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Volkswagen golf 2006, Work Description, Page: 40 / 93

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Volkswagen golf 2006 Work Description Download Page 40

  

  

„

Torque wrench V.A.G 1783  

 

 

Removing

„

Self-tapping screws, Qty. 8, torque specification 2 
Nm.   

„

Combi-screws, Qty. 3, torque specification 6 Nm.   

- Remove bolts 

- arrows  - 

. 

-  Remove noise insulation rearward.

Installing

-  Slide noise insulation 

- 3  - 

as shown into lower lock 

carrier 

- 2  - 

. 

-  The narrow latches 

-  arrow a  - 

must be slid below or 

wide latches 

- arrow b  - 

slid above the lock carrier edge 

- 

3   - 

. 

-  Retaining tabs must engange over wide tabs in lock 
carrier holes when doing so.

 

- Tighten screws 

- arrows  - 

to correct torque 

specification. 

Engine and components in engine compartment (from 

Page 30 / 37

Description of work (part 1 of 2)

Summary of Contents for golf 2006

Page 1: ...sible lifting capacity of the platform Vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent vehicle from tipping Never start engine and engage a gear with vehicle lifted so long as even one wheel has contact with the floor There is a risk of an accident if this is not observed If work is to be performed under vehicle it must be ...

Page 2: ...er contacts support plate of lifting platform at center Rear Place support plate in area of side member marking arrow A on vertical stiffener of floor plate arrow B Warning Make sure that side member stiffener contacts support plate of lifting platform at center Data stickers Apply sticker First service at the delivery inspection Page 2 10 General ...

Page 3: ... wallet Destroy the instruction after attaching the sticker Apply sticker Next service Service sticker Next service Enter a cross at the position for oil change service or inspection service next service due and enter date odometer reading Apply sticker on drivers side door beam B pillar Applying Data sticker in service schedule Apply the upper of the two data stickers arrow 1 Planning week Page 3...

Page 4: ...ecial tools testers and auxiliary items required Vehicle Diagnosis Testing and Information System VAS 5051 A Vehicle Diagnosis Testing and Information System VAS 5051B Vehicle diagnosis service syst VAS 5052 or later testers Page 4 10 General ...

Page 5: ...ystem VAS 5053 Diagnostic cable VAS 5051 6A Warning During a test drive you must always secure testing and measuring equipment on the back seat Drivers must NEVER operate these tools while driving Page 5 10 General ...

Page 6: ...witch ignition on Now follow information given on screen to start the desired functions Vehicle Identification Number VIN Component location engine compartment Vehicle Identification Number VIN is located on extension of longitudinal member arrow Meaning of Vehicle Identification Number VIN 000 234 Page 6 10 General ...

Page 7: ...spare wheel well under foam storage tray The vehicle data sticker can also be found in the service schedule for the customer Sticker contains the following vehicle data 1 Production control number 2 Vehicle Identification Number VIN 3 Model identification number 4 Model explanation engine output 5 Engine and transmission code letters 6 Paint number interior equipment identification number 7 Option...

Page 8: ...Vehicles marked with the following PR number QG2 indicates time or distance dependent service QG0 means time or distance dependent service Engine oils Approved engine oil norms for vehicles For information regarding approved oil types please refer to Additional Information Fluid Capacity Charts for appropriate model and year Engine code and engine number Engine code and engine identification are f...

Page 9: ...tained 01 3 Data stickers Vehicles with PR number QG0 QG2 Oil change service Page Oil change service at 5 000 miles 8 000 km whichever occurs first according to service interval display 01 2 Oil change service Inspection service oil change service inspection service every 10 000 miles 15 000 km or after 1 year Page Oil change service every 10 000 miles 15 000 km or after 1 year whichever occurs fi...

Page 10: ...t front door in lower area of B pillar Sticker contains the following vehicle data A Vehicle Identification Number VIN B Axle loads C Model identification number 2 door vehicles Type plate is visible after opening right door on door beam at bottom Page 10 10 General ...

Page 11: ...transmission check ATF level 09G transmission Work procedure Repair Manual Automatic transmission 09G Repair Group 37 ATF level checking and topping of Battery check battery terminals for secure seating Special tools testers and auxiliary items required Torque wrench V A G 1331 Note Page 1 37 Description of work part 1 of 2 ...

