Running gear
- Brake systems
- Technical data
- ABS, ADR, TCS, EDL, ESP
- General information on the antilock braking system (ABS)
- Information on ABS system repair
- Connect the Diagnosis, Measurement and Information System VAS 5051A /52 and select the functions
- Electrical/electronic components and installing locations
- Fault indication via control lamps
- Hydraulic unit, servo brake/brake cylinder - assembly overview
- ABS system components on the front and rear axles - remove and install
- ESP system components - assemble and disassemble
- Brake, brake mechanics
- Front wheel brake - repair
- Repair front brakes, FS II disc brake cylinder
- Brake pads, FS II brake caliper - remove and install
- FS II brake caliper - remove and install
- Front wheel brake - FS II brake caliper - repair
- Brake pads, FS III disc brake cylinder - remove and install
- FS III brake caliper - remove and install
- Front wheel brake - C 54-ll brake caliper - repair
- Remove and install brake pads, C 54-ll disc brake cylinder
- C 54 II brake caliper - remove and install
- Brake disc with visual check - check
- Rear wheel drum brake - repair
- Rear wheel disc brake - repair
- Handbrake - assembly overview
- Brake pedal - assembly overview
- Front wheel brake - repair
- Brakes, hydraulics, regulator, servo
- Front brake caliper, FS II brake caliper - repair
- Front brake caliper, C54-ll brake caliper - repair
- Rear brake caliper - repair
- Braking power adjustment - assembly overview
- Bleed the brake system
- Assembly overview: Brake cylinder/servo brake
- Brake cylinder - remove and install
- Servo brake - remove and install
- Running gear, axles, steering
- Technical data
- Front suspension, drive shafts
- Assessment of crashed vehicles
- Front suspension - repair
- I - Auxiliary frame (sub-frame) , anti-roll bar, wishbones
- repair
- Auxiliary frame (sub-frame), anti-roll bar, wishbones, - general overview of assembly
- Thread in longitudinal member - repair
- Swivel guide - check
- Swivel guide - remove and install
- Swivel guides - installation position
- Wishbone (transversal) - remove and install
- Auxiliary frame console - remove and install
- Rubber support bearing for the console - replace
- Auxiliary frame (sub-frame) - remove and install
- Auxiliary frame (sub-frame) - position
- Sway bar - remove and install
- II - Wheel roller bearings - repair
- III - Front suspension column - repair
- Constant velocity drive semi-shaft - remove and install
- IV - Constant velocity drive semi-shaft - repair
- Rear suspension, drive shaft
- Rear suspension - repairing
- Rear suspension (drum brake) - general overview of assembly
- Rear suspension (disc brake) - general overview of assembly
- Lift the rear axle in the unloaded position
- Rear axle - remove and install
- Metal-rubber bearing - remove and install
- Spring - remove and install
- Shock absorbers - assembly overview
- Shock absorber - remove and install
- Wheel bearings for drum brakes - repair
- Rear suspension - repairing
- Wheels, tyres. axle align
- Wheel screws
- Vehicle alignment
- General Remarks
- Checking conditions:
- Preparation for measurement
- Vehicle identification tag
- Sequence for vehicle alignment
- Nominal values for vehicle alignment
- Vehicles in "zero" transverse tilting position
- Camber on front axle - adjust
- Camber on rear axle - adjust
- Convergence on rear axle - adjust
- Convergence on front axle - adjust
- Left and right-hand steering - check
- Steering
- Steering wheel
- Fixed steering column - repair
- Adjustable steering column - repair
- Power steering box - repair
- Hydraulic pump, compensation reservoir, hydraulic pipes (power
steering)
- Hydraulic pump with hydraulic tubes - assembly overview
- Hydraulic pump installed on the lower part - assembly overview
- Hydraulic pump installed on the lower part - remove and install
- Hydraulic pump installed on the upper part - assembly overview
- Hydraulic pump installed on the upper part - remove and install
- Hydraulic pump operating pressure - check
- Power steering system oil - replenish
- Electrohydraulic steering - repair
- Electrohydraulic steering (JTEKT) - assembly overview
- Electrohydraulic steering (TRW) - assembly overview
- Electrohydraulic steering box - remove and install
- Electrohydraulic steering boxG250 - remove and install
- Electrohydraulic steering box (JTEKT) - disassemble and assemble
- Electrohydraulic steering box (TRW) - disassemble and assemble
- Steering bar - remove and install
- Left steering bar length - check and adjust
- Clearance, fastening and protective bellows from the steering yoke tips - check
- Correspondence of the steering yoke terminals
- Central rack position - determine
- Motor/pump set (Electrohydraulic steering) - repair
- Wheels, rim and tyre specifications
- Technical data
- General notes on rims and tyres (vehicles and passengers)
- Curiosities about rims and tires (passenger vehicles)
- Wear/tyre mileage
- Rolling noises coming from the tyres
- Drive instability due to rim/tyre
- Causes of drive instability
- Wheel balancing.
- Perform a test drive before performing the wheel balancing.
- Wheel balancing with the static balancing machine.
- Radial and axial deviation of concentricity of rim/tyre assembly
- Inspect the radial and axial deviations of the rim/tyre assembly with the Tyre gaugeV.A.G 1435
- Inspect the radial and axial deviations of rim concentricity
- Positioning of the tyre in relation to the rim
- Tyre deformation
- The vehicle deviates to one side
- Damages on the tyres
- General recommendations
- Structure of a radial tyre
- Damages caused by crashes
- Damages due to cut.
