system
- Lights, lamps, switches outside
- Lights, lamps, switches inside, anti-theft system
- Wiring
- Vehicle diagnostic, testing and information systems
- Wiring harness and connector repairs
- Contact surface cleaning setVAS 6410
- Renewing Lambda probe
- Starter-current supply-CC
- Electrical system
- Power transmission
- 6-speed automatic gearbox 09G
- Technical data
- General repair notes
- General repair notes|Gearbox
- Torque converter
- General repair notes|ATF
- Automatic gearbox control unitJ217 with fuzzy logic
- Control units in vehicle
- Information on "09G gearbox"
- General repair notes|Tools
- Gearbox
- Gaskets, seals and oil
- Nuts and bolts
- Electrical components
- Guided fault finding, vehicle self-diagnosis and test instruments
- Capacities
- Code - engine allocation
- Golf 2004 ?
- General repair notes
- Torque converter
- Automatic gearbox, control, assembly, housing
- Connecting »tester«
- Electrical and electronic components and their locations
- Multifunction switchF125
- Emergency release of selector lever
- Removing and installing selector lever handle
- Selector mechanism up to 02.2009
- Selector mechanism from 03.2009 onwards
- Checking selector mechanism
- Removing and installing gearbox, Golf 2004 ?
- Removing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI) engines
- Installing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI) engines
- Removing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 kW engines
- Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines
- Torque settings, gearbox to engine
- Transporting gearbox
- ATF cooler for 1.6 l - 85 kW and 2.0 l - 110 kW engines
- Checking ATF level and topping up
- Automatic gearbox, gears, control
- Renewing oil seal for selector shaft
- Removing and installing ATF pan
- Removing and installing ATF strainer
- Removing and installing valve body
- Removing and installing wiring harness for solenoid valves and senders
- Removing and installing gearbox input speed senderG182
- Removing and installing gearbox output speed senderG195
- Final drive, differential, differential lock
- Technical data
- 6-speed manual gearbox 0AJ
- Technical data
- Clutch, control
- Clutch operation
- Overview - clutch actuation
- Assembly overview, pedal cluster with clutch position senderG476 - Touran from 06.03, Passat, Eos, Scirocco, Golf, and Golf Plus
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Removing and installing mounting bracket
- Removing and installing master cylinder
- Removing and installing clutch position senderG476
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing slave cylinder
- Bleeding clutch system
- Clutch release mechanism
- Clutch, control|Clutch
- Clutch operation
- Gearbox mechanics,operation, construction,diff.
- Selector mechanism
- Installation position of selector mechanism
- Overview - selector mechanism
- Assembly overview - gear lever knob and cover
- Removing and installing gear knob with gaiter and noise insulation
- Assembly overview - Selector lever and selector housing
- Dismantling and assembling selector mechanism (from 11.06)
- Assembly overview - Selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox
- Transporting gearbox
- Gearbox oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Overview - dismantling and assembling gearbox
- Assembly overview - removing and installing cover for gearbox housing and 5th and 6th gears
- Assembly overview - removing and installing clutch housing
- Assembly overview - removing and installing input shaft, output shaft, differential, selector mechanism and selector forks
- Dismantling and assembling procedure
- Gearbox housing and clutch housing
- Gearbox housing cover
- Selector unit
- Selector forks
- Selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 6-speed manual gearbox 02S
- Technical data
- Clutch, control
- Clutch operation
- Overview - clutch actuation
- Assembly overview - pedal cluster
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Removing and installing mounting bracket
- Removing and installing master cylinder
- Removing and installing clutch position senderG476
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing slave cylinder
- Bleeding clutch system
- Clutch release mechanism
- Clutch, control|Clutch
- Clutch operation
- Gearbox mechanics,operation, construction,diff.
- Selector mechanism
- Installation position of selector mechanism
- Overview - selector mechanism
- Assembly overview - gear lever knob and cover
- Removing and installing gear knob with gaiter and noise insulation
- Assembly overview - Selector lever and selector housing
- Dismantling and assembling selector mechanism (from 11.06)
- Assembly overview - Selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox
- Transporting gearbox
- Assembly overview - assembly mountings
- Gearbox oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Overview - dismantling and assembling gearbox
- Assembly overview - removing and installing cover for gearbox housing and 5th and 6th gears
- Assembly overview - removing and installing gearbox housing and selector mechanism
- Assembly overview - removing and installing input shaft, output shaft, differential and selector forks
- Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th gear
- Assembly sequence - Dismantling and assembling gearbox completely
- Gearbox housing and clutch housing
- Gearbox housing cover
- Selector unit
- Selector forks
- Selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Oil seals
- Renewing left flange shaft oil seal with gearbox installed
- Distinguishing seals for right flange shaft
- Renewing right seal with manual gearbox installed (two-part seal for flange shaft and sleeve)
- Renewing right seal and sleeve together with manual gearbox installed (one-piece seal and sleeve for flange shaft)
- Adjustment overview
- Differential
- Oil seals
- 6-speed manual gearbox 02Q
- Technical data
- Front-wheel drive - gearbox identification
- Four-wheel drive - gearbox identification
- Front-wheel drive - Overview power transmission
- Overview - four-wheel drive power train
- Calculating overall gear ratio "i"
- Four-wheel drive - notes on performance test
- General repair notes
- Safety measures for vehicles with start/stop system
- Clutch, control
- Repairing clutch mechanism, Golf, Golf Plus and Scirocco
- Overview
- Assembly overview - pedal cluster
- Removing and installing over-centre spring, Golf 2004 ?
- Removing and installing clutch pedal, Golf 2004 ?
- Removing and installing mounting bracket, Golf 2004 ?
- Removing and installing master cylinder
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing clutch position senderG476
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch, in conjunction with dual-mass flywheel
- Repairing clutch, in conjunction with one-piece flywheel
- Repairing clutch mechanism, Golf, Golf Plus and Scirocco
- Gearbox mechanics,operation, construction,diff.
