Running gear
- Brake systems
- Technical data
- ABS, ADR, TCS, EDL, ESP
- General notes for anti-lock brake system (ABS)
- 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 rear brakes (drum brakes)
- Repairing rear brakes (disc brakes)
- Assembly overview - handbrake lever
- Assembly overview - brake pedal
- Brakes, hydraulics, regulator, servo
- Repairing front brake calipers
- Repairing rear brake calipers
- Pressurised leak test
- Bleeding brake system
- Assembly overview - brake servo/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)
- Vacuum pump for brake servo (vehicles with diesel engine)
- Checking non-return valve
- Vacuum pump for brakesV192
- Removing and installing brake servo pressure sensorG294
- Removing and installing brake light switchF, left-hand drive
- Removing and installing brake light switchF, right-hand drive
- Removing and installing brake master cylinder
- Removing and installing brake servo
- Repairing brake lines
- Running gear, axles, steering
- Technical data
- Front suspension, drive shafts
- Evaluating accident vehicles
- Repairing front wheel suspension
- Subframe, anti-roll bar, suspension links
- Assembly overview - subframe, anti-roll bar, suspension links
- Repairing thread in longitudinal member
- Fixing position of subframe
- Removing and installing subframe
- Checking swivel joint
- Removing and installing swivel joint
- Installation position of swivel joints
- Removing and installing suspension link
- Renewing front bonded rubber bush for suspension link
- Renewing rear bonded rubber bush for suspension link
- Removing and installing anti-roll bar
- Removing and installing rubber bush for anti-roll bar
- Assembly overview - wheel bearings
- Assembly overview - suspension strut
- Removing and installing drive shafts
- Repairing drive shafts - overview of drive shafts
- Assembly overview - drive shaft with VL90 or VL100 constant velocity joint
- Assembly overview - drive shaft with VL107 constant velocity joint
- Assembly overview - drive shaft with triple roller joint AAR 2000/108
- Rear suspension, drive shaft
- Evaluating accident vehicles
- Repairing rear axle
- Assembly overview - axle body, drum brake
- Assembly overview - axle body, disc brake
- Assembly overview - rear left vehicle level sender G76 , front-wheel drive
- Assembly overview - shock absorber
- Assembly overview - wheel bearings, drum brake
- Assembly overview - wheel bearings, disc brake
- Wheels, tyres. axle align
- Evaluating accident vehicles
- Specified tightening torque for wheel bolts
- Removing and fitting tyres with run-flat properties to wheel rims
- Tyre pressure monitor display
- Wheel alignment
- Wheel alignment|General
- Test prerequisites
- Test preparations
- Wheel alignment specifications
- Transverse vehicle inclination "zero position”
- Overview - wheel alignment procedure
- Correcting front axle camber
- Check rear axle camber
- Check rear axle toe
- Adjusting front axle toe
- Checking left and right-hand wheel lock
- 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 system VAS 6230
- Finish balancer
- Radial and lateral runout of wheels and tyres
- Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435
- Checking radial and lateral run-out on wheel rim
- Matching
- Flat spots caused by storage or handling
- Steering
- Evaluating accident vehicles
- General repair instructions
- Steering column
- Removing and installing steering wheel
- Assembly overview - steering column, left-hand drive
- Removing and installing steering column, left-hand drive vehicle
- Assembly overview - steering column, right-hand drive vehicle
- Removing and installing steering column, right-hand drive vehicle
- Handling and transporting steering column
- Electro-hydraulic power steering
- Assembly overview for electro-hydraulic power steering, left-hand drive vehicle
- Removing and installing power steering box, left-hand drive vehicle
- Removing and installing power steering sensor G250 , left-hand drive vehicle
- Assembly overview for electro-hydraulic power steering, right-hand drive vehicle
- Removing and installing power steering box, right-hand drive vehicle
- Removing and installing power steering sensor G250 , right-hand drive vehicle
- Repairing power steering box
- Assembly overview - power steering box, left-hand drive vehicle
- Assembly overview - power steering box, right-hand drive vehicle
- Removing and installing track rod
- Checking play, tightness and bellows of track rod ball joints
- Checking and adjusting left track rod length
- Allocation of track rod ball joints
- Determining centre position of steering rack
- Adjusting steering box
- Motor/pump unit
- Bleeding steering system, checking for leaks and checking fluid level
- Wheels and Tyres Guide
- Guide for using trailers
- Technical data
- Technical data|Preface
- Technical prerequisites
- Notes on operation and driving
- Technical data|General
- Drawbar load details
- Legal requirements
- Polo 2010 ?
- CrossPolo 2010 ?