Page 12: ...ated securely on the battery terminals by moving the battery Ground GND wire 1 and the battery positive wire 2 back and forth by hand Warning If the battery clamp is not seated securely on the positive terminal disconnect battery Ground GND clamp on battery negative terminal first to prevent possible accidents If the battery clamp on positive terminal is not seated securely Page 2 37 Description o...

Page 13: ...ttery clamp 1 on battery negative terminal and tighten to 9 Nm If the battery clamp on negative terminal is not seated securely Tighten ground connection 1 on battery to 9 Nm Reinstall cover Note Once the battery is reconnected Repair Manual Electrical Equipment Repair Group 27 Battery check Page 3 37 Description of work part 1 of 2 ...

Page 14: ...4 General notes Check tire inflation pressure using tire inflation device VAS 5216 and correct it if necessary Rabbit GTI 2006 01 4 Tire pressures Rabbit GTI 2006 Special tools testers and auxiliary items required Tire filling unit VAS 5216 Tire condition checking Warning If damage is discovered the tire must be examined to determine whether a new one must be installed Tests during delivery inspec...

Page 15: ...the treads may indicate faulty toe adjustment One sided tread wear is mainly attributed to incorrect camber When wear of this nature is noticed determine cause by performing alignment checks repair measure Depth of tire tread including spare wheel check Check tire tread depth Minimum depth 1 6 mm Note This value may vary for individual countries due to different legislative regulations The minimum...

Page 16: ...res on warm tires Tires pressures for the relevant model are on a sticker attached to the inside of fuel tank flap Adapt tire pressure corresponding to load The spare wheel receives the highest tire pressure designated for the vehicle Note that a basic setting should be performed after every change in pressure in vehicles with tire pressure control indicator 01 5 Tire pressure control indicator pe...

Page 17: ...e and clutch systems changing fluid Notes on application and safety 01 4 Notes on application and safety precaution Specification of brake fluid 01 4 Specification of brake fluid Work procedure changing brake fluid 01 4 Work procedure changing brake fluid Notes on application and safety precaution Note From model year 2006 a new brake fluid is introduced The new brake fluid can also be used for ol...

Page 18: ...pillage using plenty of water Do not reuse used extracted brake fluid Observe waste disposal regulations Specification of brake fluid Permissible specifications of brake fluid for vehicles up to model year 2005 Brake fluid corresponding to US standard FMVSS 116 DOT 4 previous brake fluid Brake fluid corresponding to VW standard VW 501 14 new brake fluid Permissible specifications of brake fluid fo...

Page 19: ... Brake charger bleeder unit VAS 5234 Brake pedal depressor V A G 1869 2 Unscrew brake fluid reservoir cap 1 Page 9 37 Description of work part 1 of 2 ...

Page 20: ...removed Warning Extracted brake fluid must not be re used Screw adapter 1 onto brake fluid reservoir Observe operating instructions for VAS 5234 Install brake pedal depressor V A G 1869 2 between drivers seat and brake pedal and apply tension Connect charger hose of brake charger bleeder unit VAS 5234 to adapter Page 10 37 Description of work part 1 of 2 ...

Page 21: ...d hose It must seat tightly on bleed screw so that no air can enter brake system Repeat work procedure on left side of vehicle at rear Connect collector bottle bleeder hose 1 to right front bleeder screw open bleed screw and allow the corresponding quantity to flow out see table Close bleeder screw Repeat work procedure on left side of vehicle at front Table Sequence quantity of brake fluid Sequen...

Page 22: ... hose off adapter Unscrew adapter from brake fluid reservoir Check brake fluid level and correct if necessary Screw in cap 1 for brake fluid reservoir Remove brake pedal depressor Check pedal pressure and brake pedal free play Free play Max 1 3 of pedal travel Brake fluid level check Brake fluid level at delivery inspection Brake fluid level at Inspection Service Warning If fluid level is below MI...