- Repairing selector mechanism
- Installation position of selector mechanism
- Overview of selector mechanism
- Assembly overview - gear knob and cover
- Removing and installing gaiter with gear knob and noise insulation, Golf, Eos and Scirocco
- Repairing gear lever and selector housing (through 10.06)
- Repairing gear lever and selector housing (from 11.06)
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Functional check
- Plastic relay lever
- Removing and installing gearbox, Golf 2004 ? front-wheel drive
- Removing and installing gearbox, Golf 2004 ? four-wheel drive
- Transporting gearbox
- Checking gear oil
- Removing and installing bevel box, vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particle
- Removing and installing bevel box, vehicles with turbo diesel engine and particulate filter, (Golf 2005 ?, Golf 2009 ?, Passat 2
- Checking or topping up gear oil in bevel box
- Dismantling and assembling gearbox
- Overview - gearbox, front-wheel drive, Golf 2004 ? and Touran
- Overview - gearbox, four-wheel drive
- Assembly overview - front-wheel drive
- Assembly overview - four-wheel drive
- Assembly overview - removing and installing gearbox housing and selector unit
- Assembly overview - front-wheel drive - removing and installing input shaft, output shafts, differential and selector rods; Tour
- Four-wheel drive - removing and installing input shaft, output shafts, differential, bevel box and selector rods
- Assembly order, gearbox »without« circlip A for input shaft cover made from sheet metal
- Assembly order: I = gearbox »with« circlip A for input shaft cover made from sheet metal; II = gearbox with input shaft cover ma
- Repairing gearbox housing
- Front-wheel drive - repairing clutch housing
- Four-wheel drive - repairing clutch housing
- Repairing selector unit
- Repairing selector forks
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Input shaft
- Output shaft for 1st through 4th gears
- Assembly overview - output shaft for 1st through 4th gears
- Dismantling and assembling output shaft for 1st through 4th gears
- Distinguishing 1st/2nd gear synchronisation, distinguishing 3rd gear synchronisation
- Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9
- Assembling 1st to 4th gear output shaft - from gearbox date 26 10 9 up to gearbox date 24 05 0
- Assembling 1st to 4th gear output shaft - from gearbox date 25 05 0 onwards
- Adjusting output shaft for 1st through 4th gears
- Output shaft for 5th, 6th and reverse gears
- Final drive, differential, differential lock
- Front-wheel drive - renewing seals for flange shafts or stub shaft with gearbox installed
- Renewing oil seal for left flange shaft
- Identifying gearbox to renew right oil seal, Golf and Touran
- Renewing stub shaft seal - Golf and Touran through gearbox manufacture date 31 10 4
- Renewing oil seal for right flange shaft, Golf and Touran from gearbox manufacture date 01 11 4, Golf Plus, Passat, Passat CC, C
- Four-wheel drive - renewing flange shaft oil seals with gearbox and bevel box installed
- Renewing seal between gearbox and bevel box
- Assembly overview - seals, flange shaft mount and output flange mount in bevel box
- Renewing seal between gearbox and bevel box with bevel box removed
- Renewing bevel box output flange oil seal (bevel box removed)
- Resetting shim when renewing output flange
- Renewing polygon needle bearing and seal on right flange shaft
- Adjustment overview - manual gearbox
- Differential
- Front-wheel drive - renewing seals for flange shafts or stub shaft with gearbox installed
- Technical data
- 5-speed manual gearbox 0AH
- Clutch, control
- 6-speed manual gearbox 0AG
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Removing and installing over-centre spring, Golf
- Removing and installing clutch pedal, Golf
- Removing and installing mounting bracket, Golf
- Removing and installing master cylinder
- Removing and installing clutch position senderG476
- Assembly overview - hydraulics (LHD vehicles)
- Assembly overview - hydraulics (RHD vehicles)
- Removing and installing slave cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Repairing clutch mechanism
- Gearbox mechanics,operation, construction,diff.
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Removing and installing gaiter with gear knob and noise insulation, Golf
- Repairing gear lever and selector housing (through 10.06)
- Repairing gear lever and selector housing (from 11.06)
- Assembly overview - removing and installing selector cables
- Plastic relay lever
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox, Golf
- Transporting gearbox
- Checking gear oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Assembly overview - removing and installing cover for gearbox housing and 5th and 6th gear
- Assembly overview - removing and installing clutch housing
- Assembly overview - removing and installing input shaft, output shaft (drive pinion), differential, selector mechanism and selec
- Dismantling and assembling procedure
- Repairing gearbox housing and clutch housing
- Repairing gearbox housing cover
- Repairing selector unit
- Dismantling and assembling selector forks
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5-speed manual gearbox 0A4
- Technical data
- Clutch, control
- Clutch operation
- Overview - clutch actuation
- Assembly overview - pedal cluster
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Removing and installing mounting bracket
- Removing and installing master cylinder
- Removing and installing clutch position senderG476
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing slave cylinder
- Bleeding clutch system
- Clutch release mechanism
- Clutch, control|Clutch
- Clutch operation
- Gearbox mechanics,operation, construction,diff.
- Selector mechanism
- Installation position of selector mechanism
- Overview - selector mechanism
- Assembly overview - gear lever knob and cover
- Removing and installing gear knob with gaiter and noise insulation
- Assembly overview - Selector lever and selector housing
- Dismantling and assembling selector mechanism (from 11.06)
- Assembly overview - Selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox
- Transporting gearbox
- Assembly overview - assembly mountings
- Gearbox oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview - dismantling and assembling gearbox
- Assembly overview - removing and installing cover for gearbox housing and 5th gear
- Assembly overview - removing and installing gearbox housing and selector mechanism
- Assembly overview - removing and installing input shaft, output shaft, differential and selector forks
- Assembly sequence - removing and installing cover for gearbox housing and 5th gear
- Assembly sequence - Dismantling and assembling gearbox completely
- Gearbox housing and clutch housing
- Selector unit
- Selector forks
- Selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Oil seals
- Renewing left flange shaft oil seal with gearbox installed
- Distinguishing seals for right flange shaft
- Renewing right seal with manual gearbox installed (two-part seal for flange shaft and sleeve)
- Renewing right seal and sleeve together with manual gearbox installed (one-piece seal and sleeve for flange shaft)
- Adjustment overview
- Differential
- Oil seals
- 6-speed manual gearbox 0A8
- Gearbox mechanics,operation, construction,diff.
- 5-speed manual gearbox 0AF
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Removing and installing over-centre spring, Golf 2004 ?
- Removing and installing clutch pedal, Golf 2004 ?
- Removing and installing mounting bracket, Golf 2004 ?
- Removing and installing master cylinder
- Removing and installing clutch position senderG476
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing slave cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Repairing clutch mechanism
- Gearbox mechanics,operation, construction,diff.
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Removing and installing gaiter with gear knob and noise insulation, Golf
- Repairing gear lever and selector housing (through 10.06)
- Repairing gear lever and selector housing (from 11.06)
- Assembly overview - removing and installing selector cables
- Plastic relay lever
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox, Golf 2004 ?
- Transporting gearbox
- Checking gear oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Assembly overview - removing and installing cover for gearbox housing and 5th gear
- Assembly overview - removing and installing clutch housing
- Assembly overview - removing and installing input shaft, output shaft, differential, selector mechanism and selector forks
- Dismantling and assembling procedure
- Repairing gearbox housing and clutch housing
- Repairing selector unit
- Dismantling and assembling selector forks
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 6-speed manual gearbox 02S, four-wheel drive
- Technical data
- Clutch, control
- Repairing clutch mechanism, Golf
- Overview
- Assembly overview - pedal cluster
- Removing and installing over-centre spring, Golf
- Removing and installing clutch pedal, Golf
- Removing and installing mounting bracket, Golf
- Removing and installing master cylinder
- Removing and installing clutch position sender G476
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing slave cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Repairing clutch mechanism, Golf
- Gearbox mechanics,operation, construction,diff.