- Technical data
- Wheels and Tyres Guide - General Information
- Wheels, tyres. axle align
- General notes on wheels and tyres (passenger cars)
- Legislative and technical conditions for converting wheel and tyre combinations
- Documents and codes/designations
- Useful information regarding tyres
- Identification markings on the tyre sidewall
- Explanation of tyre markings
- Speed ratings for tyres
- Undulations
- Tyre storage
- Tyre ageing
- Tyre sizes for vehicles with four-wheel drive
- Winter tyres
- Winter tyres with speed symbol "V"
- Extra Load (XL) V winter tyres
- Reinforced and Extra Load (XL) tyres
- Snow chains
- Tyre wear/ mileage for passenger car tyres
- Tyre wear/ mileage for passenger car tyres|General
- Requirements to be met by tyres
- Wear behaviour of high-speed tyres
- Factors influencing the service life of a tyre
- Driving style
- Tyre maintenance
- Evenly worn tyres
- Measuring tread depth
- One-sided wear
- Outer shoulder wear
- Wear in middle of tyre
- Diagonal washout
- Tyre noise
- Vehicle pulls to one side
- Tyre damage
- General information
- Construction of a radial belted tyre
- Impact damage
- Tyre damage|Cuts
- Damage caused by foreign bodies
- Loss of air from tyre
- Tyre inflation pressure
- Tyre damage due to insufficient tyre inflation pressure
- Rising tyre temperature caused by insufficient tyre inflation pressure
- Tyre damage due to fitting error (fitting damage)
- Tyres with run-flat properties
- Rolling resistance optimised tyres
- Facts about wheels (passenger cars)
- 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 and installing bonnet hinge
- Removing and installing insulation
- Removing and installing support rod
- Assembly overview - bonnet lock and release components
- Removing and installing lid lock - LHD vehicle
- Removing and installing lid lock - RHD vehicle
- Separating Bowden cable
- Removing and installing striker pin
- Removing and installing release lever
- Adjusting bonnet
- Adjusting striker pin
- Rear lid
- Rear lid|Tools
- Assembly overview - rear lid
- Removing and installing rear lid
- Assembly overview - gas strut
- Removing gas strut
- Releasing gas from gas strut
- Assembly overview - rear lid hinge
- Removing and installing rear lid hinge
- Removing and installing striker pin
- Removing and installing stop buffer
- Adjusting rear lid
- Removing and installing lid lock
- Removing and installing release element
- Rear lid seal
- Removing and installing rear lid seal
- Tank flap unit
- Bonnet, flaps, cab, central locking|Bonnet
- Front door, central locking
- Front door
- Door components
- Door components|Tools
- Assembly overview - front door (2-door model)
- Assembly overview - front door (4-door model)
- Removing and installing cover (2-door model)
- Removing and installing cover (4-door model)
- Removing and installing door retaining strap
- Removing and installing striker pin
- Assembly overview - door handle and door lock
- Removing and installing lock cylinder cover cap
- Removing and installing lock cylinder
- Removing and installing cover cap (without lock cylinder)
- Removing and installing door handle
- Removing and installing door lock
- Removing and installing bearing bracket
- Removing and installing window slot inner seal
- Removing and installing window slot outer seal (2-door model)
- Removing and installing window slot outer seal (4-door model)
- Removing and installing door inner seal
- Removing and installing door outer seal (2-door model)
- Removing and installing door outer seal (4-door model)
- Assembly overview - insulation (2-door model)
- Assembly overview - insulation (4-door model)
- Central locking
- Rear door,sliding door,wing doors,central locking
- Rear door
- Door components
- Door components|Tools
- Assembly overview - rear door
- Removing and installing cover
- Removing and installing door retaining strap
- Removing and installing striker pin
- Assembly overview - door handle and door lock
- Removing and installing cover cap
- Removing and installing door handle
- Removing and installing door lock
- Removing and installing bearing bracket
- Removing and installing trim
- Removing and installing window slot inner seal
- Removing and installing window slot outer seal
- Removing and installing door inner seal
- Removing and installing door outer seal
- Assembly overview - insulation
- Sliding roof
- Panorama tilting sunroof
- Panorama tilting sunroof|Tools
- Function
- Panoramic sliding roof normalisation run
- Assembly overview - panorama tilting sunroof
- Removing glass panel for panorama tilting sunroof
- Removing glass panel when drive is defective
- Installing glass panel
- Adjusting glass panel (height adjustment)
- Removing and installing glass panel seal
- Removing and installing cover
- Removing and installing drive for panorama tilting sunroof glass panel
- Removing and installing panorama tilting sunroof switch
- Operating without current
- Removing and installing wind deflector
- Removing and installing interior seal
- Sun blind
- Removing and installing guide rails
- Cleaning water drain hoses
- Assembly frame and hider
- Removing and installing assembly frame
- Removing trim panel
- Installing trim panel
- Preparing body flange for bonding
- Installation instructions
- Minimum curing period for frame
- Minimum curing period for trim
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Panorama tilting sunroof
- Bumper
- Front bumper cover
- Front bumper cover, Polo
- Rear bumper cover
- Rear bumper cover, Polo
- Towing bracket
- Glazing/window mechanism
- Flush bonded windows
- Flush bonded windows|Tools
- Materials
- Assembly overview - windscreen
- Removing windscreen
- Installing windscreen
- Assembly overview - rear window
- Removing undamaged rear window
- Removing broken rear window
- Installing rear window
- Assembly overview - side window (2-door model)
- Removing undamaged side window (2-door model)
- Assembly overview - side window (4-door model)
- Removing undamaged side window (4-door model)
- Removing broken side window
- Installing side window
- Preparing old undamaged window for glazing
- Preparing new window without 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 window
- Rear door window
- Flush bonded windows
- Exterior equipment
- Wheel housing liner
- Exterior mirror
- Exterior mirror|Tools
- Assembly overview - exterior mirror
- Removing and installing mirror glass
- Removing and installing adjustment unit with motor
- Removing and installing mirror housing
- Removing and installing trim
- Removing and installing assembly bracket with side turn signal repeater
- Removing and installing exterior mirror (manual operation)