- Damages caused by strange bodies
- Loss of air from the tyres
- Air pressure
- Damages to the tyres due to insufficient air pressure
- Rise of temperature in tyres with insufficient air pressure
- Damages to the tyres due to assembly failure (assembly damages)
- Useful notes related to tyres and wheels
- Technical data
- Body
- General body repairs, exterior
- Body front
- Front panel
- Body front|Wing
- Lower noise insulation in the engine compartment
- Engine compartment partition panel
- Bonnet, flaps, cab, central locking
- Bonnet, flaps, cab, central locking|Bonnet
- Bonnet, flaps, cab, central locking|Tools
- Front bonnet - assembly overview
- Bonnet - remove and install
- Front bonnet shock absorber (? 2006) - remove and install
- Front bonnet supporting rod (2007 ?) - remove and install
- Bonnet - adjust
- Front bonnet latch operating cable - remove and install
- Operating lever - remove and install
- Front bonnet latch - Assembly overview
- Front bonnet latch - remove and install
- Rear door - Hatch
- Rear door - Hatch|Tools
- Assembly overview
- Rear door shock absorber - remove and install
- Rear door shock absorber - make useless for discarding
- Rear door - adjust
- Rear door lock - remove and install
- Rear door latch cylinder - assembly overview
- Rear door latch cylinder - disassemble and assemble
- Rear door lock cylinder (central locking) - assembly overview
- Rear door latch cylinder - disassemble and assemble
- Disassemble
- Assemble
- Rear door - Sedan
- Rear door - Assembly overview
- Rear door shock absorber - remove
- Rear door - adjust
- Cylinder housing of the lock with symbol (without central locking) - remove and install
- Rear door lock (without central locking) - remove and install
- Rear door lock (with central locking) - remove and install
- Cylinder housing of the lock with symbol (with central locking) - remove and install
- Rear door latch activation handle - assembly overview
- Rear door latch activation handle (without central locking) - remove and install
- Rear door latch activation handle (with central locking) - remove and install
- Rear door latch cylinder - assembly overview
- Rear door latch cylinder - disassemble and assemble
- Fuel reservoir nozzle compartment and lid set
- Bonnet, flaps, cab, central locking|Bonnet
- Front door, central locking
- Front door
- Front door|Tools
- Assembly overview
- Door - remove and install
- Front door lock operating cable - remove and install
- Door - adjust
- Door buffer - adjust
- External door handle and lock - assembly overview
- Latch cylinder - remove and install
- External door handle - remove and install
- Lock - remove and install
- Lock button (locking rod) - remove and install
- Front door packings - assembly overview
- Internal front door packing - remove and install
- External front door packing - remove and install
- Central locking
- Front door
- Rear door,sliding door,wing doors,central locking
- Rear door
- Rear door|Tools
- Assembly overview
- Rear passenger door (sedan) - assembly overview
- Door - remove and install
- Rear passenger door lock operating cable - remove and install
- Door - adjust
- External door handle and lock - assembly overview
- External door handle - remove and install
- Door latch - remove and install
- Rear door packings - assembly overview
- Internal rear door packing - remove and install
- External rear door packing - remove and install
- Rear door
- Sliding roof
- Sliding / tilting sunroof
- Operation
- Sliding / tilting roof with glass pane - assembly overview
- Sliding / tilting sunroof glass pane - remove and install
- Glass pane for sliding / tilting sunroof - height adjustment
- Cover packing - adjust
- Cover packing - replace
- Air deflector - remove
- Sun protective coating - remove and install
- Sliding sunroof movement control unit J245 - remove
- Sunroof sliding adjustment E139 - remove
- Sliding sunroof drive motor V1 - remove
- Sliding sunroof drive motor V1 (zero position) - adjust
- Parallelism - check
- Parallelism - adjust
- Sliding guide - remove
- Assembly unit - remove and install
- Guide with steel cable - remove
- Draining hoses - clean
- Sliding / tilting sunroof
- Bumper
- Front bumper
- Front bumper|Tools
- Front protector - repair
- Front protector (? 06.06) - assembly overview
- Front protector (? 2006) - remove and install
- Protector support (? 2006) - assembly overview
- Front protector (2007 ?) - assembly overview
- Front protector (2007 ?) - remove and install
- Front protector additional components (2007 ?)
- Front protector support (2007 ?) - assembly overview
- Front bumper spoiler - Blue Motion - remove and install
- Rear bumper - hatch
- Rear bumper - sedan
- Front bumper
- Glazing/window mechanism
- Glued glasses
- Glued glasses|Tools
- Auxiliary materials for the Brazilian market
- Auxiliary materials for the export market
- Matching table
- Repair the windscreen
- Labels for engraving the chassis number on glass - replacement
- Windscreen - Assembly overview
- Lower windscreen covering - remove and install
- Windscreen - remove
- Windscreen - install
- Side glass (hatch) - assembly overview
- Undamaged side glass (hatch) - remove
- Damaged side glass (hatch) - remove
- Side glass (hatch) - install
- Rear door glass - assembly overview
- Rear door glass (undamaged) - remove
- Rear door glass (damaged) - remove
- Rear door glass - install
- Undamaged rear door glass - remove
- Rear door glass (damaged) - remove
- Rear door glass - install
- Prepare the undamaged glass for glass assembly
- Prepare the new glass with encapsulation for glass assembly
- Prepare the new glass without encapsulation for glass assembly
- Prepare the body flange for glass assembly
- Rear window (sedan) - assembly overview
- Undamaged rear window (Sedan) - remove
- Rear window - install
- Damaged rear window (sedan) - remove
- New rear window (sedan) - prepare a new glass for assembly
- Assembly instructions
- Minimum drying time
- Repair damage to painting
- Cleaning in case of dirt due to the adhesive
- Door windows
- Door windows|Tools
- Front door window - assembly overview
- Front door window - remove and install
- Front door window - adjust
- Front subframe - remove and install
- Front and rear door window drive crank - remove and install
- Rear door window - assembly overview
- Rear door window - remove
- Rear door window - install
- Rear subframe - remove and install
- Power window drive mechanism (automatic opening and closing system) with force limiter
- Re-establish the operation after the force limiting activation
- Power window drive mechanism motor - remove and install
- Rear door window (sedan) - assembly overview
- Fixed rear door window (sedan) - remove
- Glued glasses
- Exterior equipment
- Wheel case protector
- External rear-view mirror
- External rear-view mirror|Tools
- External rear-view mirror (with electric command ? 2006) - assembly overview
- External rear-view mirror (with manual command ? 2006) - assembly overview
- Mirror cover (? 2006) - remove
- External rear-view mirror (2007 ?) - assembly overview
- Mirror glass (2007 ?) - remove and install
- Mirror cover (2007 ?) - remove and install
- Cover with direction indicator (2007 ?) - remove and install
- External rear-view mirror (2007 ?) - remove and install
- Front grille
- Front grille (? 2006) - assembly overview
- Front grille (? 2006) - remove and install
- Front grille (2007 ?) - assembly overview
- Front grille (2007 ?) - remove and install
- Front grille (2007 ?, GT) - assembly overview
- Front grille (2007 ?, GT) - remove and install
- Front grille - Blue Motion - assembly overview
- Front grille - Blue Motion - remove and install
- Exterior equipment|Trims
- Door trims - remove and install
- Rear lid trim (Hatch, 2010?) - replace
- Rear lid trim (Sedan, 2010?) - replace
- External longitudinal member lining (front door - GT) - replace