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Removing and installing gaiter with gear knob and noise insulation, Golf
- Repairing gear lever and selector housing (through 10.06)
- Repairing gear lever and selector housing (from 11.06)
- Assembly overview - removing and installing selector cables
- Plastic relay lever
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox, Golf
- Checking and topping up gear oil
- Removing and installing bevel box
- Checking or topping up gear oil in bevel box
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Removing and installing cover for gearbox housing and 5th and 6th gears
- Removing and installing gearbox housing and shift mechanism
- Removing and installing input shaft, output shaft, differential, selector forks and bevel box
- Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th gear
- Assembly sequence - Dismantling and assembling gearbox completely
- Repairing gearbox housing and clutch housing
- Repairing gearbox housing cover
- Repairing selector unit
- Dismantling and assembling selector forks
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Renewing flange shaft oil seals with gearbox and bevel box installed
- Renewing seal between gearbox and bevel box with gearbox installed
- Renewing seal between gearbox and bevel box with gearbox removed
- Renewing bevel box output flange oil seal (bevel box removed)
- Renewing polygon needle bearing and seal on right flange shaft
- Adjustment overview
- Differential
- 6-speed manual gearbox 02Q four-wheel drive
- Technical data
- Clutch, control
- Fault finding, power transmission
- Repairing clutch mechanism, Golf
- Overview - clutch actuation
- Assembly overview - pedal cluster
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Removing and installing mounting bracket, Golf
- Removing and installing master cylinder
- Removing and installing clutch position sender G476
- Assembly overview - hydraulic system
- Bleeding clutch system
- Repairing clutch release mechanism
- Clutch - vehicles with turbo diesel engine
- Clutch - vehicles with petrol engine
- Gearbox mechanics,operation, construction,diff.
- Fault finding, power transmission
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Removing and installing gaiter with gear knob and noise insulation, Golf
- Repairing gear lever and selector housing (through 10.06)
- Repairing gear lever and selector housing (from 11.06)
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Functional check
- Plastic relay lever
- Removing and installing gearbox, Golf
- Checking gear oil in gearbox
- Removing and installing bevel box, vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particle
- Removing and installing bevel box, vehicles with turbo diesel engine and particle filter
- Checking or topping up gear oil in bevel box
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Removing and installing gearbox housing and selector mechanism
- Removing and installing input shaft, output shafts, differential, bevel box and selector rods
- Assembly order, gearbox "without” retaining ring A for input shaft sealing cover
- Assembly order, gearbox "with” retaining ring A for input shaft sealing cover
- Repairing gearbox housing
- Repairing clutch housing
- Repairing selector mechanism, gearbox side
- Repairing selector forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Renewing flange shaft oil seals with gearbox and bevel box installed
- Renewing seal between gearbox and bevel box
- Renewing seal between gearbox and bevel box with bevel box removed
- Renewing bevel box output flange oil seal (bevel box removed)
- Renewing polygon needle bearing and seal on right flange shaft
- Adjustment overview
- Differential
- Propshaft and rear final drive
- Technical data
- Final drive, differential, differential lock
- Vehicle diagnosis, testing and information systemVAS 5051: Connecting and selecting function
- Propshaft - Golf 2004 ? up to calendar week 26/07
- Propshaft - Golf 2004 ? from calendar week 27/07 onwards
- Removing and installing rear final drive, Golf 2004 ?
- Renewing bonded rubber bush on rear final drive
- Renewing oil seals for flange shafts
- Renewing propshaft flange oil seal on rear final drive (final drive installed)
- Checking function of Haldex coupling "Haldex generation II"
- Electrical and electronic components and their locations
- Assembly overview - all-wheel drive control unitJ492, Golf 2004 ? and Passat 2006 ?
- Assembly overview - Haldex coupling
- Removing and installing Haldex coupling, Golf 2004 ? and Passat 2006 ?
- Assembly overview - dismantling and assembling Haldex coupling (generation II), Golf 2004 ? and Passat 2006 ?
- Removing and installing oil filter for Haldex coupling, Golf 2004 ? and Passat 2006 ?
- Checking oil level or topping up oil in rear final drive, Golf 2004 ? and Passat 2006 ?
- Checking oil level or topping up oil in Haldex coupling (generation II), Golf 2004 ? and Passat 2006 ?
- 7-speed dual clutch gearbox 0AM
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Selector mechanism
- Renewing gear oil
- Removing and installing gearbox, 1.4 l - 90 kW TSI engine
- Emergency release of selector lever
- Transporting gearbox
- Removing and installing selector lever handle
- Selector mechanism in vehicles up to 02.2009
- Selector mechanism from 03.2009 onwards
- Checking selector mechanism
- Safety note on mechatronic unit for dual clutch gearboxJ743
- Overview - mechatronic unit
- Removing mechatronic unit for dual clutch gearboxJ743; gearbox is installed
- Moving mechatronic unit for dual clutch gearboxJ743 into »removal position« by hand
- Installing mechatronic unit for dual clutch gearboxJ743
- View on selector forks; mechatronic unit is removed
- "Removing and installing gearbox" (erWin overview)
- Notes on different vehicles, different gearboxes
- Removing gearbox; Golf 2004 ?, Golf Plus 2005 ? and Cross Golf 1.4 l - 90, - 118 kW - TSI engine
- Removing gearbox; Golf 2004 and Golf Plus 2005 1.9 l - 77 kW - TDI engine
- Installing gearbox
- Torque settings »Gearbox to engine« and notes on assembly mounting
- Transporting gearbox and securing to assembly stand
- Gearbox,mechanics,gears,shafts,internal operation
- Notes on gearbox disassembly
- Dismantling gearbox
- Assembling gearbox
- Dismantling and assembling gearbox housing
- Dismantling and assembling clutch housing
- Dismantling and assembling outer input shaft
- Dismantling and assembling inner input shaft
- Dismantling and assembling output shaft 1 - overview
- Dismantling and assembling output shaft 2 - overview
- Dismantling and assembling output shaft 3 - overview
- Notes on gearbox adjustment
- Calculating shims for gearbox housing
- Removing and installing parking lock
- Final drive, differential, differential lock
- 6-speed dual clutch gearbox 02E
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Electrical and electronic components and their locations DSG
- Removing and installing gearbox oil cooler
- Removing and installing oil pump
- Renewing selector shaft lever oil seal with gearbox removed
- Emergency release of selector lever
- Removing and installing selector lever handle
- Selector mechanism up to 02.2009
- Checking selector mechanism
- Selector mechanism from 03.2009 onwards
- "Removing and installing gearbox"
- Removing gearbox, Golf 2004 ? with 1.9 l - 77 kW diesel engine, with 2.0 l - 100 and 103 kW diesel engine
- Removing gearbox, Golf 2004 ? with 125 kW - 2.0 l diesel engine
- Removing gearbox, Golf 2004 ? with 1.4 l - 103 kW and 125 kW petrol engine
- Removing gearbox, Golf 2004 ? with 147 kW - 2.0 l petrol engine
- Removing gearbox, Golf 2004 ?, with 3.2 l - V6 engine (R32 four-wheel drive)
- Installing gearbox
- Torque settings »gearbox to engine«
- Torque settings (ELSA)
- Torque settings and notes concerning engine mountings
- Torque settings and notes concerning engine mountings
- Torque settings and notes concerning engine mountings
- Torque settings (ELSA)
- Transporting gearbox and securing to assembly stand
- Removing and installing bevel box, Golf 2004 ? and Passat 2006 ?