Page 23: ...ake fluid level at delivery inspection At time of delivery inspection brake fluid level must be at MAX mark 1 Note To prevent the brake fluid from overflowing from the reservoir the level must not be over the MAX mark 1 Brake fluid level at Inspection Service The fluid level must always be judged in conjunction with brake pad wear When vehicle is in use the fluid level tends to drop slightly due t...

Page 24: ...ake master cylinder Brake booster on anti lock braking system Hydraulic unit Brake pressure regulator and Brake calipers Check that brake hoses are not twisted Turn steering to left stop and to right stop During this operation no brake hose must touch any vehicle components Check brake hoses are not porous or brittle Check brake hoses and pipes for chafing Check brake connections and methods of se...

Page 25: ...ter to loosen tighten the anti theft wheel bolts is located in the vehicle tool kit 01 5 Tire repair kit Front disc brake pads For better judgement of remaining pad thickness remove the front wheel on the drivers side Pull off wheel bolt covers if necessary 01 5 Wheel securing bolts tighten to correct torque setting Mark position of wheel in relation to brake disc Unbolt wheel securing bolts and r...

Page 26: ...scs is a repair measure Check brake disc for wear Repair Manual Suspension Wheels Brakes Steering Repair Group 46 Front brakes servicing Install wheel to marked position Tighten wheel securing bolts using diagonal sequence to tightening torque 01 5 Wheel securing bolts tighten to correct torque setting Place adapter with vehicle tool kit after completing work Reinstall wheel bolt covers if necessa...

Page 27: ... measure Check brake disc for wear Repair Manual Suspension Wheels Brakes Steering Repair Group 46 Rear brakes servicing 6 speed Direct Shift Gearbox 02E Oil and filter changing Work procedure Repair Manual 6 Spd Direct Shift Automatic Transmission 02E Front Wheel Drive Repair Group 34 Electric windows check positioning Note After disconnecting and reconnecting the battery the run up and run down ...

Page 28: ...longer than 1 second Lift button again for 1 second Now when the button is pressed briefly the window will lower fully and when the button is lifted briefly the window will raise fully Switch off ignition Vehicle system test perform Connect diagnostic tester 01 3 Diagnostic unit connecting Switch ignition on Select operating mode Guided Fault Finding on the display Then perform vehicle identificat...

Page 29: ...pair this malfunction via Guided Fault Finding Sporadic malfunctions In the event only sporadic malfunctions or notes are stored in DTC memory and the customer has made registered no complaint in conjunction with an electronic vehicle system erase DTC memory Press the Continue button again to enter the test plan Now end Guided Fault Finding via Go to button and then End All DTC memories will be ch...

Page 30: ... at vibration damper belt pulley using a socket wrench Check ribbed belt 1 for Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base break up Fraying of cord strands Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks Page 20 37 Description of work part 1 of 2 ...

Page 31: ... off rear window heater Turn off ignition Cooling system freeze protection and coolant level checking Note All engines are filled with coolant additive G 12 Plus according to TL VW 774 F color purple G 12 Plus can be mixed with the previous coolant additives G 11 and G 12 red Ensure that the system is replenished only with G12 Plus due to its positive properties G 12 Plus is suitable as a filled f...

Page 32: ...tely 13 F 25 C Checking freeze protection and adding coolant additive if necessary Special tools testers and auxiliary items required Refractometer T10007 Note Read the bright dark boundary to obtain an accurate reading for the following tests Place a drop of water on the glass to improve the readability of the bright dark boundary The bright dark boundary can be clearly recognized on the WATERLIN...

Page 33: ...be increased but only up to 60 freeze protection to about 40 F 40 C otherwise freeze protection and cooling effectiveness will be reduced If freeze protection is insufficient drain off required quantity shown in freeze protection table and add coolant additive G 12 Plus Note Observe waste disposal regulations Freeze protection to C Difference amount in liters Actual value Specified value 4 cylinde...

Page 34: ...ssary With engine at operating temperature coolant level must be at top marking with engine cold it must be in center of hatched area Delivery inspection Coolant level above the MIN marking arrow Inspection service Coolant level above the MIN marking arrow If coolant is too low add required amount according to mixture ratio Note Determine cause of fluid loss which cannot be attributed to normal us...