- Measures to position the inscriptions on the rear door
- "CONFORTLINE” and "SPORTLINE” inscriptions - replace
- "BlueMotion” inscription on rear lid - replace
- Lower longitudinal member trim (Blue Motion) - assembly overview
- Lower longitudinal member trim (Blue Motion) - remove and install
- Auxiliary materials for the Brazilian market
- Auxiliary materials for the export market
- Matching table
- Lower longitudinal member trim (Blue Motion) - remove and install|Remove
- Lower longitudinal member trim (Blue Motion) - remove and install|Install
- Minimum drying time
- Cleaning in case of dirt due to the adhesive
- Spoiler - Hatch
- Rear spoiler (? 07.08)
- Rear spoiler (08.08 ?) - assembly overview
- Rear spoiler ( 08.08 ? ) - remove
- Rear spoiler ( 08.08 ? ) - install
- Rear spoiler (Blue Motion)
- Preparation of rear lid for adhesion
- Assembly instructions
- Minimum drying time
- Repair damage to painting
- Cleaning in case of PU adhesive dirt
- Rear spoiler - Sedan
- Exclusive components for Blue Motion version
- Body front
- General body repairs, interior
- Interior equipment
- Internal rearview mirror
- Internal rear-view mirror with automatic anti-glare
- Internal rear-view mirror (without rain sensor) - remove and install
- Internal rearview mirror support plate - glue
- Internal rear-view mirror (with rain sensor) - remove and install
- Mirror fastening support (with rain sensor) - install
- Rain sensor and mirror - install
- Object compartment, covers and lids
- Centre console (upper)
- Centre console (lower)
- Handle of the emergency brake lever - remove and install
- Objects holder
- Glove compartment
- Glove compartment lid - remove and install
- Central frame of the instrument panel - remove and install
- Fastening hook (Sedan) - general assembly overview
- Sun visor
- Centre sun visor - remove and install
- Roof`s Safety Handles
- Door sill's trims
- Internal rearview mirror
- Passenger protection
- safety belts - general information
- Safety belts - checking
- safety belts
- Rear safety belts
- Passenger protection|Airbag
- Installation locations - assembly overview
- Safety measures for Airbag works
- Airbag ignition devices after an accident - replacing
- Ignition device for driver's airbagN95 (steering wheel with 3 spokes) - removal and installation
- Ignition device for driver's airbagN95 (multifunction steering wheel) - removal and installation
- Ignition device for driver's airbagN95 (steering wheel with 4 spokes) - removal and installation
- Connector of the airbag coil and return spring with sliding ringF138 - remove and install
- Trigger 1 for front passenger's airbagN131- remove and install
- Control unit for the airbagJ234 - removal and installation
- Components - adapting/verifying
- Trim, noise insulation
- Instrument panel
- Door lining
- Lining of columns and sides
- Upper pillar A lining - remove and install
- Lower A pillar lining (right side) - remove and install
- Lower A pillar lining (left side) - remove and install
- B-pillar lining - assembly overview
- Lower B pillar lining - remove and install
- Upper B pillar lining - remove and install
- C pillar upper lining (Hatch) - remove and install
- Upper pillar C lining (Sedan) - remove and install
- Lower C pillar lining (Hatch) - remove and install
- C pillar lower lining (Sedan) - remove and install
- Linings of the luggage compartment
- Roof lining
- Noise insulation
- Seat frames
- Front seats
- Front seats|Tools
- Front seat - remove and install
- Lower front seat cushion cover (without height adjustment)
- Lower front seat cushion cover (with height adjustment)
- Fire extinguisher support - removal and installation
- Front seat head rest - assembly overview
- Front seat backing - removal and installation
- Height adjustment mechanism - remove and install
- Front seat head rest guide - removal and installation
- Front seats|Installation
- Tray under the front seat - remove and install
- Rear seats
- Rear seat cushion (split) - remove and install
- Rear seat back (split) - remove and install
- (Bench) back seat backrest - remove and install
- Back seat head rest - assembly overview
- Rear seat head rest - removal and installation
- Rear seat head rest guide - removal and installation
- Rear seat backrest release button - assembly overview
- Rear seat rest unlocking button - removal and installation
- Front seats
- Seat padding, covers
- Linings, stuffing of front seats
- Linings and stuffing of front seats
- Rear seat cushion lining and filling (bench) - assembly overview
- Rear seat cushion lining and filling (bench) - remove and install
- Lining and stuffing of the back seat (one-piece) backing - assembly overview
- Lining and stuffing of the back seat (one-piece) backing - removal and installation
- Lining and stuffing of the back seat (two-piece) backing - assembly overview
- Lining and stuffing of the back seat (two-piece) backing - removal and installation
- Interior equipment
- Chemicals Manual
- Technical data
- Introduction
- List of Suppliers
- 3 M do Brasil
- Alba Química Ind. Com. Ltda
- Aletron Produtos Químicos Ltda
- Brascola Ltda
- Castrol Brasil Ltda
- Cia Brasileira de Petróleo Ipiranga
- Colauto - Adesivos e Massas Ltda
- Cremer S.A. Prod. Texteis e Cirúrgicos
- Dow Corning do Brasil Ltda
- Dow Automotive System
- Du Pont S/A
- Elf Lubrificantes do Brasil
- Esso Brasileira de Petróleo Ltda
- Formiquímica Com. e Repres. de Produtos Químicos Ltda
- Gratec System Industria de Produtos Químicos Ltda
- Henkel do Brasil Ltda
- Indaco Industria e Comércio Ltda
- Klüber Lubrification Lubrificantes Especiais Ltda
- Loctite Brasil Ltda
- Lumobrás Imp. Com. Ind. Ltda
- ExxonMobil do Brasil Ind. Com. Ltda
- Motul Synthetic Lubricants
- Nippondenso Compressores Ltda
- Pentosin do Brasil Ltda
- Petrobras Distr. S/A
- Promax Prods. Máximos S/A Indústria e Comércio
- Repsol - YPF S.A. Divisão Lubrificantes Brasil
- Quaker Chemical Industria e Comércio Ltda
- Shell Brasil S/A
- Sika S/A
- Solplás - Ind. de Plásticos Ltda
- Solvay Química
- Texaco Brasil S/A Produtos de Petróleo
- Three Bond do Brasil Ind. e Com. Ltda
- Total Lubrificantes Brasil Ltda
- Tutela Lubrificantes S/A
- Valvoline Lubrificantes Internacionais Ltda
- Wal Química S/A
- List of authorized products
- Assembly Sticker
- Adhesive for polyurethane and polypropylene
- Resin adhesive
- Polyurethane-based sealing adhesive
- Instant adhesive
- Adhesive for sealing gaskets
- Permanent adhesive
- Adhesive for packings and linings
- Polyurethane adhesive
- Polyurethane adhesive
- Adhesive with 2 components
- Epoxy adhesive with 2 components
- Sealing adhesives for engines
- High-resistance locking adhesive
- Low viscosity lock adhesive
- Locking adhesive
- Locking adhesive for mechanical seals
- Medium torque locking adhesive
- Adhesive for plastic cap gaskets
- Metal-glass adhesive
- Sealing adhesive
- 2-component adhesive
- Activating agent for pre-laminated glass
- Additives for coolants - G11
- Coolant additive - G12 Plus
- Additive for the windscreen/rear window washer reservoir
- Additives for petrol
- Silicone rubber
- Filling and acoustic isolation foam
- Polyurethane adhesive tape
- Polyurethane adhesive tape
- Cotton tape
- Self-adhesive PVC tape
- Transferable adhesive tape
- Sealing tape
- Double-sided adhesive tape
- Double-sided acrylic foam adhesive tape
- Medium density double-sided adhesive tape
- Hydraulic brake fluid (DOT 4)
- Automatic transmission fluid
- Refrigerant gas - R134a
- Multi-purpose grease
- Semi-fluid grease
- Multi-purpose grease
- Multi-purpose grease
- Multi-purpose grease
- Special lubrification grease
- Lubricating grease
- Complex grease
- Graphite grease
- Grease for front wheel cylinder support guide pin
- Grease for transmission side seals
- Lubricating grease
- Grease for electrical contacts
- Polyurea grease
- High temperature grease
- Temperature resistant grease
- Lubricating grease
- Multi-purpose grease