- Oil and oil filter
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Overview - seals
- Renewing oil seal for left flange shaft - front and four-wheel drive
- Renewing oil seal for propshaft drive flange at bevel box
- Assembly overview - Flange shafts and seals on bevel box
- Checking and topping up gear oil in bevel box
- Checking function of Haldex coupling
- Propshaft and rear final drive
- 5-speed manual gearbox 02R Volkswagen R GmbH
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Propshaft and rear final drive Volkswagen R GmbH
- Technical data
- Final drive, differential, differential lock
- Electrical/electronic components and their locations
- Propshaft
- Removing and installing propshaft
- Removing and installing propshaft - Golf 2004 ?
- Removing and installing propshaft - Golf 2004 ?
- Removing and installing propshaft - Golf 2004 ?
- Removing and installing propshaft - Golf 2004 ?
- Removing and installing rear final drive
- Removing and installing rear final drive - Golf 2004 ?
- Removing and installing rear final drive - Golf 2004 ?
- Renewing bonded rubber bush on rear final drive
- Renewing bonded rubber bush on rear final drive - Golf
- Renewing bonded rubber bush on rear final drive - Golf
- Renewing oil seals for flange shafts (rear final drive installed)
- Checking function of Haldex coupling "Haldex generation II"
- Assembly overview - all-wheel drive control unitJ492 - Golf 2004 ? and Passat 2006 ?
- Removing and installing Haldex coupling - Golf 2004 ? and Passat 2006 ?
- Assembly overview - dismantling and assembling Haldex coupling (generation II) - Golf 2004 ? and Passat 2006 ?
- Checking oil level or topping up oil in rear final drive - Golf 2004 ? and Passat 2006 ?
- Checking oil level or topping up oil in Haldex coupling (generation II) - Golf 2004 ? and Passat 2006 ?
- 6-speed manual gearbox 02Q Volkswagen R GmbH
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Removing and installing over-centre spring
- Removing and installing clutch pedal - Golf 2004 ?
- Removing and installing mounting bracket - Golf 2004 ?
- Removing and installing master cylinder
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Bleeding clutch mechanism
- Removing and installing clutch position senderG476
- Bleeding clutch mechanism
- Repairing clutch mechanism
- Gearbox mechanics,operation, construction,diff.
- 6-speed dual clutch gearbox 02E Volkswagen R GmbH
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Electrical and electronic components of the dual clutch gearbox (DSG®) and their locations
- Electrical and electronic components and their locations
- Removing and installing mechatronic unit for dual clutch gearboxJ743 (gearbox installed)
- Removing and installing mechatronic unit for dual clutch gearboxJ743 (gearbox removed)
- Removing and installing gearbox input speed senderG182 and oil temperature sender in multi-plate clutchG509
- Removing and installing gearbox oil cooler
- Removing and installing oil pump
- Renewing seal on gearbox selector lever
- Emergency release of selector lever
- Removing and installing knob
- Selector mechanism up to 02.2009
- Selector mechanism from 03.2009 onwards
- Removing and installing gearbox
- General notes on removing and installing gearbox
- Removing gearbox, Golf 2004 ?, with 2.0 l engine (front-wheel drive)
- Removing gearbox, Golf 2004 ?, with 3.2 l V6 engine (all-wheel drive)
- Removing gearbox, Passat 2011 ? with 3.6 l V6 engine (all-wheel drive)
- Transporting gearbox and securing to assembly stand
- Installing gearbox
- Torque settings and note on engine mountings
- Removing and installing bevel box, Golf 2004 ? and Passat 2006 ? with V6 engine
- Removing and installing bevel box , Passat 2011 ? with 3.6 l V6 engine
- Oil and oil filter
- Electrical and electronic components of the dual clutch gearbox (DSG®) and their locations
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Overview - seals
- Renewing seals for flange shaft or stub shaft
- Renewing oil seal for left flange shaft - front and all-wheel drive
- Renewing seals for right flange shaft or stub shaft - front-wheel drive
- Renewing oil seal for right flange shaft - all-wheel drive
- Dismantling and assembling flange shaft
- Checking and topping up gear oil in bevel box
- Checking oil level in front bevel box - all-wheel drive
- Renewing oil seal for propshaft drive flange at bevel box
- Assembly overview - Flange shafts and seals on bevel box
- Checking function of Haldex coupling
- Propshaft and rear final drive
- 6-speed automatic gearbox 09G
- Power unit
- 6-cylinder injection engine
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Cylinder head
- Assembly overview - cylinder head
- Removing and installing cylinder head
- Assembly overview - cover
- Checking valve timing
- Removing and installing camshaft adjuster
- Removing and installing camshaft timing chain and intermediate shaft drive chain
- Removing and installing cylinder head cover
- Checking compression
- Valve gear
- Cylinder head
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - cooling system, engine side (vehicles with manual gearbox)
- Assembly overview - cooling system, engine side (vehicles with DSG®)
- Assembly overview - thermostat housing
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing fan support with fans
- Removing and installing radiator
- Checking continued coolant circulation pump
- Removing and installing coolant pump
- Removing and installing thermostat housing
- Removing and installing thermostat
- Removing and installing coolant pipe
- Checking cooling system for leaks
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel tank
- Repairing fuel supply
- Electronic power control (EPC)
- Activated charcoal filter system
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- General notes on the injection system
- Technical data
- Assembly overview - intake manifold
- Removing and installing throttle valve moduleJ338
- Removing and installing intake manifold
- Assembly overview - fuel rail
- Assembly overview - air filter
- Assembly overview - resonator with resonance air pipe
- Checking intake air preheating
- Checking components
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.6 l roller rocker finger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flanges and flywheel or drive plate
- Crankshaft
- Dismantling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Cylinder head
- Repairing valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system - engine side, engine codes BGU, BSE and BSF
- Assembly overview - parts of cooling system, engine side, engine codes CCSA, CMXA
- Assembly overview - parts of cooling system, body side (radiator with 2 radiator fans)
- Assembly overview - parts of cooling system, body side (radiator with one radiator fan)
- Coolant hose schematic diagram - engine codes BGU, BSE and BSF
- Coolant hose schematic diagram - engine codes CCSA, CMXA
- Draining and filling coolant
- Removing and installing coolant pump
- Removing and installing thermostat
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
- Checking cooling system for leaks
- Assembly overview - engine preheating (engine codes CCSA, CMXA)
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Fuel tank
- Repairing fuel supply
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Assembly overview - fuel filter with attachments
- Removing and installing fuel filter
- Checking fuel pump
- Checking function and voltage supply
- Checking fuel delivery rate, engine code BGU
- Checking fuel delivery rate, engine codes BSE, BSF, CCSA, CMXA
- Checking current consumption
- Checking fuel pump non-return valve, engine code BGU
- Checking non-return valve of fuel pump, engine codes BSE, BSF, CCSA, CMXA
- Bleeding fuel system
- Electronic power control (EPC)
- Activated charcoal filter system
- Mixture preparation system, electronic inj.,Gas
- Injection system
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold with attachments, engine code BGU
- Assembly overview - intake manifold with attachments, engine codes BSE, BSF, CCSA, CMXA
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter with attachments
- Removing and installing intake manifold lower part, engine code BGU
- Removing and installing intake manifold lower part, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing complete intake manifold, engine code BGU
- Removing and installing complete intake manifold, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing injectors
- Checking components
- Engine control unit J623 (Golf 2004 ?)