Page 35: ...r round Especially in countries with tropical climates or when vehicle is driven under heavy load the coolant improves the engine reliability by its increased boiling point The coolant concentration must not be reduced by adding water even during the warmer season The coolant additive ratio must be at least 40 Air cleaner clean housing and replace filter element Removing and installing air filter ...

Page 36: ...ed for fastening the upper part of the air filter housing to the lower part of air filter housing as well as the intake supports If these bolts are loosened of tightened using a drill motor the threads in the upper part of air filter housing can be damaged For this reason a drill motor may only be used when the following prerequisites are met The drill motor RPM is max 200 min The torque must be a...

Page 37: ...en lightly press on Both housing halves must fit together flush arrows Tighten bolts arrows to maximum 3 Nm Upper engine cover removing and installing Caution Be sure to not strike the engine cover with a fist or a tool when installing it and engaging the fastening points There is a risk of damage Page 27 37 Description of work part 1 of 2 ...

Page 38: ...SI gasoline engines Removing and installing engine cover 2 0L TFSI gasoline engines Special tools testers and auxiliary items required Spring type clip pliers VAS 5024A Removing Release spring clip A using spring type clip pliers VAS 5024A and slide air intake B from engine compartment cover C Page 28 37 Description of work part 1 of 2 ...

Page 39: ...ening clips arrows A First release engine cover at arrow 3 then arrow 4 and raise Installing Installation is the reverse of removal Lower engine compartment cover noise insulation removing and installing Special tools testers and auxiliary items required Page 29 37 Description of work part 1 of 2 ...

Page 40: ...ing Slide noise insulation 3 as shown into lower lock carrier 2 The narrow latches arrow a must be slid below or wide latches arrow b slid above the lock carrier edge 3 Retaining tabs must engange over wide tabs in lock carrier holes when doing so Tighten screws arrows to correct torque specification Engine and components in engine compartment from Page 30 37 Description of work part 1 of 2 ...

Page 41: ... Ensure that all malfunctions detected are rectified within repair measures If fluid losses are greater than can be reasonably expected determine cause and repair repair measure Engine oil level check Note Observe waste disposal regulations After stopping engine wait at least 3 minutes to allow oil to flow back into oil pan Pull out dipstick wipe off with a clean cloth and re insert dipstick again...

Page 42: ...e damaged When oil level is below marking C top off with oil to marking A Oil specification 01 3 Engine oils Engine oil draining or extracting changing oil filter and filling engine oil Engine oil Drain or extract and fill 01 4 Engine oil draining or extracting Replace oil filter 01 4 Oil filter replacing Filling with engine oil 01 4 Filling engine oil Engine oil draining or extracting Special too...

Page 43: ...xtraction unit replace oil drain plug This prevents leaks Observe waste disposal regulations Extract engine oil using old oil collecting and extracting unit V A G 1782 or Remove oil drain plug Drain engine oil Note The oil drain plug is equipped with a permanent seal therefore the oil drain plug must always be replaced Observe waste disposal regulations Screw in new oil drain plug with sealing rin...

Page 44: ...d A torque figure that is too high may lead to leaks or even damage the oil pan Oil filter replacing Replacing oil filter 2 0L TFSI engines Special tools testers and auxiliary items required Oil drain adapter T40057 Oil filter wrench VAS 3417 Torque wrench V A G 1331 Page 34 37 Description of work part 1 of 2 ...

Page 45: ...and hold hose into an oil collecting pan Note When screwing in oil drain adapter T40057 a valve in the oil filter housing is opened If oil drain adapter T40057 is unscrewed again the valve closes automatically again Allow engine oil to drain Unscrew oil drain adapter T40057 again Oil filter housing can now be unscrewed using oil filter wrench VAS 3417 Page 35 37 Description of work part 1 of 2 ...

Page 46: ... housing 2 Filling engine oil Oil specifications 01 3 Engine oils Engine oil capacities Repair Manual 2 0 Liter 4 Cyl 4V Turbo Engine Mechanical Fuel Injection Ignition Engine Code s BPY Repair Group 17 General notes Note Observe waste disposal regulations After topping off with oil wait at least 3 minutes then check oil level Page 36 37 Description of work part 1 of 2 ...