- Removing and installing exterior mirror (electric operation)
- Radiator grille
- Mouldings and trims
- Removing and installing roof railing
- Roof edge spoiler
- Roof edge spoiler|Tools
- Materials
- Roof edge spoiler, Polo Blue Motion
- Assembly overview - roof edge spoiler, Polo Blue Motion
- Removing middle piece of roof edge spoiler, Polo Blue Motion
- Installing middle piece of roof edge spoiler, Polo Blue Motion
- Removing adapter
- Removing side piece of roof edge spoiler, Polo Blue Motion
- Installing side piece of roof edge spoiler, Polo Blue Motion
- Roof spoiler, Polo »GTI«
- Equipment-dependent attachments
- Safety requirements
- Instructions for fitting equipment-dependent attachments
- Equipment-dependent attachments|Tools
- Materials
- Assembly overview - Polo Blue Motion attachments
- Side member extension, Polo Blue Motion
- Assembly overview - Cross Polo attachments
- Side member extension, Cross Polo
- Front wheel arch trim, Cross Polo
- Rear wheel arch trim, Cross Polo
- Front door cover, Cross Polo
- Rear door cover, Cross Polo
- Wheel arch trim, rear door, Cross Polo
- Assembly overview - attachments, Polo »GTI«
- Side member extension, Polo »GTI«
- Preparing attachment for bonding
- Preparing body kit component for bonding
- Installation instructions
- Minimum curing period
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Cleaning guidelines
- Lettering
- Scuff protection film
- General body repairs, interior
- Interior equipment
- Interior mirror
- Interior mirror|Tools
- Automatic anti-dazzle interior mirror
- Removing and installing interior mirror with rain and light sensorG397
- Bonding retaining plate for interior mirror with rain and light sensorG397
- Removing and installing interior mirror
- Bonding on retaining plate for interior mirror without rain sensor
- Compartments, covers and trims
- Compartments, covers and trims|Tools
- Removing and installing centre console without armrest
- Removing and installing centre console with armrest
- Removing and installing support (vehicles with arm rest)
- Removing and installing rear cup holder (vehicles with arm rest)
- Removing and installing
- Removing and installing hand brake cover cap
- Removing and installing cover for centre console
- Removing and installing dash panel middle trims
- Removing and installing centre dash panel compartment
- Removing and installing centre dash panel storage compartment
- Removing and installing dash panel end trims
- Removing and installing glove compartment
- Removing and installing fuse box cover
- Removing and installing steering column trim
- Removing and installing sun visors
- Sill mouldings and wheel housing trims
- Grab handles
- Interior mirror
- Passenger protection
- Seat belts
- Seat belts|Tools
- 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 (4-door models)
- Removing and installing front seat belt (2-door models)
- Removing and installing belt anchor rail (2-door models)
- Removing and installing front belt height adjuster (4-door models)
- Removing and installing front belt height adjuster (2-door models)
- Removing and installing front belt buckle
- Removing and installing outer rear seat belts (4-door models)
- Removing and installing outer rear seat belts (2-door models)
- Removing and installing centre rear seat belts
- Removing and installing rear double belt buckle
- Inspecting seat belts
- Checking child seat anchors (ISOFIX) after an accident
- Passenger protection|Airbag
- Passenger protection|Tools
- 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)
- Renewing airbag units following an accident
- Removing and installing airbag control unitJ234
- Removing and installing driver airbag unit
- Removing and installing return spring with slip ring
- Removing and installing front passenger airbag unit
- Removing and installing side airbag (vehicles with curtain airbag)
- Removing and installing side airbag (vehicles without curtain airbag)
- Removing and installing curtain airbag
- Removing and installing seat occupied sensor, front passenger sideG128
- Adapting components
- Crash sensors
- Crash sensors|Tools
- Removing and installing side airbag crash sensor on driver sideG179 (4-door models)
- Removing and installing side airbag crash sensor on front passenger sideG180 (4-door models)
- Removing and installing side airbag crash sensor on driver sideG179 (2-door models)
- Removing and installing side airbag crash sensor on front passenger sideG180 (2-door models)
- Removing and installing rear side-airbag crash sensor, driver sideG256
- Removing and installing rear side-airbag crash sensor, front passenger sideG257
- Seat belts
- Trim, noise insulation
- dash panel
- Door and side trims
- Pillar trims
- Pillar trims|Tools
- Removing and installing upper A-pillar trims
- Removing and installing lower A-pillar trim (driver side)
- Removing and installing lower A-pillar trim (passenger side)
- Releasing and securing upper B-pillar trims (4-door models)
- Removing and installing B-pillar trims (4-door models)
- Releasing and securing B-pillar trims (2-door models)
- Removing and installing B-pillar trims (2-door models)
- Removing and installing C-pillar trims (4-door models)
- Releasing and securing C-pillar trims (2-door models)
- Removing and installing C-pillar trims (2-door models)
- Rear lid trim
- Luggage compartment trims
- Luggage compartment trims|Tools
- Removing and installing lock carrier cover
- Removing and installing luggage compartment floor covering
- Removing and installing luggage compartment cover side support
- Removing and installing mounting parts for variable luggage compartment floor
- Removing and installing luggage compartment side trim panel
- Roof trims
- Seat frames
- Front seats
- Front seats|Tools
- Removing and installing front seat
- Removing and installing seat trim on sill side (seat without height adjustment)
- Removing and installing seat trim on sill side (seat with height adjustment)
- Removing and installing seat height adjustment operating lever
- Removing and installing seat trim on tunnel side
- Removing and installing mounting for drawer
- Removing and installing lumbar adjustment lever
- Removing head restraint guides
- Removing and installing front seat backrest
- Rear seats
- Front seats
- Seat padding, covers
- 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
- Assembly overview, vehicles with starter battery in engine compartment
- Assembly overview, vehicles with starter battery in luggage compartment
- Disconnecting and connecting battery, models with starter battery in engine compartment
- Disconnecting and connecting battery, models with starter battery in luggage compartment