- Silicone based grease
- Windscreen adhesive set
- Windscreen adhesive set
- Glass-metal adhesive set
- Glass adhesion kit
- Lithium-based lubricant
- Addhesive paste and grey sealant
- Adhesive material for glass
- Sealing paste
- Adhesive material for glass
- Sealing paste for bodywork
- Silicone paste
- Mouldable paste for caulking
- Sealing paste
- Lubricating paste for high temperatures
- Lubricating paste for constant velocity joints
- Sealing paste
- Sealing paste
- Sealing paste
- Sealing paste
- Sealing paste
- Paste for bucket protection
- Sealing paste for engines
- Sealing paste
- Sealing paste for engine
- List of authorized products|Nyogel
- Liquid sealant
- Lubricating oil for engines (Petrol, Ethanol, Totalflex and GNV - VW 501 01 and VW 502 00)
- Lubricating oil for diesel engines - VW 505 00
- Lubricating oil for diesel engines - VW 505 01
- Lubricating oil for mechanical transmission and steering box - SAE 90, MIL-L-2105B, API-GL5
- Lubricating oil for mechanical transmission - SAE 80, MIL-L-2105, API-GL4
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Special oil
- Oil for mechanical transmission
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for power steering
- Lubricating oil for automatic transmission and power steering
- Lubricating oil for the automatic transmission differential - SAE 75 W 90
- High performance oil for the clutch
- VW ATF oil for power steering
- VW ATF oil for power steering
- ATF oil for automatic transmissions
- VW ATF oil for power steering
- Oil for gear selection mechanism
- Air conditioning compressor oil - R 134a
- Oil for the air conditioning compressor
- Universal oil
- Lubricating oil for assembly
- White lubricating grease
- Moly grease
- Lubricating grease
- Molybdenum bisulphate lubricating grease
- Copper grease
- High temperature paste
- List of authorized products|Primer
- Glass primer
- Adhesive remover
- Cleaning remover
- Corrosive paste
- Odourless solvent
- Cleaning solution
- Engine leak detection spray
- Cylinder lubricating spray
- Primer for polyurethane surface
- Adhesive sealant
- Elastic sealand
- Mixing tube
- Liquid sealant
- Silicone sealant for engines
- Sealant for exhaust connections
- Teflon thread sealant
- Work Instructions for Handling Chemicals
- Application guide
- Repair Group 10 - Cylinders, engine block, support, protector
- Repair Group 13 - Crankshaft, pistons
- Repair Group 15 - Cylinder head, valve control mechanism
- Intermediate shaft seal - lubricate for assembly
- Camshaft valve bearing cover (1st and 5th) - Seal
- Cylinder head sealing gasket - glue
- Lower rear studs fastening the head - rear stud (crankshaft) / lower front studs (flywheel) - Seal
- Cylinder head cover - seal
- Cylinder head cover - seal
- Cylinder head cover - seal
- Repair Group 17 - Lubrication system
- Repair Group 19 - Cooling system
- Repair Group 20 - Supply system - tank, fuel pump
- Repair Group 26 - Exhaust system
- Repair Group 30 - Clutch - control system
- Clutch pedal bung - lubricate
- Clutch control cable - lubricate
- Clutch fork, contact with bearing - lubricate
- Clutch fork bungs - lubricate
- Butterfly nut for clutch control cable adjustment - lubricate
- Sealing ring for the de-clutch bearing guide - lubricate for assembly
- Clutch cable - lubricate
- Clutch fork and clutch operating lever - lubricate
- Clutch pedal fastening - lubricate
- Clutch operating cable - lubricate
- Primary shaft splines - lubricate
- Clutch pedal / clutch pedal bung - lubricate
- Pedal support - seal
- Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate
- Fastening flange for the hydraulically activated slave cylinder of the clutch - seal
- Repair Group - 34 - Drive, housing
- Linkage rod, front/rear section - lubricate
- Gearshift lever bearing
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate
- Gearshift lever guide plate - lubricate
- Rubber shim for the clutch compartment cover - glue
- Clutch compartment cover - seal
- Linkage rod bellows for the gearshift lever assembly - fasten / seal
- Junction of cases and differential cover housing (gearbox / differential) - seal
- Gearshift lever handle - fasten
- Fastening screw for the rear support of the transmission cushion - seal
- Transmission cushion - lubricate
- Gear selection mechanism - fill up
- Electric connectors of the gear selection mechanism - apply nyogel
- Repair Group 35 - Gears and shafts
- Repair Group - 37 - Drive, housing
- Planetary gear box (automatic transmission) - Fill / top up oil level
- Planetary gear box (automatic transmission) - Fill / top up oil level
- Planetary gear box (automatic transmission) - Fill / top up oil level
- Repair Group - 39 - Transmission shafts, differential
- Repair Group - 40 - Front suspension
- Repair Group - 42 - Rear suspension
- Repair Group - 46 - Brakes - Mechanical systems
- Repair Group - 47 - Brakes - Servo brake hydraulic system
- Repair Group - 48 - Steering
- Oil tank for the power steering system - Fill / top up oil level
- Oil tank for the power steering system - Fill / top up oil level
- Steering box - Fill / top up level
- Steering box mechanism - lubricate
- Adapter (sleeve) for the upper steering shaft - lock
- Repair Group - 53 - Body - Rear section
- Repair Group - 55 - Covers
- Repair Group - 57 - Front doors / components / central lock
- Repair Group - 58 - Rear doors / components
- Repair Group - 64 - Windscreens, windows, window mechanism
- Door window activation mechanism - lubricate
- Vent window latch - lubricate
- Front door glass support - lubricate
- Front door window activation mechanism - lubricate
- Window crank fastening screw - lock
- Windscreen, side window glass and rear window glass - glue
- Windscreen, side window glass and rear window glass - seal
- Glass - engrave chassis number
- Front and rear door window guide groove - glue
- Vent window - seal
- Repair Group - 66 - External equipment
- Repair Group - 68 - Internal equipment
- Repair Group - 70 - Lining/insulation
- Repair Group - 72 - Seat framework
- Repair Group - 87 - Air conditioning
- Repair Group - 92 - Windscreen, rear window and headlight wiper and washer
- Repair Group - 94 - Switches, lights, and external bulbs
- Repair Group - 97 - Cables and electrical harnesses
- Technical data
- Painting Manual
- Technical data
- Introduction
- Safety at the Working Area
- Technical data|Colors
- 1995 line - Imported vehicles
- 1995 line - Domestically manufactured vehicles
- 1996 line - Imported vehicles
- 1996 line - Domestically manufactured vehicles
- 1997 line - Imported vehicles
- 1997 line - Domestically manufactured vehicles
- 1998 line - Imported vehicles
- 1998 line - Domestically manufactured vehicles
- 1999 line - Imported vehicles
- 1999 line - Domestically manufactured vehicles
- 2000 line - Imported vehicles
- 2000 line - Domestically manufactured vehicles
- 2001 line - Imported vehicles
- 2001 line - Domestically manufactured vehicles
- 2002 line - Imported vehicles
- 2002 line - Domestically manufactured vehicles
- 2003 line - Imported vehicles
- 2003 line - Domestically manufactured vehicles
- 2004 line - Imported vehicles
- 2004 line - Domestically manufactured vehicles
- 2005 line - Imported vehicles
- 2005 line - Domestically manufactured vehicles
- 2006 line - Imported vehicles
- 2006 line - Domestically manufactured vehicles
- 2007 line - Imported vehicles
- 2007 line - Domestically manufactured vehicles
- 2008 line - Imported vehicles
- 2008 line - Domestically manufactured vehicles
- 2009 line - Imported vehicles
- 2009 line - Domestically manufactured vehicles
- 2010 line - Imported vehicles
- 2010 line - Domestically manufactured vehicles
- 2011 line - Imported vehicles
- 2011 line - Domestically manufactured vehicles
- 2012 line - Imported vehicles
- 2012 line - Domestically manufactured vehicles
- Special colors
- Special colors
- Fox Blackfox 2012
- Fox Crossfox
- Fox Crossfox 2012 ?