Page 47: ...st not be topped off B Oil can be topped off After topping off oil may be in range A C Oil must be topped off It is sufficient when oil level is in area B grooved field If oil level is above area A the catalytic converter can be damaged When oil level is below marking C top off with oil to marking A Oil specification 01 3 Engine oils Page 37 37 Description of work part 1 of 2 ...

Page 48: ...el and effectiveness pulling to one side juddering squeal ABS function When braking with activated ABS the brake pedal must pulse noticeably Steering Function steering free play steering wheel centralized when wheels are in straight ahead position Sunroof Function Radio Radio Navigation system Function Reception GALA interference Multifunction indicator MFI Functions A C system Function Vehicle Mo...

Page 49: ...oving wheel center cover example Insert removal hook into one of the holes of the wheel center cap and pull in direction of arrow Installation notes Note The covers protect the wheel bolts and should be reinstalled after retightening the wheel mounting bolts Note that on some rims the center wheel cover tab must engage in rim cut out After completing work place adapter and pulling hook with vehicl...

Page 50: ...hicle tool kit If there is no adapter installed in the vehicle for loosening tightening the anti theft wheel bolts use master wheel bolt key set T10101 In case of losing the adapter a replacement adapter can only be obtained via the code number The adapters code number for loosening tightening the anti theft wheel bolts is stamped at the face of the adapter Special tools testers and auxiliary item...

Page 51: ...htening torque Retighten wheel securing bolts Special tools testers and auxiliary items required Torque wrench V A G 1332 Note Ensure wheel bolts are retightened alternately Tightening torque 120 Nm Radio navigation system activating anti theft coding Volkswagen Radio and Navigation units Radio units radio navigation systems are shipped with a Page 4 46 Description of work part 2 of 2 ...

Page 52: ...Group 91 Radio Telephone Navigation Trip computer Tire pressure control indicator performing basic setting Note Basic setting of Tire Pressure Monitoring Display Indicator Lamp K220 should always only be performed after tire inflation pressure values have first been corrected to the proper values If no pressure loss and no tire damage is detected after a tire pressure warning the erroneous warning...

Page 53: ...el per axle was replaced Tire Pressure Monitoring Display Indicator Lamp K220 has a yellow indicator light in instrument cluster arrow BLINKING LIGHT means that no INITIAL BASIC SETTING was performed yet STEADY LIGHT in conjunction with warning buzzer means WARNING a loss of pressure was detected check tire inflation pressures perform system basic setting Performing INITIAL basic setting Switch ig...

Page 54: ...irm by a notifying tone On next new ignition start warning does not appear Performing basic setting Switch ignition on After changing tire pressures or changing one or more tires tire pressure display SET button item 2 in illustration must be pressed until a confirmation tone is heard Warning will no longer appear next time engine is switched on Page 7 46 Description of work part 2 of 2 ...

Page 55: ... the bottle has a limited shelf life Therefore on the bottle the expiration date arrow is displayed In this example the expiration date 05 2003 has passed and the bottle must then be replaced Check the expiration date and enter in maintenance tables Replace tire sealant if expiration date has been reached Caution Tire sealant must not be older than 4 years Page 8 46 Description of work part 2 of 2...

Page 56: ...be mixed with other fluids and must be disposed of Observe disposal regulations Dust and pollen filter clean housing and replace filter element Note Clean the surrounding area of the dust and pollen filter in air conditioner shaft or heating before installing a new filter Perform the following work procedure Remove screw clips A and remove insulation mat B Page 9 46 Description of work part 2 of 2...

Page 57: ...er B in direction of arrow C and remove cover Remove filter element A from shaft B of air conditioner or heater Note Observe waste disposal regulations Using e g a vacuum cleaner clean shaft B of A C unit or heater Install in reverse order of removal Headlight adjustment check Adjusting gas discharge headlights 01 5 Adjusting headlights with gas discharge lamps Page 10 46 Description of work part ...