- Removing and installing battery
- Battery isolation igniterN253
- Starter, vehicles with manual gearbox
- Starter, vehicles with dual clutch gearbox (DSG)
- Starter, vehicles with automatic gearbox
- Alternator
- Checking poly V-belt
- Checking alternatorC
- Securing B+ (battery positive) wire to alternator
- Alternator, 1.2 l, 51 kW MPI engine
- Alternator, 1.4 l, 63 kW MPI engine
- Alternator, 1.2 l, 66 kW/77 kW TSI engine
- Alternator, 1.4 l, 132 kW TSI engine
- Alternator 1.2 l TDI
- Alternator, 1.6 l TDI engine
- Removing and installing poly V-belt pulley on alternator
- Voltage regulator for alternator
- Cruise control system (CCS)
- Start/stop system
- Instruments, GCI
- Windscreen wipe/wash system
- Windscreen wiper system
- Assembly overview - windscreen wiper system
- Removing and installing wiper arms
- Removing wiper frame with linkage and wiper motor
- Removing wiper motor from wiper frame and installing
- Adjusting wiper blade park position
- Removing and installing joint-free wipers
- Removing and installing wiper blade of joint-free wiper
- Removing and installing rain and light sensorG397
- Windscreen washer system
- Rear window wiper system
- Rear window washer system
- Headlight washer system
- Washer fluid line hose couplings
- Hose repair
- Windscreen wiper system
- Lights, lamps, switches outside
- Operation and safety notes for gas discharge bulbs
- H4 headlights
- Assembly overview - headlights with halogen bulb H4
- Removing and installing headlight
- Adjusting headlight installation position
- Renewing headlight bulbs
- Removing and installing headlight range control motor
- Converting headlights for use when driving on the left or right (halogen headlight)
- Adjusting headlights
- H7 headlights
- Assembly overview - headlights with halogen bulb H7
- Removing and installing headlight
- Adjusting headlight installation position
- Renewing headlight bulbs
- Removing and installing headlight range control motor
- Converting headlights for use when driving on the left or right (halogen headlight H7)
- Adjusting headlights
- Headlights with gas discharge bulbs
- General description
- Assembly overview
- Removing and installing headlight
- Adjusting headlight installation position
- Renewing gas discharge headlight bulb
- Headlight starter for gas discharge bulb
- Headlight range control unitJ431
- Headlight range control motor
- Headlight screen adjustment solenoid
- LED module for daytime running light and side light
- Converting headlights for use when driving on the left or right
- Repairing headlight retaining tabs
- Adjusting headlights
- Fog lights
- Fog light Polo Cross (Polo Dune)
- Daytime running lights
- Tail light
- Number plate light
- Additional brake light
- Steering column switch
- Ignition/starter switch and lock cylinder
- Steering lock housing
- Parking aid
- 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 headlight range control regulatorE102 and switch and instrument illumination regulatorE20
- Buttons, switches and warning lamps in centre of dash panel
- Removing and installing petrol or gas fuel selection switchE395
- Removing and installing tyre pressure monitor display buttonE492
- Removing and installing key-operated switch to deactivate front passenger side airbagE224
- Removing and installing left footwell lightW9 and right footwell lightW10
- Lights and switches in doors
- Removing and installing window regulator switch in front passenger doorE107
- Removing and installing switch module for driver side window regulator
- Removing and installing switch module for mirror adjustment on driver side
- Removing and installing driver side interior locking button for central locking systemE308
- Components - front door locks
- Driver side interior locking warning lampK174 and central locking deadlock function warning lamp on front passenger sideK204
- Lights and switches in luggage compartment and rear lid
- Lights and switches in roof trim
- 12 V socket
- Cigarette lighterU1
- Lights, lamps, switches inside, anti-theft system|Horn
- Immobiliser
- Anti-theft alarm (ATA)
- Wiring
- Starter-current supply-CC
- Communication
- Infotainment
- Communication Systems
- Radio units and radio navigation systems in general
- Radio system "RCD 210"
- Radio system "RCD 310"
- Radio system "RCD 510"
- Features of radio unit "RCD 510"
- General notes
- Overview of radio system "RCD 510"
- 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 navigation system "RNS 310"
- Multimedia system control unit
- Loudspeaker systems
- Telephone system
- Aerial systems
- General notes
- Overview of aerial systems
- Aerial preparation for single AM/FM aerial
- Aerial preparation for single AM/FM/FM2 aerial with diversity function
- Aerial system for vehicles with radio system "RCD 210"
- Aerial system for vehicles with radio system "RCD 310"
- Aerial system for vehicles with radio system "RCD 510"
- Aerial system for vehicles with radio navigation system "RNS 310"
- Removing and installing aerial modules
- Removing and installing 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
- 5-speed manual gearbox 02T
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview - clutch actuation
- Assembly overview - pedal cluster, Polo 2010 ?
- Distinguishing between clutch pedal switchesF36
- Removing and installing, adjusting clutch pedal switchF36 with round housing
- Removing and installing clutch pedal switchF36 with round housing
- Removing and installing mounting bracket with master cylinder, Polo 2010 ?
- Removing and installing clutch pedal with over-centre spring, Polo 2010 ? LHD
- Removing and installing clutch pedal with extension spring, Polo 2010 ? LHD
- Removing and installing clutch pedal, Polo 2010 ? RHD
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing master cylinder, Polo 2010 ?
- 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
- Overview of selector mechanism
- Assembly overview - selector lever knob and cover, Polo 2010 ?
- Removing and installing gear knob and cover, Polo 2010 ?
- Repairing gear lever and selector housing (from 06.06)
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox, Polo 2010 ?
- 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
- 5-speed manual gearbox 02R
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview - clutch actuation
- Assembly overview - pedal cluster, Polo 2010 ?
- Distinguishing between clutch pedal switchesF36
- Removing and installing clutch pedal switchF36 with rectangular housing
- Removing and installing clutch pedal switchF36 with round housing
- Removing and installing mounting bracket with master cylinder, Polo 2010 ?