- Injection system
- Exhaust system
- Exhaust system, engine codes BGU, BSE, BSF, CCSA
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system stress free
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
- Exhaust system, engine code CMXA
- Assembly overview - exhaust manifold and front exhaust pipe with catalytic converter
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system free of stress
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
- Exhaust gas recirculation system, engine code BGU
- Secondary air system, engine codes BGU, BSE, CCSA, CMXA
- Exhaust system, engine codes BGU, BSE, BSF, CCSA
- Ignition system, glow plug system
- 4-cylinder diesel engine (2.0 l engine, 4 valve)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flange and flywheel
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Removing and installing engine speed senderG28
- Renewing crankshaft sealing flange - flywheel end
- Pistons and conrods
- Crankshaft
- Engine cylinder head, valve gear
- Cylinder head
- Valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, Touran)
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing fan support with fans
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Rules for cleanliness
- Parts of fuel supply system (Golf, Golf Plus)
- Accelerator mechanism
- Tandem pump
- Exhaust turbocharger, G-charger
- Fuel preparation system Diesel injection
- Diesel direct injection system
- Safety precautions
- Rules for cleanliness
- Assembly overview - intake manifold with attachments
- Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
- Removing and installing pre-wired wiring harness for unit injectors and glow plugs
- Assembly overview - unit injector
- Removing and installing unit injector
- Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR)
- Removing and installing O-rings for unit injector
- Assembly overview - air filter
- Engine control unit (Golf)
- Diesel direct injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.4 l engine)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview - aluminium cylinder block
- Renewing crankshaft oil seal - pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Renewing crankshaft sealing flange - flywheel end
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Assembly overview - parts of cooling system (radiator with two fans), body side
- Assembly overview - parts of cooling system (radiator with one fan), body side
- Assembly overview - parts of cooling system - thermostat side
- Assembly overview - parts of cooling system - coolant pump side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Removing and installing coolant pump
- Checking cooling system for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Parts of fuel supply system
- Assembly overview - dismantling and assembling fuel tank with add-on parts and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Emptying fuel tank
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Removing and installing fuel tank
- Assembly overview - fuel filter with add-on parts (engine code BCA)
- Removing and installing fuel filter
- Crash fuel shut-off
- Checking fuel pump (vehicles ? model year 2006)
- Checking fuel pump (vehicles model year 2006 ?)
- Bleeding fuel system
- Electronic power control (EPC)
- Activated charcoal filter system
- Parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Injection system
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Assembly overview - intake manifold (engine code BCA)
- Assembly overview - intake manifold (engine codes BUD and CGGA)
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter housing (engine code BCA)
- Assembly overview - air filter housing (engine codes BUD and CGGA)
- Removing and installing air filter housing (engine codes BUD and CGGA)
- Cleaning throttle valve moduleJ338
- Removing and installing injectors
- Checking components
- Engine control unitJ623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.4 and 1.6 l direct injection)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Sealing flange and flywheel or drive plate
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Characteristics of the sealing flange and the assembly deviceT10017 and T10134
- Renewing crankshaft sealing flange - flywheel end (assembly toolT10134)
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Renewing crankshaft sealing flange - flywheel end (assembly toolT10017)
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
- Dismantling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Cylinder head
- Assembly overview
- Checking valve timing
- Adjusting valve timing
- Removing and installing timing chain and chain drive for oil pump (engine codes BAG, BLP, BLF)
- Removing and installing timing chain and chain drive for oil pump (engine codes BKG, BLN)
- Removing and installing camshaft housing
- Removing and installing cylinder head
- Checking compression
- Repairing valve gear
- Cylinder head
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side, radiator with two fans (Golf, Golf Plus)
- Assembly overview - parts of cooling system, body side, radiator with one fan (Golf, Golf Plus)
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Removing and installing coolant pump
- Checking cooling system for leaks
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Mixture preparation system, electronic inj.,Gas
- Injection system
- General notes on injection
- Technical data
- Assembly overview - air filter
- Removing and installing air filter
- Assembly overview - intake manifold (engine codes BAG, BKG)
- Assembly overview - intake manifold (engine codes BLF, BLN, BLP)
- Assembly overview - fuel rail with injectors
- Cleaning throttle valve moduleJ338
- Removing and installing high-pressure pump (engine codes BAG, BKG)
- Removing and installing high-pressure pump (engine codes BLF, BLN, BLP)
- Removing and installing injectors
- Checking components
- Engine control unitJ623 (Golf, Eos)
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder diesel engine (1.9 l engine)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flange and flywheel
- Assembly overview - sealing flanges and flywheel
- Removing and installing dual-mass flywheel
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange - pulley end
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Removing and installing engine speed senderG28
- Crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Parts of cooling system, body side (radiator with two radiator fans)
- Removing and installing fan support with fans (Golf, Golf Plus, Touran)
- Parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator (Golf, Golf Plus, Touran)
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking engine oil cooler for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Rules for cleanliness
- Parts of fuel supply system (Golf, Golf Plus)
- Accelerator mechanism
- Tandem pump
- Exhaust turbocharger, G-charger
- Fuel preparation system Diesel injection
- Diesel direct injection system
- Safety precautions
- Rules for cleanliness
- Removing and installing pre-wired wiring harness for unit injectors and glow plugs
- Assembly overview - unit injector
- Removing and installing unit injector
- Adjusting non-contact gap of unit injectors
- Removing and installing O-rings for unit injector
- Assembly overview - intake manifold
- Cleaning the intake manifold flap support, Engine code BLS and BXJ
- Assembly overview - air filter
- Engine control unit
- Diesel direct injection system
- Exhaust system
- Exhaust system
- Assembly overview - front exhaust pipe with catalytic converter
- Assembly overview - front exhaust pipe with particulate filter
- Assembly overview - silencer with mountings (vehicles with front wheel drive)
- Assembly overview - silencer with mountings (vehicles with four-wheel drive)
- Aligning exhaust system free of stress
- Exhaust gas recirculation system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (2.0 l engine, turbocharger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Cylinder head
- Valve gear
- Engine lubrication
- Parts of lubrication system
- Engine oil
- Assembly overview - parts of lubrication system
- Draining oil filter housing
- Removing and installing sump
- Removing and installing oil pump with balancer shaft gear assembly
- Removing and installing oil filter bracket
- Removing and installing oil pressure switchF1
- Checking oil pressure and oil pressure switch (single pin oil pressure switch)
- Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
- Parts of lubrication system
- Engine cooling
- Parts of cooling system