Page 58: ...tment requirements Tire pressure must be OK Lenses must not be damaged or dirty Reflectors and bulbs OK Vehicle must be properly loaded Move vehicle back and forth for 1 meter 3 to 4 feet or bounce front and rear of vehicle several times up and down to settle suspension Vehicle and headlight adjuster must be on a level surface Operating instructions of headlight adjuster VAS 5046 or operating inst...

Page 59: ...t The curb weight is the weight of the vehicle ready to be operated with filled fuel tank at least 90 filled including the weight of all equipment usually carried in the car such as spare wheel tools car jack fire extinguisher etc If the fuel tank is not at least 90 full adjust the weight as follows Read fuel level from fuel gauge Calculate additional weight needed using the following table Place ...

Page 60: ...ine Headlights Check the following With the low beam switched on check whether the horizontal light dark border of the setting line 1 contacts the test surface Check whether the break away point 2 between the left horizontal part and the rising part on the right of the light dark border runs vertically through the center point 3 The bright core of the light beam must be on the right of the vertica...

Page 61: ...g line Fog lights Check whether the upper light dark border touches the setting line horizontally over the complete test screen width Other additional headlights Accessory auxiliary light systems must be checked and adjusted according to the guidelines valid for them Adjusting headlights with gas discharge lamps Perform basic setting Page 14 46 Description of work part 2 of 2 ...

Page 62: ...s are interrogated Press the following selections in the order shown Go To Functions and component selection Body Electrical Equipment 01 On Board Diagnostic OBD capable systems 55 Dynamic Headlamp Range Control J 431 Dynamic Headlamp Range Control Functions J 431 Headlamp Range Control Module basic setting Page 15 46 Description of work part 2 of 2 ...

Page 63: ...ent and adjust headlights if necessary Complete function program for J431 Headlamp Range Control Module basic setting Note Also check whether both headlights work evenly when operating the manual headlight range control Adjust left headlight Rabbit GTI 2004 Adjustment screws for right headlight are arranged symmetrically Adjustment screw 1 for vertical adjustment Adjustment screw 2 for height late...

Page 64: ...To adjust the height turn the adjustment screws 1 and 2 with the same number of revolutions To adjust laterally turn only the adjustment screw 2 Adjusting fog lights and other auxiliary lights Fog lights in headlights Note The adjustment of fog lights is performed automatically when adjusting headlights Fog lights in bumper right Rabbit 2004 Adjusting screw on left fog light is arranged symmetrica...

Page 65: ...mper To adjust the lamp range turn the adjustment screw arrow Lateral adjustment is not possible Fog lights in bumper right GTI Adjusting screw on left fog light is arranged symmetrically Inclination figures Fog lights 20 cm Page 18 46 Description of work part 2 of 2 ...

Page 66: ...avoid breaking retaining tabs To adjust the lamp range turn the adjustment screw arrow Secure cover in reversed sequence Other auxiliary lights Accessory auxiliary light systems must be checked and adjusted according to the guidelines valid for them Service interval display reset Service Reminder Indicator must for Vehicle release inspection Page 19 46 Description of work part 2 of 2 ...

Page 67: ...display does not appear as in work sequence see Vehicle Diagnostic Testing and Information System operating instructions Press button to confirm Select in succession Brand Model Model year Engine code Confirm vehicle identification Select in succession Instrument cluster ARROW Resetting Service Reminder Indicator SRI Page 20 46 Description of work part 2 of 2 ...

Page 68: ... display Press exit button in exit menu Turn off ignition and disconnect diagnostic connection Switch ignition on After switching on the ignition service event is no longer indicated in the odometer display in the instrument panel insert Service interval display recoding Connect diagnostic tester 01 3 Diagnostic unit connecting Switch ignition on Page 21 46 Description of work part 2 of 2 ...

Page 69: ...Select in succession Brand Model Model year Engine Code Confirm vehicle identification If the vehicle identification procedure was performed correctly press button for confirmation Select in succession Instrument cluster ARROW Adapt service interval extension Perform adaptation according to instructions of GUIDED FUNCTIONS End Adaptation Page 22 46 Description of work part 2 of 2 ...

Page 70: ...n display Press exit button arrow on display Press exit button in exit menu Turn off ignition and disconnect diagnostic connection Sunroof checking function cleaning and lubricating guide rails Perform the following work procedure Page 23 46 Description of work part 2 of 2 ...