- Removing and installing clutch pedal with over-centre spring, Polo 2010 ? LHD
- Removing and installing clutch pedal with extension spring, Polo 2010 ? LHD
- Removing and installing clutch pedal, Polo 2010 ? RHD
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing master cylinder, Polo 2010 ?
- 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
- Overview of selector mechanism
- Assembly overview - selector lever knob and cover, Polo 2010 ?
- Removing and installing gear knob and cover, Polo 2010 ?
- Repairing gear lever and selector housing (from 06.06)
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing gearbox, Polo 2010 ?
- 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 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
- Repairing gearbox housing and clutch housing
- Dismantling and assembling selector mechanism on gearbox side (selector shaft can be removed from selector mechanism cover)
- Dismantling and assembling selector mechanism on gearbox side (selector shaft cannot be removed from selector mechanism cover)
- Dismantling and assembling selector forks
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 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 testing
- Gearbox identification
- Identification codes, engine allocation, Polo 2010 ?
- Capacities
- 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
- Checking selector mechanism
- Removing and installing gearbox; 1.6 l - 77 kW engine
- Transporting gearbox
- Checking ATF level and topping up
- ATF cooler
- Automatic gearbox, gears, control
- Final drive, differential, differential lock
- Technical data
- 7-speed dual clutch gearbox 0AM
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Renewing gear oil
- Selector mechanism in vehicles up to 02.2009
- Emergency release of selector lever
- Removing and installing selector lever handle
- 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; Polo 2010 ?, 1.2 l - 63 and 77 kW petrol engine
- Removing gearbox; Polo 2010 ?, 1.4 l - 63 kW petrol engine
- Removing gearbox; Polo 2010 ?, 1.6 l - 66 kW diesel engine
- Removing gearbox; Polo 2010 ?, 1.4 l - 132 kW petrol 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 manual gearbox 02U
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview - clutch actuation
- Assembly overview - pedal cluster
- Removing, installing and adjusting clutch pedal switchF36
- Removing and installing mounting bracket with master cylinder
- Removing and installing clutch pedal with over-centre spring, LHD
- Removing and installing clutch pedal with extension spring, LHD
- Removing and installing clutch pedal, RHD
- Assembly overview - hydraulics (LHD)
- Assembly overview - hydraulics (RHD)
- Removing and installing master cylinder
- 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
- Overview of selector mechanism
- Assembly overview - gear knob and cover
- Removing and installing gear knob and cover
- Repairing gear lever and selector housing
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism
- Removing and installing 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, differential, selector mechanism and selector forks
- 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 02T
- Power unit
- 4-cyl. injection engine with timing chain
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Characteristics of the sealing flange and the assembly device T10017 and T10134
- Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
- 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 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
- Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
- 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 - Pressing sender wheel
- Removing and installing crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- 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 G
- Removing and installing fuel tank
- Assembly overview - fuel filter with attachments
- Removing and installing fuel filter
- Crash fuel shut-off
- Checking fuel pump
- 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
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Removing and installing injectors
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve module J338
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Engine control unit J623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cyl. injection engine (toothed belt drive)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview
- Pulling needle bearing out of and driving into crankshaft
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Removing and installing drive plate
- 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 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
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Parts of cooling system
- Fuel supply, gas operation
- 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 (engine code CGGB)
- 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
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Checking injectors
- Checking intake air preheating
- Safety precautions
- Rules for cleanliness
- Technical data
- Engine control unitJ623
- Injection system
- Exhaust system
- Parts of the exhaust system
- Assembly overview - front exhaust system with attachments
- Assembly overview - front exhaust system with attachments
- Assembly overview - silencers with mountings
- Exhaust gas recirculation system
- Parts of the exhaust system
- 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
- Cylinder block (pulley end)
- Assembly overview - poly V-belt drive
- Assembly overview - cylinder block, belt pulley end
- Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet)
- Removing and installing ancillary bracket
- Renewing crankshaft oil seal - pulley end
- Removing and installing crankshaft pulley
- Cylinder block, gearbox end
- Assembly overview - cylinder block, gearbox end
- Removing and installing sealing flange on gearbox side
- 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
- Pistons and conrods
- Cylinder block (pulley end)
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Cooling system, coolant
- Coolant pump, regulation of cooling system
- Assembly overview - thermostat
- Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Removing and installing coolant circulation pumpV50 (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)
- Radiator, radiator fan
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder diesel engine (1.6 l engine, common rail)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block (pulley end)
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive (vehicles with idler roller and air conditioner compressor)
- Assembly overview - poly V-belt drive (vehicles with tensioning element and air conditioner compressor)
- Removing and installing poly V-belt (vehicles without air conditioner compressor)
- Removing and installing poly V-belt (vehicles with idler roller)
- Removing and installing poly V-belt (vehicles with tensioning element)
- Removing and installing tensioner for poly V-belt
- Removing and installing vibration damper
- Ancillary bracket (removing and installing)