- Fox Extreme
- Fox Silverfox 2012
- Gol Rallye
- Vintage Gol
- Special colors|Golf GT
- Golf Silver Edition
- Golf Black Edition 2011
- Silver series Kombi
- Parati Track and Field (Generation IV)
- Parati Surf
- Parati Titan
- Saveiro Crossover (generation III)
- Saveiro Crossover (generation IV)
- Saveiro Titan
- Saveiro Surf
- Saveiro Trooper 2010 ?
- Saveiro Cross 2010 ?
- Special colors
- Technical data|Paints
- Complements
- Repainting
- Body sealing
- Application of anti-corrosion fluid
- Technical data
- Body Repair - General Information
- Technical data
- Safety indications
- Removal of components
- Battery, welding works
- Electronic control units
- Painting, windows, stuffing, trims
- Fuel tank or fuel line
- Air conditioning system
- Airbag System - Safety measures for works
- Ignition devices of the airbag after an accident - what must be replaced
- Checking the seat belts
- Safety standards for belt tensioner
- Works on vehicles with belt tensioner
- Repair, alignment and/or body works on vehicles with airbag
- Removal of front seats with side airbag
- Basic indications
- Explanation of symbols
- Explanation of symbols for welding works
- Explanation of symbols for working processes
- Explanation of symbols for working processes|Sanding
- Explanation of symbols for working processes|Lower
- Perforate
- Explanation of symbols for working processes|Drill
- Sanding
- Application of anti-corrosion fluid
- Explanation of symbols for working processes|Gluing
- Explanation of symbols for working processes|Sealing
- Tools for body repair
- Glued parts of the body
- Anti-corrosive protection measures
- Indications on residue elimination
- Steel panels repair
- Safety indications
- Technical data
- General body repairs, exterior
- Engine
- 4-cylinder injection engine
- 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
- Renewing crankshaft oil seal - pulley end
- Removing and installing drive plate
- Renewing crankshaft sealing flange - flywheel end
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A-Assembling sealing flange with sender wheel on assembly appliance T10017
- B-Assembling appliance T10017 with sealing flange on crankshaft flange
- C-Fitting assembly appliance T10017 onto crankshaft flange
- D-Pressing sender wheel onto crankshaft flange with assembly appliance T10017
- 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
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleeding fuel system
- Checking electronic power control (EPC)
- Active charcoal filter system
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- 4 - Cyl. injection engine (4-valve, rolling rockers)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine - disassemble and assemble
- Crank shaft rear flange - remove and install
- Crank shaft seal pulley side - replace
- Crank shaft rear flange, driving wheel side - replace
- Extract flange with rotor
- Operation sequence
- Introduce flange under pressure with rotor
- A-Install flange with rotor on Assembly tool T10017
- B-Install Assembly tool T10017 with flange on the crank shaft
- Operation sequence
- C-Thread Assembly tool T10017 to crank shaft flange
- D-Press rotor with Assembly tool T10017 onto crank shaft flange
- E-Check assembly position of crank shaft rotor
- F- retighten driving wheel
- Crank shaft - remove and install
- Piston and rod - remove and install
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Fuel supply system components - remove and install
- Fuel container with accessory parts and fuel filter - remove and install
- Safety measures for jobs on fuel supply system
- Cleaning rules
- Oil pump - remove and install
- Fuel level sensor - remove and install
- Fuel container - remove and install
- System for fuel supply interruption in case of collision
- Fuel pump - check
- Test conditions
- Power supply and operation - check
- Fuel flow - check
- Test conditions
- Test sequence
- Fuel pump retaining valve - check
- Test conditions
- Test sequence
- Engine power electronic regulation (E-gas electronic throttle) - check
- Activated charcoal filter system.
- Fuel supply system components - remove and install
- Mixture preparation system, electronic inj.,Gas
- Injection system - repair
- Injection components - check
- Engine command unit
- Exhaust system
- Ignition system, glow plug system
- 4 - Cyl. diesel engine (with distributor injection pump)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Fuel supply system components - remove and install
- Fuel preparation system Diesel injection
- Direct injection system-Diesel - repair
- Engine command unit
- Exhaust system
- Exhaust system parts - remove and install
- Exhaust system - remove and install
- Condition
- Operations sequence
- Operations sequence
- Operations sequence
- Exhaust system - remove and install
- Exhaust gas return system
- Exhaust system parts - remove and install
- Ignition system, glow plug system
- 4 - Cyl. diesel engine (with unit injectors)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Head - disassembly and assembly
- Valve command unit - repair
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Supply system components - remove and install
- Fuel container with accessories - remove and install
- Fuel filter - repair
- Safety measures in jobs on the supply system
- Cleaning rules
- Fuel radiator - remove and install
- Fuel container - remove and install
- Fuel pump - remove and install
- Fuel level meter - remove and install
- Fuel pump - check
- Throttle starting system - repair
- Tandem pump - check
- Tandem pump - remove and install
- Supply system components - remove and install
- Exhaust turbocharger, G-charger
- Fuel preparation system Diesel injection
- Exhaust system
- Ignition system, glow plug system
- 4 - Cyl. injection engine
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine - disassemble and assemble
- Engine - assembly and disassembly
- Crankshaft and flywheel flanges - remove and install
- Crankshaft - remove and install
- Pistons and connecting rods - dismantle and assemble
- Pistons and conrods - remove and install
- Engine cylinder head, valve gear
- Engine cylinder head - remove and install
- Cylinder head - assembly and disassembly
- Valve control mechanism - repair
- Camshaft mechanism - repair
- Engine lubrication
- Engine cooling
- Cooling system components - remove and install
- Fuel supply, gas operation
- Supply system components - remove and install
- Fuel tank with assembly parts and fuel filter - remove and install
- Safety measures when working in the supply system
- Cleaning rules
- Cold start system components - remove and install
- Fuel pump (pre-supply pump) G6 - remove and install
- Fuel level indicator sensor G - remove and install
- Fuel reservoir - remove and install
- Fuel cutoff in case of impact
- Fuel pump (pre-supply pump) G6 - check
- Fuel supply system components - remove and install
- Fuel tank components with accessories and fuel filter - remove and install
- Safety measures regarding work on the fuel supply systems
- Cleaning rules
- Cold start system components - remove and install
- Cold start system components
- Fuel pump (pre-supply pump)G6 - remove and install
- Fuel gauge sensorG - remove and install
- Fuel tank - remove and install
- Fuel shutoff system in case of crashes
- Fuel pump (pre-supply pump)G6 - check
- Engine power electronic adjustment (E-Gas electronic accelerator) components - repair .