- Assembly overview - parts of cooling system, engine side
- Assembly overview - coolant circulation pumpV50 (vehicles with bypass thermostat)
- Assembly overview - coolant circulation pumpV50 (vehicles with no bypass thermostat)
- Assembly overview - parts of cooling system, body side
- Coolant hose schematic diagram (vehicles to 06.2005)
- Coolant hose schematic diagram (vehicles from 06.2005)
- Bypass thermostat
- Draining and filling coolant
- Removing and installing coolant pump
- Removing and installing coolant pipes
- Removing and installing coolant thermostat housing with thermostat
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator, Golf and Eos
- Checking cooling system for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Rules for cleanliness
- Fuel tank, Golf
- Repairing fuel supply system, Golf, Eos
- Electronic power control (EPC)
- Activated charcoal filter system (Golf, Eos)
- Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
- Checking fuel tank breather (engine codes AXX, BWA)
- Schematic diagram of activated charcoal filter system (engine code BPY)
- Assembly overview - activated charcoal filter system (Golf with engine code BPY)
- Removing and installing activated charcoal filter (engine code BPY)
- Removing and installing fuel system diagnostic pumpV144 (Golf with engine code BPY)
- Checking fuel system for leaks
- Exhaust turbocharger, G-charger
- Turbocharger
- Charge air system
- Mixture preparation system, electronic inj.,Gas
- Injection system
- General notes on injection
- Technical data
- Assembly overview - engine cover/air filter
- Removing and installing engine cover/air filter
- Removing and installing air filter element
- Assembly overview - intake manifold
- Removing and installing intake manifold
- Removing and installing intake manifold flap motorV157 and intake manifold flap potentiometerG336
- Assembly overview - fuel rail (vehicles up to 05.2006)
- Assembly overview - fuel rail (vehicles from 05.2006)
- Removing and installing fuel rail
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump
- Removing and installing high-pressure pump
- Removing and installing fuel pressure senderG247
- Checking fuel pressure senderG247
- Removing and installing injectors
- Renewing Teflon seal on injector
- Checking components
- Engine control unitJ623, Golf, Eos
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flange and flywheel
- Assembly overview - sealing flange and flywheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembly tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Pressing sender wheel on fully
- Removing and installing engine speed sender G28
- Crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Parts of cooling system, body side
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing fan support with fans
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Fuel tank, vehicles with front wheel drive
- Fuel tank, vehicles with four-wheel drive
- Repairing fuel supply system
- Exhaust turbocharger, G-charger
- Charge air system with turbocharger
- Safety precautions
- Rules for cleanliness
- Installing hose connections with connector couplings
- Assembly overview - turbocharger
- Removing and installing exhaust gas temperature sender 1 G235
- Removing and installing turbocharger
- Assembly overview - charge air cooling
- Checking charge air system for leaks
- Charge air system with turbocharger
- Fuel preparation system Diesel injection
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (2.0 l engine, direct injection)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block attachments, engine code AXW
- Cylinder block attachments, engine codes BLX, BLY, BLR, BVX, BVY, BVZ
- Sealing flange and flywheel or drive plate
- Crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Cylinder head
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
- Removing and installing cylinder head
- Removing and installing toothed belt, engine code AXW
- Removing and installing toothed belt, Golf without split toothed belt guard (BLR, BLX, BLY, BVX, BVY, BVZ)
- Removing and installing toothed belt, Golf with split toothed belt guard (BVX, BVY, BVZ)
- Checking compression
- Valve gear
- Cylinder head
- Engine lubrication
- Parts of lubrication system
- Engine oil
- Assembly overview - parts of lubrication system
- Draining oil filter housing
- Removing and installing sump, engine codes AXW, BLX, BLY, BLR
- Removing and installing sump, engine codes BVX, BVY, BVZ
- Removing and installing oil pump with balancer shaft gear assembly
- Removing and installing oil filter bracket
- Checking oil pressure and oil pressure switch
- Parts of lubrication system
- Engine cooling
- Parts of cooling system
- Assembly overview - parts of cooling system, engine side, engine codes AXW, BLX, BLY, BLR
- Assembly overview - parts of cooling system, engine side, engine codes BVX, BVY, BVZ
- Assembly overview - parts of cooling system, body side
- Coolant hose schematic diagram, engine codes AXW, BLX, BLY, BLR
- Coolant hose schematic diagram, engine codes BVX, BVY, BVZ
- Draining and filling coolant
- Removing and installing coolant pump
- Removing and installing coolant pipe
- Mapped cooling, engine codes AXW, BLX, BLY, BLR
- Removing and installing coolant distributor housing with thermostat, engine codes BVX, BVY, BVZ
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
- Checking cooling system for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Fuel tank (Golf with front-wheel drive)
- Fuel tank (Golf with four-wheel drive)
- Repairing fuel supply system (Golf)
- Electronic power control (EPC)
- Activated charcoal filter system (Golf)
- Mixture preparation system, electronic inj.,Gas
- Injection system
- General notes on injection
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold
- Assembly overview - fuel rail with intake manifold flap motor V157 , engine code AXW
- Assembly overview - fuel rail with intake manifold flap motor V157 , engine codes BLR, BLX, BLY
- Assembly overview - fuel rail with intake manifold flap motor V157 , engine codes BVX, BVY, BVZ
- Assembly overview - air filter
- Removing and installing intake manifold
- Removing and installing fuel rail with intake manifold flaps
- Assembly overview - high-pressure pump, engine code AXW
- Assembly overview - high-pressure pump, engine codes BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing high-pressure pump
- Removing and installing fuel pressure sender G247
- Checking fuel pressure sender G247
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning throttle valve module J338
- Engine control unit J623 (Golf)
- Checking components
- Injection system
- Exhaust system
- Parts of exhaust system
- Assembly overview - exhaust manifold with catalytic converter, engine codes AXW, BLX, BLR, BVX
- Assembly overview - exhaust manifold with catalytic converter, engine code BVY
- Assembly overview - exhaust manifold, engine codes BLY, BVZ
- Removing and installing exhaust manifold
- Assembly overview - exhaust system, engine codes BLR, BVY
- Assembly overview - exhaust system, engine codes AXW, BLX
- Assembly overview - exhaust system, engine codes BLY, BVZ
- Assembly overview - exhaust system, Golf with four-wheel drive
- Removing and installing front exhaust pipe with catalytic converter
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Exhaust gas recirculation system, engine codes AXW, BLX, BLR, BVX, BVY
- Parts of exhaust system
- Ignition system, glow plug system
- 4-cylinder diesel engine (2.0 l engine, 2-valve, SDI)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flange and flywheel
- Assembly overview - sealing flange and flywheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembling tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Removing and installing engine speed sender G28
- Crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Parts of cooling system - body side
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing fan support with fans
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
- Parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Assembly overview - fuel tank
- Assembly overview - fuel filter
- Removing and installing fuel cooler
- Emptying fuel tank
- Removing and installing fuel tank
- Removing and installing fuel delivery unit
- Removing and installing fuel sender
- Checking fuel pump
- Checking tandem pump
- Removing and installing tandem pump
- Assembly overview - accelerator mechanism
- Removing and installing parts of fuel supply system
- Fuel preparation system Diesel injection
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine, 2005?