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing sealing flange - pulley end
- Removing and installing poly V-belt
- Assembly overview - poly V-belt drive without air conditioning compressor
- Assembly overview - poly V-belt drive with tensioning element and air conditioner compressor
- Removing and installing poly V-belt without air conditioner compressor
- Removing and installing poly V-belt with tensioning element
- Removing and installing tensioning element for poly V-belt
- Cylinder block, gearbox end
- Assembly overview - cylinder block, gearbox end
- Removing and installing flywheel (vehicles with dual-mass flywheel)
- Assembly overview - removing and installing flywheel (vehicles with single flywheel)
- Removing and installing sealing flange on gearbox side
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- a) Securing seal with sender wheel on assembly toolT10134
- b) Securing 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
- 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 sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- a) Securing seal with sender wheel on assembly toolT10134
- b) Securing 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
- Pistons and conrods
- Crankshaft
- Cylinder block (pulley end)
- Engine cylinder head, valve gear
- Cylinder head
- Assembly overview - cylinder head
- Removing and installing Hall senderG40
- Assembly overview - cylinder head cover
- Removing and installing cylinder head cover
- Removing and installing injector seal in cylinder head cover
- Removing, installing and tensioning toothed belts
- Removing and installing cylinder head
- Removing and installing vacuum pump
- Checking compression
- Valve gear
- Toothed belt drive
- Cylinder head
- Engine lubrication
- Engine oil
- Sump, oil pump
- Parts of lubrication system
- Engine oil cooler
- Oil filter, oil pressure switch
- Oil filter bracket, oil pressure, engine oil cooler and oil supply line
- Oil circuit
- Oil supply line and turbocharger support
- Engine cooling
- Cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - cowling with radiator fanV7
- Parts of cooling system, engine side
- Assembly overview - coolant pump and 4/2-way valve with thermostat
- Removing and installing 4/2-way valve with thermostat
- Coolant hose schematic diagram
- Removing and installing cowling with radiator fanV7
- Removing and installing radiator and detaching charge air cooler from radiator
- Removing and installing coolant temperature senderG62
- Removing and installing coolant temperature sender at radiator outletG83
- Removing and installing coolant circulation pump 2V178
- Removing and installing coolant pump
- Removing and installing front coolant pipe
- Removing and installing right coolant pipes
- Cooling system, coolant
- Draining and replenishing coolant
- Coolant pump, regulation of cooling system
- Coolant pipes
- Coolers, radiator, radiator fan
- Cooling system
- Fuel supply, gas operation
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Repair instructions if tank has been filled with incorrect
fuel
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are metal particles in fuel delivery unit and fuel tank)
- Step 4 (There are no metal particles in fuel delivery unit and fuel tank)
- Step 5 (There are metal particles in high-pressure pump)
- Step 6 (There are no metal particles in high-pressure pump)
- Emptying fuel tank
- Parts of fuel supply system
- Fuel gauge sender G 6
- Repairing fuel supply
- Testing low-pressure fuel systems (fuel pump)
- Exhaust turbocharger, G-charger
- Charge air system with turbocharger
- Turbocharger
- Checking charge air system
- Charge air system
- Vacuum system
- Fuel preparation system Diesel injection
- Injection system
- Safety precautions, rules for cleanliness, assembly instructions
- Injectors, high pressure accumulator
- Mixture preparation, 1.6 l common rail
- High-pressure pump
- Removing and installing components of the diesel direct injection system
- Senders and sensors
- Filling/bleeding/checking the diesel direct injection system
- Lambda probe
- Intake manifold
- Assembly overview - intake manifold with attachments (vehicles with intake manifold flapV157)
- Assembly overview - intake manifold with attachments (vehicles without intake manifold flap)
- Removing and installing intake manifold (vehicles with intake manifold flapV157)
- Removing and installing intake manifold (vehicles without intake manifold flapV157)
- Removing and installing throttle valve moduleJ338
- Air filter
- Engine control unit
- Exhaust system
- Exhaust system
- Exhaust pipes, silencers
- Exhaust gas recirculation system
- Cleansing exhaust emissions
- Exhaust gas temperature regulation
- Exhaust gas recirculation
- Ignition system, glow plug system
- 3-cylinder injection engine (4-valve)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- 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 senderG
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleeding fuel system
- Activated charcoal filter system
- Electronic power control (EPC)
- Parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Injection system
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Cleaning throttle valve moduleJ338
- Checking injectors
- Safety precautions
- Rules for cleanliness
- Technical data
- Engine control unitJ623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 3-cylinder injection engine (2-valve)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- 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 senderG
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleeding fuel system
- Activated charcoal filter system
- Electronic power control (EPC)
- Parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Injection system
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Cleaning throttle valve moduleJ338
- Checking injectors
- Check non-return valve for crankcase breather
- Safety precautions
- Rules for cleanliness
- Technical data
- Engine control unitJ623
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Cylinder block (pulley end)
- Cylinder block, gearbox end
- Assembly overview - cylinder block, gearbox end
- Removing and installing crankshaft sealing flange on gearbox side
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- Mounting seal with sender wheel on assembly toolT10134
- Mounting assembly toolT10134 with sealing flange on crankshaft flange
- Bolting assembly toolT10134 onto crankshaft flange
- Pressing sender wheel onto crankshaft flange using assembly toolT10134
- Checking sender wheel installation position on crankshaft
- Re-pressing sender wheel
- Removing and installing ancillary bracket (top)
- Removing and installing ancillary bracket (bottom)
- Crankshaft
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- 3-cylinder diesel engine (1.2 l engine, common rail)
- Engine assy,cylinder block,crankcase
- 4-cylinder injection engine (1.6 l engine, BiFuel) Volkswagen R GmbH
- Technical data
- Self diagnosis, V.A.G Inspection Service
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - 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