- Engine power electronic adjustment (electronic throttle) - check
- Activated charcoal filter system
- Supply system components - remove and install
- Mixture preparation system, electronic inj.,Gas
- Injection - repair
- General notes on injection
- Component location - overview
- Injection components - remove and install
- Intake manifold (upper part) - disassemble and assemble
- Intake manifold (lower part) - disassemble and assemble
- Fuel distributor with injection valves - remove and install
- Air filter - disassemble and assemble
- Safety measures
- Cleaning rules
- Technical data
- Injection system - repair
- General instructions regarding the injection system
- Component location
- Injection components - remove and install
- Intake manifold - remove and install
- Fuel rail with injectors - remove and install
- Fuel rail with injectors - remove and install
- Air filter case - disassemble and assemble
- Safety measures
- Cleaning rules
- Technical data
- Injection components - check
- Component checks
- Engine control unit J623
- Injection - repair
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine
- Vehicle electrics
- Electrical system
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- BatteryA - disconnect and connect
- BatteryA - remove and install
- Remove the BatteryA (Version 1).
- Install the BatteryA (Version 1).
- Remove the BatteryA (Version 2).
- Install the BatteryA (Version 2).
- Remove the BatteryA (Version 3).
- Install the BatteryA (Version 3).
- Remove the BatteryA (Version 4).
- Install the BatteryA (Version 4).
- Remove the BatteryA (Version 5).
- Install the BatteryA (Version 5).
- BatteryA console - remove and install
- Tightening torques - Battery
- Starter-current supply-CC|Starter
- Alternator
- Generator (Alternator)C - fastening cable B+
- Generator (Alternator)C - check Poly-V belt
- Generator (Alternator)C for 1.6l (CCRA) engine - assembly overview
- Generator (Alternator)C for 1.0 and 1.6l (ARA, BPA, BAH) engines - assembly overview
- Generator (Alternator)C for 1.4 and 1.6l (BBZ, BBY, BKY, BAH) engines - assembly overview
- Generator (Alternator)C for 1.4l (BAY) engine - assembly overview
- Generator (Alternator)C for 1.9l (ASY) engine - assembly overview
- Generator (Alternator)C for 2.0l (BBX, CFEA) engines - assembly overview
- Generator (Alternator)C - replace Poly-V belt pulley
- Voltage regulatorC1 (Manufacturer Bosch) - disassemble and assemble
- Voltage regulatorC1 (Manufacturer Valeo) - disassemble and assemble
- Tightening torques - Alternator
- Starter-current supply-CC|Battery
- Instruments, GCI
- Combined instrument
- Indication of Service Interval
- Cigarette lighter and 12V socket
- Windscreen wipe/wash system
- Windscreen wiper system
- Windscreen wiper system - assembly overview
- Windscreen wiper blade - remove and install
- Windscreen wiper blade and arm set - remove and install
- Windscreen wiper mechanism - remove and install
- Windscreen wiper motorV - disassemble and assemble
- Windscreen wiper blade resting position - adjust
- Blade application angle on the windscreen - adjust
- Tightening torque - Windscreen wiper system
- Rain sensorG213 - remove and install
- Rain sensor and sunlight penetration photosensorG397 - remove and install
- Windscreen washer system
- Windscreen washer system - assembly overview
- Reservoir for the windscreen and rear window washer system (version 1) - remove and install
- Reservoir for the windscreen and rear window washer system (version 2) - remove and install
- Windscreen and rear window washer pumpV59 - remove and install
- Tightening torque - windscreen and rear window washer system
- Windscreen washer system washer jets - replace
- Windscreen washer system washer jets - adjust
- Rear window wiper system
- Rear window washer system
- Windscreen wiper system
- Lights, lamps, switches outside
- Main headlights (?07/06)
- Main headlights (?07/06) - general assembly overview
- Main headlights (?07/06) - remove and install
- Main headlights (?07/06) - correct the assembly position
- Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer - automotiv lighti
- Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer - Valeo) - remove
- Mains headlight lamps (?07/06) - replace
- Left front sidelight lampM1 and/or Right front sidelight lampM3 - replace
- Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 - replace
- Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 - replace
- Left front indicator light lampM5 and/or Right front indicator light lampM7 - replace
- Main headlights (?07/06) - repair fastening tabs
- Main headlights (?06/11)
- Main headlights (?06/11) - general assembly overview
- Main headlights (?06/11) - remove and install
- Main headlights (?06/11) - correct the assembly position
- Left headlight beam reach control motor V48 and/or Right headlight beam reach control motorV49 (Manufacturer - Hella) - remove
- Main headlights "Manufacturer: Hella" (?06/11)
- replace the lamp
- Left front sidelight lampM1 and/or Right front sidelight lampM3 - replace
- Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 - replace
- Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 - replace
- Left front indicator light lampM5 and/or Right front indicator light lampM7 - replace
- Main headlights "Manufacturer: Valeo" (?06/11)
- replace the lamp
- Left front sidelight lampM1 and/or Right front sidelight lampM3 - replace
- Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 - replace
- Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 - replace
- Left front indicator light lampM5 and/or Right front indicator light lampM7 - replace
- Main headlights (?06/11) - repair fastening tabs
- Main headlights (07/11?)
- Main headlights (07/11?) - general assembly overview
- Main headlights (07/11?) - remove and install
- Main headlights (07/11?) - correct the assembly position
- Main headlights (07/11?) - replace lamp
- Left front sidelight lampM1 and/or Right front sidelight lampM3 - replace
- Left low-beam headlight lampM29 and/or Right low-beam headlight lampM31 - replace
- Left high-beam headlight lampM30 and/or Right high-beam headlight lampM32 - replace
- Left front indicator light lampM5 and/or Right front indicator light lampM7 - replace
- Main headlights (07/11?) - repair fastening tabs
- Fog lights (?07/06)
- Fog headlights (?06/11)
- Fog lights (07/11?)
- Headlights - check adjustment
- Turn signal repeater lights
- Taillights (?07/06)
- Taillights (08/06?)
- Number plate light
- Additional brake light
- Light switches on the instrument panel
- Switch set
- Steering lock set
- Ignition/starter switch and key cylinder
- Auxiliary parking system
- Locating defects and indicating faults
- Auxiliary parking system - assembly general view
- Control unit for Park Assist steeringJ446 (Hatch) - remove and install
- Warning buzzer for rear Park Assist steeringH15 (Hatch) - remove and install
- Control unit for Park Assist steeringJ446 (Sedan) - remove and install
- Warning buzzer for rear Park Assist steeringH15 (Sedan) - remove and install
- Park Assist steering sensor - remove and install
- Main headlights (?07/06)
- Lights, lamps, switches inside, anti-theft system
- Lights and internal switches
- Lights and switches in the engine compartment
- Switched on the instrument panel
- Front door lights and switches
- Rear door lights and switches
- Lights and switches in luggage compartment
- Roof lining lights and switches
- Internal front lightW1
- Front internal lightW1 with
reading light
- Front internal lightW1 with reading light - remove and install
- Front internal lightW1 with sunroof - remove and install
- Sunroof sliding adjustmentE139 - remove and install
- Front internal lightW1 with reading light (version 1) - replace the lamp
- Front internal lightW1 with reading light (version 2) - replace the lamp
- Driver side reading lightW19 and/orPassenger side reading lightW13 (version 1) - replace the lamps
- Driver side reading lightW19 and/orPassenger side reading lightW13 (version 2) - replace the lamps
- Make-up mirror lighting - remove and install
- Internal rear lightW43
- Lights, lamps, switches inside, anti-theft system|Horns
- Immobilizer
- Alarm System
- Wiring
- Fuse holder
- Fuse box
- Relay carrier
- Power distributor
- Coupling stations and multi-pin connector
- Coupling station - A pillar
- Coupling station - B pillar
- Multi-pin connector in the fire wall
- Removing and installing the multi-pin connector on the engine side (version 1)
- Removing and installing the multi-pin connector on the cabin side (version 1)
- Removing and installing the multi-pin connector on the engine side (version 2)
- Removing and installing the multi-pin connector on the cabin side (version 2)
- Control units
- Starter-current supply-CC
- Communication
- Infotainment
- Communication Systems
- Infotainment|Radio R
- "CD player"R89
- Speakers
- Multifunction steering wheel
- Antenna system
- Interference suppression measures
- Infotainment
- Electrical system - General information
- Starter-current supply-CC
- BatteryA
- BatteryA - check
- BatteryA check sequence
- Check visually
- Check BatteryA with inspection visor (magic eye)
- Check the BatteryA with inspection window (magic eye) "3 colors"
- Check the BatteryA with inspection window (magic eye) "2 colors"
- Checking the low-maintenance BatteryA
- Checking the charge of the BatteryA.