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system - engine side
- Assembly overview - parts of cooling system - body side
- Draining and filling coolant
- Removing and installing coolant pump
- Removing and installing thermostat
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
- Checking cooling system for leaks
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Dismantling and assembling intake manifold - Upper part
- Dismantling and assembling intake manifold - lower part
- Fuel rail
- Dismantling and assembling air cleaner
- Removing and installing intake manifold
- Removing and installing fuel rail with intake manifold flaps
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning throttle valve module J338
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.4 l direct injection engine, turbocharger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flanges and flywheel or drive plate
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing crankshaft pulley
- Renewing crankshaft sealing flange - flywheel end
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft
- Dismantling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177 (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)
- Checking cooling system for leaks
- Removing and installing radiator (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Separating push-on couplings
- Fuel tank (Golf, Golf Plus, Golf Cabriolet, Scirocco)
- Repairing fuel supply system (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)
- Repairing electronic power control (EPC)
- Activated charcoal filter system (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Injection system
- Assembly overview - parts l and II, intake manifold
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Removing and installing intake manifold
- Assembly overview - high-pressure pump
- Checking fuel pressure senderG247
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
- Engine control unitJ623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.8 and 2.0 l engine, chain drive)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block (pulley end)
- Cylinder block on gearbox side
- Crankshaft
- Engine cylinder head, valve gear
- Chain drive
- Assembly overview - timing chain covers
- Removing and installing inlet camshaft control valve 1N205
- Removing and installing upper timing chain cover
- Removing and installing lower timing chain cover (Golf, Eos, Scirocco)
- Renewing oil seal for vibration damper
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Assembly overview - balancer shaft timing chain
- Removing and installing balancer shaft module
- Removing and installing inlet side balancer shaft
- Removing and installing exhaust side balancer shaft
- Checking valve timing
- Cylinder head
- Valve gear
- Chain drive
- Engine lubrication
- Sump and oil pump
- Assembly overview - sump, oil pump
- Removing and installing coarse oil separator
- Removing and installing lower part of sump
- Removing and installing oil pump
- Removing and installing upper part of sump
- Removing and installing oil pressure control valveN428 (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)
- Engine oil
- Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)
- Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)
- Sump and oil pump
- Engine cooling
- Cooling system
- Coolant pump, thermostat, coolant pipes
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing thermostat
- Removing and installing coolant temperature senderG62
- Assembly overview - coolant pipes
- Removing and installing coolant pipes (front)
- Removing and installing small coolant pipe
- Continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
- Radiator and radiator fans
- Fuel supply, gas operation
- Safety precautions
- Rules for cleanliness
- Fuel tank (Golf, Scirocco)
- Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)
- Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
- Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)
- Emptying fuel tank (engine codes CBFA, CCTA, CCTB)
- Removing and installing fuel tank
- Repairing fuel supply system (Golf, Eos, Scirocco)
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
- Checking fuel pumpG6
- Checking function and voltage supply
- Checking fuel pressure
- Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking holding pressure
- Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)
- Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking current draw
- Electronic power control (EPC)
- Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA)
- Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
- Exhaust turbocharger, G-charger
- Turbocharger
- Charge air system
- Mixture preparation system, electronic inj.,Gas
- Safety precautions and rules for cleanliness
- Injection system
- Technical data
- Overview of fitting locations
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Assembly overview - intake manifold
- Fuel rail - exploded view
- Removing and installing intake manifold with fuel rail
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning injectors
- Removing and installing fuel pressure senderG247
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump with fuel pressure regulating valveN276
- Removing and installing high-pressure pump
- Checking components
- Engine control unitJ623 (Golf, Eos to 11/08)
- Exhaust system
- Exhaust system (Golf, Eos, Scirocco)
- Assembly overview - exhaust system (engine code CAWB)
- Assembly overview - exhaust system (Golf 2004 ?, Eos, Scirocco, engine codes CCTA, CCZA, CCZB)
- Assembly overview - exhaust system (engine code CBFA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Removing and installing catalytic converters with front exhaust pipe
- Checking exhaust system for leaks
- Secondary air system - engine code CBFA
- Exhaust system (Golf, Eos, Scirocco)
- Ignition system, glow plug system
- 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Removing and installing sealing flanges and flywheel or drive plate
- Assembly overview
- Removing and installing engine speed senderG28
- Removing and installing crankshaft seal on belt pulley end
- Removing and installing crankshaft pulley
- Removing and installing crankshaft sealing flange on flywheel end
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft
- Dismantling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side (engine codes BLG, BMY)
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram (engine codes BLG, BMY)
- Draining and filling coolant
- Checking cooling system for leaks
- Removing and installing radiator fanV7 and radiator fan 2V177 (engine codes BLG, BMY)
- Removing and installing radiator (engine codes BLG, BMY)
- Removing and installing coolant pump
- Removing and installing coolant pump pulley
- Removing and installing coolant circulation pumpV50
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Safety precautions
- Fuel tank
- Removing and installing parts of fuel supply system
- Repairing electronic power control (EPC)
- Activated charcoal filter system
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Injection system
- Assembly overview - parts l and II, intake manifold
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Assembly overview - fuel rail with injectors
- Checking vacuum reservoir for leaks
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing regulating flap control unitJ808 and throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump
- Checking fuel pressure in high-pressure section
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
- Engine control unitJ623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH
- Engine cooling
- Fuel supply, gas operation
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- 6-cylinder injection engine Volkswagen R GmbH
- Fuel supply, gas operation
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Fuel supply system - Petrol engines
- Technical data
- Fuel supply, gas operation
- Fuel tank (front-wheel drive)
- Fuel delivery unit, fuel gauge sender
- Detaching push-on connectors
- Fuel filter
- Activated charcoal filter system
- Accelerator mechanism
- Fuel pump
- Checking fuel pump
- Checking function and voltage supply (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking function and voltage supply (engine codes CBTA, CBUA, BGP, BGQ)
- Checking fuel pressure (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking holding pressure (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking fuel delivery rate (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking fuel delivery rate (engine codes CBTA, CBUA, BGP, BGQ)