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- 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
- Checking cooling system for leaks
- Removing and installing cowling with radiator fanV7
- Removing and installing radiator fanV7
- Removing and installing radiator
- Removing and installing coolant pump
- Parts of cooling system
- Fuel supply, gas operation
- Parts of fuel supply system
- Assembly overview - fuel tank with attachments
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Emptying fuel tank
- Removing and installing fuel delivery unit
- Removing and installing external fuel gauge senderG with two cable connections
- Removing and installing interior fuel gauge senderG
- Removing and installing fuel tank
- Removing and installing fuel filter
- Crash fuel shut-off
- Checking fuel pump
- Bleeding fuel system
- Parts of Autogas (LPG) fuel supply system
- Emptying the fuel tank (Autogas)
- Emptying the gas line
- Assembly overview - gas tank (Autogas)
- Removing and installing pressure relief valve
- Removing and installing inlet valve
- Gas gauge senderG707
- Removing and installing fuel gauge sender
- Removing and installing gas tank valveN495
- Removing and installing fuel tank (Autogas)
- 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
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Removing and installing injectors
- Fuel rail, removing and installing gas rail
- Removing and installing gas injectors
- Removing and installing gas rail sensorG401
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Safety precautions
- Rules for cleanliness
- Technical data
- Renewing filter on Autogas system
- Removing and installing vaporiser on vehicles which can be operated with liquid gas
- Checking components
- Engine control unitJ623
- Gas mode control unitJ659
- Injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.4 l engine, BiFuel) Volkswagen R GmbH
- Technical data
- Self diagnosis, V.A.G Inspection Service
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Removing and installing drive plate
- Characteristics of the sealing flange and the assembly devicesT10017 and assembly deviceT10134
- 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 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 - 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
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- 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
- Parts of Autogas (LPG) fuel supply system
- Emptying the fuel tank (Autogas)
- Emptying the gas line
- Assembly overview - gas tank (Autogas)
- Removing and installing pressure relief valve
- Removing and installing inlet valve
- Gas gauge senderG707
- Removing and installing fuel gauge sender
- Removing and installing gas tank valveN495
- Removing and installing fuel tank (Autogas)
- 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
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Fuel rail, removing and installing gas rail
- Assembly overview - air filter
- Removing and installing air filter housing
- Cleaning throttle valve moduleJ338
- Checking injectors
- Safety precautions
- Rules for cleanliness
- Technical data
- Removing and installing vaporiser on vehicles which can be operated with liquid gas
- Engine control unitJ623
- Removing and installing engine control unitJ623
- Removing and installing anti-theft engine control unitJ623
- Removing and installing anti-theft engine control unitJ623
- Gas mode control unitJ659
- Injection system
- Exhaust system
- Ignition system, glow plug system
- Fuel supply system - Diesel engines
- Technical data
- Fuel supply, gas operation
- What to do if fuel tank filled with incorrect fuel
- Step 1 (Engine was started with incorrect fuel)
- Step 2 (Engine was not started with incorrect fuel)
- Step 3 (There are filings in fuel delivery unit and fuel tank)
- Step 4 (There are no filings in fuel delivery unit or fuel tank)
- Step 5 (There are filings in high-pressure pump)
- Step 6 (There are no filings in high-pressure pump)
- Fuel tank
- Assembly overview - fuel tank
- Removing, installing and checking breather valve
- Removing and installing fuel tank
- Emptying fuel tank
- Emptying fuel tank when fuel pump is intact (CAYA, CAYB, CAYC)
- Emptying fuel tank when fuel pump is intact (CFWA)
- Emptying fuel tank when it is more than 3/4 full (CAYA, CAYB, CAYC)
- Emptying fuel tank if it is more than 3/4 full (CFWA)
- Emptying fuel tank when it is less than 3/4 full (CAYA, CAYB, CAYC)
- Emptying fuel tank if it is less than 3/4 full (CFWA)
- Fuel delivery unit, fuel gauge sender
- Detaching push-on connectors
- Fuel filter
- Accelerator mechanism
- Fuel pump
- Checking fuel pump
- Checking fuel delivery rate of fuel system pressurisation pumpG6 (CAYA, CAYB, CAYC)
- Checking fuel delivery rate of fuel system pressurisation pumpG6 (CFWA)
- Checking fuel pressure of fuel pumpG6 for delivery rate (CFWA)
- Checking delivery pressure in the fuel return line (CFWA)
- Checking the current consumption of fuel pump for delivery rateG6 (CAYA, CAYB, CAYC)
- Checking current consumption of the fuel pump for delivery rateG6 (CFWA)
- Checking voltage supply of the fuel pump for delivery rateG6 (CAYA, CAYB, CAYC)
- Checking current consumption of the fuel pump for delivery rateG6 (CFWA)
- Checking fuel pump
- What to do if fuel tank filled with incorrect fuel
- Fuel supply system - Petrol engines
- Technical data
- Fuel supply, gas operation
- 4-cyl. injection engine with timing chain
- Heating, ventilation, air conditioning system
- Heating, air conditioning
- Heating
- Repairing heating system
- Passenger compartment heating
- Removing and installing fresh air blowerV2
- Removing and installing fresh air blower series resistor with overheating fuseN24
- Removing and installing dust and pollen filter
- Removing vents
- Removing and installing controls for heated and fresh air
- Pin assignment for multi-pin connectors on back of controls for heated and fresh air
- Removing and installing flexible shafts, checking
- Checking ventilation
- Removing and installing heater unit
- Dismantling and assembling heater unit
- Removing and installing air distribution flap actuator
- Removing and installing temperature flap actuator
- Removing and installing fresh air and air recirculation flap control motorV154
- Assembly overview - heat exchanger
- Removing and installing heat exchanger
- Removing and installing auxiliary air heater elementZ35
- Checking auxiliary air heater elementZ35
- Repairing heating system
- Air conditioner
- Notes on repair work to vehicles with air conditioning and on handling refrigerant
- Climatic air conditioning system with manual regulation up to week 44/10
- Climatic - passenger compartment
- Functions of the Climatic* heating regulation and air-conditioning system
- Removing and installing Climatic heating regulation and air-conditioning system
- Pin assignment for multi-pin connectors on back of Climatic heating regulation and air-conditioning system
- Removing and installing flexible shaft
- Checking water drain valve
- Removing and installing temperature flap control motorV68
- Air conditioning system with manual regulation from week 45/10