- Consumption of current test
- Check the resting current of the battery
- Check the final battery charge
- Checking the resting voltage of batteries (unused or stored vehicles)
- BatteryA - charging
- Battery chargerVAS 5095A
- Battery chargerVAS 5900
- Description of the Battery chargerVAS 5900
- Charging the BatteryA with the Battery chargerVAS 5900
- Servicing charge with the Battery chargerVAS 5900
- Charging a completely drained battery with the Battery chargerVAS 5900
- Auxiliary operations with the Battery chargerVAS 5900
- Trickle charge operational mode with the Battery chargerVAS 5900
- Battery chargerVAS 5903
- Description of the Battery chargerVAS 5903
- Charging the BatteryA with the Battery chargerVAS 5903
- Servicing charge with the Battery chargerVAS 5903
- Charging a significantly drained BatteryA with the Battery chargerVAS 5903
- Auxiliary operations with the Battery chargerVAS 5903
- Trickle charge operational mode with the Battery chargerVAS 5903
- Completely flat batteries
- Battery (Delphi) - charging procedure
- Speed regulator (GRA)
- Windscreen wipe/wash system
- Lights, lamps, switches outside
- Wiring
- Starter-current supply-CC
- Electrical system
- Power transmission
- 4 - Speed automatic gearbox 001
- Technical data
- Identification of gearbox
- Indications related to the "4-speed automatic gearbox 001”
- Filling quantities
- Distinctive letters, correspondence of groups, speed reductions, equipment
- General indications for repair
- General indications for repair|Tools
- General indications for repair|Gearbox
- Gaskets, retainers and oil
- Fasteners
- Screws, nuts
- Bearings
- Segments
- Internal discs
- Adjusting washers
- Clutches
- General indications for repair|Brakes
- Automatic transmission control valve assembly
- Assisted troubleshooting for damages, vehicle self-diagnosis and measurement module
- Torque converter
- Automatic gearbox, control, assembly, housing
- Electric and electronic components and their location
- Transmission activation mechanism
- Transmission activation mechanism: check
- Selector lever cable: check and adjust
- Operation of the ignition key anti-extraction blocking: check
- Transmission activation mechanism: disassemble and assemble
- Electromagnet for blocking the selector lever -N110-: disassemble and assemble
- Selector lever cable: disassemble and assemble
- Selector lever: disassemble and assemble
- Blocking cable: disassemble and assemble
- Blocking cable: adjust
- Gearbox: disassemble and assemble
- ATF level: check and add
- Gearbox with command elements
- Automatic gearbox, gears, control
- ATF pump: disassemble and assemble
- Idler pinion: disassemble and assemble
- 1st to 3rd gear clutch -K1-: disassemble and assemble
- Reverse clutch -K2-: disassemble and assemble
- 3rd and 4th gear clutch -K3-: disassemble and assemble
- Reverse brake -B1-: disassemble and assemble
- Plungers for the 2nd and 4th -B2- brake: disassemble and assemble
- Automatic transmission control valve assembly: disassemble and assemble
- Parking blocking: disassemble and assemble
- Final drive, differential, differential lock
- Technical data
- 5 - Speed manual gearbox 02T
- Technical data
- Clutch, control
- Clutch operating mechanism - repair
- I - Command pedals - assembly overview
- Clutch pedal switch F36 with rectangular case - remove - install
- Clutch pedal switch F36 with round case - remove and install
- Clutch pedal return spring - remove and install
- Clutch pedal support - remove and install
- Clutch pedal - remove install
- II - Hydraulic system - assembly overview
- Transmitting cylinder - clutch hydraulic drive - remove and install
- Clutch hydraulic drive slave cylinder - remove and install
- Clutch system - bleed
- Clutch - repair
- Clutch operating mechanism - repair
- Gearbox mechanics,operation, construction,diff.
- Shift mechanism
- Shift mechanism - installation position
- I - Handle and bellows on the gearshift lever - remove and install
- Handle and bellows on the gearshift lever - remove and install
- Handle and bellows on the gearshift lever - disassemble and assemble
- II - Gearshift lever and mechanism - repair
- III - Drive cables - remove and install
- Gear selection mechanism - remove and install
- Gear selection mechanism - adjust
- Transmission - remove and install
- Transmission oil level - check and replenish
- Transmission - disassemble and assemble
- Transmission and clutch cases - repair
- Gear selection mechanism - disassemble and assemble
- Selection forks - disassemble and assemble
- Shift mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Troubleshooting, Mechanical Transmission
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- 4 - Speed automatic gearbox 001
- Heating, ventilation, air conditioning
- Heating, air conditioning
- Heating
- Heating - passenger compartment components
- Heat exchanger/engine compartment partition panel sealing
- Natural air fanV2
- Fresh air fan pre-resistance with overheating fuseN24 (version 1) - remove and install
- Fresh air fan pre-resistance with overheating fuseN24 (version 2) - remove and install
- Dust and pollen filter - remove and install
- Air baffles (central) - remove and install
- Air baffles (sides) - remove and install
- Footwell vent - remove and install
- Demister nozzle - remove and install
- Exhaust valve - remove and install
- Ventilation adjustment mechanism
- Ventilation / heating adjustment mechanism power connectors
- Command cable - remove and install
- Plenum chamber (ventilation and heating) - remove and install
- Plenum chamber (heating) - disassemble and assemble
- Air distribution drive mechanism (Behr box) - remove and install
- Temperature adjustment mechanism (Behr box) - remove and install
- Control motor for natural air valve and recirculation valveV154 (Behr box) - remove and install
- Control motor for natural air valve and recirculation valveV154 (Behr box) - check
- Auxiliary heating resistanceZ35 (Behr box) - remove and install
- Additional heating resistanceZ35
- Heat exchanger - remove and install
- Heating - passenger compartment components
- Air conditioner
- Notes on repairing vehicles with air conditioning system and on handling refrigerant
- Ventilation adjustment mechanism (heating and air conditioning).