- Checking current draw
- Checking fuel pressure regulator and holding pressure (engine codes CBTA, CBUA, BGP, BGQ)
- Checking fuel pump non-return valve (engine codes CBTA, CBUA, BGP, BGQ)
- Checking fuel pump
- 6-cylinder injection engine
- Heating, ventilation, air conditioning system
- Heating, air conditioning
- Heating
- Repairing heating system
- Passenger compartment heating
- Removing and installing heater unit baffle plate
- Removing fresh air blowerV2
- Removing and installing fresh air blower series resistor with overheating fuseN24
- Removing and installing dust and pollen filter
- Removing vents
- Removing centre vents
- Installing
- Removing right or left vent
- Removing
- Installing
- Removing and installing right and left rear footwell air ducts
- Installing
- Removing right footwell vent
- Installing
- Removing left footwell vent
- Installing
- Removing and installing controls for heated and fresh air
- Connectors on controls for heated and fresh air
- Removing and installing flexible shaft for air distribution
- Removing and installing Bowden cable for temperature flap
- Removing and installing fresh air and air recirculation flap control motorV154
- Removing and installing heat exchanger
- Removing and installing auxiliary air heater elementZ35 on vehicles up to 1K-7P015628 and 1K-7B084800
- Testing, removing and installing auxiliary air heater elementZ35 on vehicles from 1K-7P015629 und 1K-7B084801
- Checking ventilation
- Removing and installing inlet grilles
- Removing and installing heater unit
- Dismantling and assembling heater unit
- Repairing heating system
- Air conditioner
- Notes on repair work to vehicles with air conditioning and on handling refrigerant
- Air conditioning system with manual controls "Climatic"
- Air conditioning and heating - passenger compartment
- Removing and installing heating and air conditioning controls, "Climatic" with air conditioning system control unitJ30
- Connectors on controls for heating and air conditioning "Climatic"
- Removing and installing flexible shaft for air distribution
- Checking condensation water drainage hose on heater and air conditioner unit
- Removing and installing air recirculation flap control motorV113
- Removing and installing temperature flap control motorV68
- Removing and installing footwell vent temperature senderG192
- Removing and installing centre vent temperature senderG191
- Ambient temperature sensorG17
- Air conditioning system with automatic regulation "Climatronic"
- Procedure for checking and adjusting components
- Function of operating and display unit for Climatronic air conditioning systemE87
- Removing and installing operating and display unit for Climatronic air conditioning systemE87 with Climatronic control unitJ255
- Connectors on Climatronic control unitJ255
- Climatronic - passenger compartment
- Indirect ventilation
- Assembly overview - evaporator housing
- Removing and installing fresh air blower control unitJ126
- Removing and installing left footwell vent temperature senderG261
- Removing and installing right footwell vent temperature senderG262
- Removing and installing evaporator temperature sensorG308 or evaporator output temperature senderG263
- Ambient temperature sensorG17
- Function of air quality sensorG238
- Removing and installing air quality sensorG238
- Removing left vent temperature senderG150 and right vent temperature senderG151
- Removing sunlight penetration photosensorG107 or sunlight penetration photosensor 2G134
- Checking condensation water drainage hose on heater and air conditioner unit
- Renewing control motors for air conditioning regulation
- Removing and installing air recirculation flap control motorV113
- Removing and installing air flow flap control motorV71 for vehicles up to calendar week 17/2007
- Removing and installing control motor for fresh air and air recirculation flap and air flow flapV425 for vehicles from calendar
- Removing and installing setting unit for fresh air and air recirculation flap and air flow flap
- Removing and installing defroster flap control motorV107
- Removing and installing left temperature flap control motorV158
- Removing and installing right temperature flap control motorV159
- Removing and installing central flap control motorV70
- Removing and installing ancillary bracket for air conditioner compressor
- Engine codes: AZV, BDK, BJB, BKC, BKD, BLS, BMM, BMN, BRM, BRU, BVB, BXE, BXF and BXJ
- Engine codes: BCA, BUD
- Engine codes: BLG, BMY
- Engine codes: BAG, BKG, BLF, BLN, BLP and CAXA
- Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA
- Engine codes: BGP, BGQ, BTK, CBTA and CBUA
- Engine codes: BUB, CBRA
- Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics
- Testing equipment and tools
- Removing and installing heater and air conditioning unit
- Dismantling and assembling heater and air conditioner unit "Climatic"
- Dismantling and assembling heater and air conditioner unit "Climatronic"
- Renewing refrigerant circuit components
- Removing and installing high-pressure senderG65
- Removing and installing receiver with dryer
- Removing and installing receiver with drier, Modine
- Removing and installing air conditioner compressor
- Assembly overview - poly V-belt pulley (air conditioner compressor from "Denso")
- Removing and installing poly V-belt pulley (air conditioner compressor from "Denso")
- Checking high-pressure safety valve on air conditioner compressor
- Expansion valve, function and removing
- Removing and installing evaporator
- Removing and installing condenser
- Notes on installing air conditioner compressor
- Removing evacuating and charging valve, low-pressure side and high-pressure side
- Capacities
- Heating
- Auxiliary heater
- Aux. heater/heater booster
- Auxiliary heater Thermo Top V
- Notes on general repairs on vehicles with auxiliary heaters
- Rules for cleanliness when working on the auxiliary heater and the fuel system
- Repairing auxiliary heater Thermo Top V
- Removing and installing auxiliary heater Thermo Top V
- Components of auxiliary heater Thermo Top V
- Removing auxiliary heater Thermo Top V
- Installing auxiliary heater Thermo Top V
- Removing ancillaries of auxiliary heater Thermo Top V
- Dismantling and assembling auxiliary heater Thermo Top V
- Inner components of auxiliary heater
- Removing and installing heater coolant shut-off valveN279
- Bleeding coolant circuit
- Connecting auxiliary heater Thermo Top V to coolant circuit
- Connection diagram for coolant hoses in vehicles with auxiliary heater, engine codes BKC, BJB, BLS, BRV
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code BMM
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BLG, BMY
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AXX, BPY, BWA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AZV, BKD, BMN
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BAG, BKG, BLF, BLN, BLP
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BGU, BSE, BSF, CCSA, CMXA, CHGA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code BKD
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AXW, BLX, BLY, BLR
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BUB, CBRA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BVX, BVY, BVZ
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CAVB, CAVC, CAVD
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code CAXA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CBAA, CBBB, CBAB, CBDC, CJAA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BXE, BXF, BXJ
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CAWB, CBFA, CCTA, CCZB, CDAA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CAYB, CAYC
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CBZB, CBZA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CFFA, CFFB, CFGB
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BCA, BUD, CGGA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BGB, BGQ, CBTA, CBUA
- Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BYD, CDCA, CDLF
- Fuel supply for auxiliary heater Thermo Top V
- Regulation of auxiliary heater Thermo Top V
- Electric engine preheater, 230 V or 115 V
- Rules for cleanliness when working on engine preheater
- Removing and installing connector for mains plug
- Checking connector
- Testing safety switch (optional)
- Removing and installing engine preheater
- Connecting engine preheater into cooling circuit
- Aux. heater/heater booster
- Heating, air conditioning