- Climatronic air conditioning with automatic regulation
- Procedure for checking and adjusting components
- Function of operating and display unit for Climatronic air conditioning systemE87 with Climatronic control unitJ255
- Removing and installing operating and display unit for Climatronic air conditioning systemE87 with Climatronic control unitJ255
- Pin assignment of multi-pin connectors on rear of Climatronic control unitJ255
- Climatronic - passenger compartment
- Removing and installing footwell vent temperature senderG192
- Removing and installing evaporator output temperature senderG263
- Removing and installing centre vent temperature senderG191
- Removing and installing sunlight penetration photosensorG107
- Removing and installing fresh air blower control unitJ126
- Locally manufacturing an adapter cable to activate control motors
- Removing and installing air flow flap control motorV71
- Removing and installing central flap control motorV70
- Removing and installing defroster flap control motorV107 and temperature flap control motorV68
- Removing and installing ancillary bracket for air conditioner compressor
- Differences in repair work for right-hand drive vehicles
- Air conditioning system with manual controls "Climatic", right-hand drive vehicles
- Air conditioning system with automatic regulation "Climatronic", right-hand drive vehicles
- Climatronic - passenger compartment
- Removing and installing evaporator output temperature senderG263
- Removing and installing centre vent temperature senderG191
- Removing and installing central flap control motorV70
- Removing and installing air flow flap control motorV71
- Removing and installing defroster flap control motorV107 and temperature flap control motorV68
- Removing and installing heater and air conditioning unit, right-hand drive vehicles
- Repair work on refrigerant circuit which may be performed only in appropriate workshops by specially trained mechanics
- Required special tools, facilities, testing and measuring instruments and auxiliary items
- 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 evacuating and charging valve, high-pressure side and low-pressure side
- Removing and installing high-pressure senderG65
- Removing dryer cartridge
- Dismantling and assembling evaporator housing
- Removing and installing poly V-belt pulley or air conditioning system magnetic clutchN25
- Checking high-pressure safety valve on air conditioner compressor
- Removing and installing air conditioner compressor
- Notes on installing air conditioner compressor
- Expansion valve, function and removal
- Removing and installing condenser
- Capacities
- Heating
- Air conditioning system with refrigerant R134a
- Technical data
- General notes on air conditioning systems
- Introduction
- Additional information
- Basics of air conditioning
- Vapour pressure table for refrigerant R134a
- Refrigerant R134a
- Characteristics of refrigerant R134a
- Refrigerant machine oil
- General notes on air conditioning systems|Comfort
- How air conditioning works
- General safety
- Product characteristics
- Handling refrigerants
- Wear protective glasses
- Wear protective gloves and apron
- Do not allow liquid refrigerant to come in contact with the skin
- Do not breath in refrigerant vapour
- Absolutely NO SMOKING
- Welding and soldering on refrigeration systems
- Pungent smell
- First aid
- Handling pressure vessels
- Do not heat above 50° C
- Do not apply uncontrolled heat
- Seal empty containers
- Safety instructions for using extraction and charging equipment
- Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a
- Basics for working on refrigerant circuit
- General information on refrigerant circuit
- Refrigerant circuit components
- Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides
- Air conditioning system compressor with magnetic clutch:
- Air conditioner compressor without magnetic clutch
- Air conditioner compressor without magnetic clutch, with elastic drive coupling
- Electric compressor for hybrid vehicles
- Condenser
- Evaporator
- Reservoir
- Restrictor
- Receiver
- Expansion valve
- Refrigerant circuit components|O-ring
- Pipes and hoses in refrigerant circuit
- High-pressure safety valve
- Design of refrigerant circuit
- Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit
- Switch and sender in refrigerant circuit and related connections
- High-pressure switch for air conditioning systemF23
- High-pressure switch for magnetic clutchF118
- Low-pressure switch for air conditioning systemF73
- Connections to valves for switches in the refrigerant circuit
- Air conditioning system pressure switchF129
- High-pressure senderG65
- Refrigerant pressure and temperature senderG395
- Air conditioner compressor regulating valveN280
- Electrical components not installed in refrigerant circuit
- Pressures and temperatures in the refrigerant circuit
- Refrigerant circuit with expansion valve
- Refrigerant circuit with restrictor and reservoir
- Test and measurement work that can be performed using a pressure gauge
- Air conditioner service and recycling equipment
- Notes to repairs on refrigerant circuit
- Refrigerant circuit components
- Statutory texts and instructions
- Refrigerant circuit
- Working with the air conditioner service station
- Important notes for working with the air conditioner service station
- Connecting air conditioner service station for measuring and checking
- Draining refrigerant circuit using air conditioner service station
- Evacuating refrigerant circuit using air conditioner service station
- Charging refrigerant circuit using air conditioner service station
- Bringing air conditioning system into service after charging
- Charging container in air conditioner service station with refrigerant
- Draining air conditioner service station
- Detecting leaks in refrigerant circuit
- Clearing refrigerant circuit of contaminants
- Complaints
- Connecting air conditioner service station
- Checking pressures on vehicles
- Checking pressures in refrigerant circuit (using air conditioner service station)
- Checking systems with a restrictor and collector (with internally regulated air conditioner compressor)
- Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor)
- Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor)
- Checking systems with a restrictor and reservoir and air conditioner compressor regulating valveN280 (with externally regulated
- Checking systems with an expansion valve, receiver and air conditioner compressor regulating valveN280 (with externally regulate
- With expansion valve, receiver and electric compressor for hybrid vehicles
- Renewing components
- Testing equipment and tools
- List of test equipment, tools and materials
- Tools and materials available from distribution centre or importer
- Tools and materials commercially available
- Tools to be made locally
- Tools and materials available from distribution centre or importer
- Tools and materials commercially available
- Tools to be made locally
- List of test equipment, tools and materials
- General notes on air conditioning systems
- Technical data
- Heating, air conditioning