- Command cables - remove and install
- Service valves - location
- Air conditioning with manual adjustment/Climatic
- Plenum chamber (heating and air conditioning/Climatic) - disassemble and assemble
- Air conditioning with automatic adjustment, (Climatronic)
- Heating and air conditioning - passenger compartment components
- Air conditioning command and indicator unit / ClimatronicE87 with Climatronic control unitJ255 - Functions
- Air conditioning command and indicator unit / ClimatronicE87 with the Climatronic control unitJ255 - remove and install
- Air conditioning command and indicator unit / ClimatronicE87 with Climatronic control unitJ255 - check
- Air outlet temperature sensor for the feet regionG192 - remove and install
- Air outlet temperature sensor for the feet regionG192 - check
- Air outlet temperature sensor for the central baffleG191 - remove and install
- Air outlet temperature sensor for the central baffleG191 - check
- Air outlet temperature sensor for the evaporatorG263 - remove and install
- Air outlet temperature sensor for the evaporatorG263 - check
- Sun radiation photo sensorG107 - remove and install
- Sun radiation photo sensorG107 - check
- Fresh air aspiration duct temperature sensorG89 - remove and install
- Fresh air aspiration duct temperature sensorG89 - check
- Ambient temperature sensorG17 - vehicles up to 2007)- remove and install
- Plenum chamber (heating and air conditioning/Climatronic) -
disassemble and assemble
- Plenum chamber (Climatronic heating and air conditioning) - remove and install
- Air conditioning adjustment and control unitJ127 - remove and install
- Central valve control motorV70 - remove and install
- Central valve control motorV70 - check
- Defrosting valve control motorV107 and Control motor for temperature adjustment valveV68 - remove and install
- Defrosting valve control motorV107 and Control motor for temperature adjustment valveV68 - remove and install|Removal
- Defrosting valve control motorV107 and Control motor for temperature adjustment valveV68 - remove and install|Installation
- Create the adaptation cable for the activation of the adjusting motors
- Valve control motor for defrostingV107 - check
- Control motor for natural air valve and recirculation valveV154 (version 1) - remove and install
- Control motor for natural air valve and recirculation valveV154 (version 2) - remove and install
- Air conditioner compressor support
- Air conditioning compressor support for engines 1.0L (ARA), 1.4L (BBY, BKY) and 1.6L (BAH) - remove and install
- Air conditioning compressor bracket for 1.6L (BAH, BPA) engines - remove and install
- Air conditioning compressor bracket for 1.4L (BAY) engines - remove and install
- Air conditioning compressor bracket for 1.4L (BBY, BKY) engines - remove and install
- Air conditioning compressor bracket for 1.6L (CCRA) engines - remove and install
- Air conditioning compressor bracket for 1,9L - (ASY) engines - remove and install
- Air conditioning compressor bracket for 2.0L (BBX, CFEA) engines - remove and install
- Refrigerant circuit - assembly overview
- Air conditioning magnetic couplingN25 manufacturer Delphi (model 1) - repair
- Air conditioning magnetic couplingN25 manufacturer Delphi (model 2) - repair
- Electromagnetic clutch for Delphi compressor (model 2) - remove and install
- Compressor - remove and install
- Condenser - remove and install
- High pressure sensorG65 - remove and install
- High pressure sensorG65 - check
- Expansion valve - remove and install
- Quick-release coupling - remove and install
- Filling capacities
- Heating
- Air conditioning with refrigerant R134a
- Technical data
- General information on air conditioning
- Basics of air conditioning
- Vapor pressure table for R134a refrigerant gas
- R134a refrigerant gas
- Properties of R134a refrigerant gas
- Refrigeration system oil
- General information on air conditioning|Comfort
- Environmental aspects
- Air conditioning effects
- Safety at work
- Product characteristics
- Handling refrigerant gas
- Wear protective goggles
- Use protective gloves and apron
- Refrigerant gas should never come into contact with skin.
- Never inhale refrigerant gas vapors
- Smoking is strictly prohibited
- Soldering work in refrigeration systems
- Active smell
- First aid
- Handling of pressurized tanks
- Do not heat above 50 °C
- Monitor the heating process
- Close empty containers
- Safety measures related to handling refrigerant gas suction and filling equipment
- General remarks on the refrigerant gas loop
- Refrigerant gas loop components
- Distribution of refrigerant gas loop components and their influence on the high and low pressure areas.
- Air conditioning compressor with magnetic coupling:
- Air conditioning compressor without magnetic coupling
- Condenser
- Evaporator
- Collection tank
- Butterfly (throttle)
- Liquid tank
- Expansion valve
- O-ring seals
- Rigid tubes and flexible tubes in the refrigerant gas loop
- Overpressure valve
- Refrigerant gas loop components
- Quick coupling connections in the refrigerant gas loop
- Switches and sensors for the refrigerant gas loop and their connections
- Air conditioning high pressure switch F23
- High pressure switch for magnetic coupling F118
- Air conditioning low pressure switch F73
- Valve connections for switch in the refrigerant gas loop
- Air conditioning pressure switch F129
- High pressure sensor G65
- Pressure and temperature sensor for the refrigerant gas G395
- Magnetic valve for refrigerant fluid circulation N43
- Adjustment valve for the air conditioning compressor N280
- Electrical components not assembled in the refrigerant gas loop
- Pressures and temperatures in the refrigerant gas loop
- Refrigerant gas loop with expansion valve
- Refrigerant gas loop with butterfly (throttle) and collection tank
- Checking and measuring work with a pressure gauge
- Notes on doing repair work on the refrigerant gas loop
- Refrigerant gas loop components
- Legislation and standards
- Using the climate control recovery, recycling, refilling, and cleaning equipment
- Important notes for using the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Connect the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Empty the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Fill the refrigerant gas loop with the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Introduce refrigerant gas into the tank of the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Emptying the tank of the Climate control recovery, recycling and refill set or EQ 7098 VAS 6008
- Checking pressure values in the refrigerant gas loop
- Checking pressure values
- Verification for vehicles with butterfly (throttle) and collection tank (air conditioning compressor with internal adjustment de
- Verification for vehicles with expansion valve and liquid loop / dryer (air conditioning compressor with internal adjustment dev
- Verification for vehicles with expansion valve, liquid tank / dryer and Adjustment valve for the air conditioning compressor N2
- Verification for vehicles with butterfly (throttle), collection tank and regulating valve for the air conditioning compressor N
- Detecting leaks in the refrigerant gas loop
- Detecting leaks in the refrigerant gas loop with the R134a air conditioning leak detector or EQ 7051 VAG 1796
- Detecting leaks in the refrigerant gas loop by pressurizing the system
- Detection of leaks in the refrigerant gas loop with the air conditioning recovery, recycling, recharging and cleaning set
- Cleaning the refrigerant gas loop
- Problems
- Replacing components
- Test equipment and tools
- General information on air conditioning
- Technical data
- Heating, air conditioning
- Clutch and gearbox
- 5-speed manual gearbox 02R
- Technical data
- Clutch, control
- Control system - service
- Cutch release mechanism - service
- Clutch - service
- Gearbox mechanics,operation, construction,diff.
- Gear selector mechanism - service
- Gearbox - remove and install
- Gearbox oil - check
- Gearbox - dismantle and assemble
- Gearbox housing and clutch housing - service
- Gearbox selector mechanism - dismantle and assemble
- Selector forks - dismantle and assemble
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5-speed manual gearbox 02R