Page 71: ...ht wash system Check spray nozzle adjustment adjust if necessary 01 5 Headlight wash system Spray nozzle adjustment checking adjusting if necessary Rabbit GTI 2006 Checking freeze protection content of fluid if necessary top off with fluid Special tools testers and auxiliary items required Refractometer T10007 Read the bright dark boundary to obtain an accurate reading for the following tests Plac...

Page 72: ...ully Use only windshield cleanser concentrate G 052 164 all year round when topping up the windshield wash wipe system Note Windshield cleanser concentrate G 052 164 protects the spray nozzles fluid reservoir and hoses from freezing All vehicles with fan type spray jets must be filled with windshield cleanser concentrate G 052 164 as this fluid has a low viscosity at minus temperatures The complic...

Page 73: ...n spray pattern remove spray nozzle and rinse it with water in the opposite direction of spray Repair Manual Electrical Equipment Repair Group 92 Subsequently blowing through in the opposite direction of the spray flow with compressed air is permitted Caution Do not use solid objects to clean the spray nozzles Do not use a needle or similar under any circumstance to adjust spray nozzles otherwise ...

Page 74: ...r nozzles are preset Small height adjustments can be made If both spray fields are not at same height adjust spray direction upward or downward as follows Adjust the spray stream by turning at the adjuster arrow with a screwdriver Clockwise deeper adjustment Page 27 46 Description of work part 2 of 2 ...

Page 75: ...ent tool T10127 so that fluid sprays onto upper third of rear window as shown Headlight wash system Spray nozzle adjustment checking adjusting if necessary Rabbit GTI 2006 Note In the event contamination in spray nozzle produces an uneven spray pattern remove spray nozzle and rinse it with water in the opposite direction of spray Repair Manual Electrical Equipment Repair Group 92 Subsequently blow...

Page 76: ...iliary items required Adjustment device T10167 Spray jet adjustment for left headlight right headlight is identical but reversed Check spray jet setting Switch on driving lights Operate windshield washer system for front window Headlights are washed when windshield washer lever is held in wipe position at least 1 5 seconds Spray pattern should encounter headlight lamps at center Page 29 46 Descrip...

Page 77: ... Spray nozzles arrow are driven outward Perform the following work procedure Direct the spray direction of respective nozzle using adjustment tool T10167 or adjustment tool 3019A at upper edge of headlight item B and item C Windshield wiper blades park position checking Front windshield wiper blades check park position Rabbit GTI 2006 Deactivate APS function Page 30 46 Description of work part 2 o...

Page 78: ...over at the bottom of the windshield Dimension a 0 to 10 mm Dimension b 0 to 10 mm If necessary adjust wiper arm Adjust windshield wiper blades Repair Manual Electrical Equipment Repair Group 92 Windshield wiper blades Parked position Note For right hand drive vehicles the placement is a mirror image Rear windshield wiper blades park position checking Page 31 46 Description of work part 2 of 2 ...

Page 79: ... wiper arm Repair Manual Electrical Equipment Repair Group 92 Windshield wiper blades park position Tie rod ends check play security and joint boots Perform the following work procedure With vehicle raised wheels hanging free check play by moving tie rods and wheels Play zero play Check mountings Check tie rod joint boots arrow for damage and proper seating Page 32 46 Description of work part 2 of...

Page 80: ...own arrows Use solid lubricant G 000 150 Transportation mode deactivating Connect diagnostic tester 01 3 Diagnostic unit connecting Switch ignition on Indicated on display Select mode of operation Press button for Vehicle Self Diagnosis on display Note Page 33 46 Description of work part 2 of 2 ...

Page 81: ...structions for Vehicle Diagnosis Testing and Information System VAS 5051 or Vehicle Diagnosis Service Syst VAS 5052 Indicated on display Press Grouped services on display Indicated on display Press Switch off transport mode on display End procedure Page 34 46 Description of work part 2 of 2 ...

Page 82: ...Service System VAS 5052 must possibly remain connected for various tests Transport protection removing locking pieces from front axle struts In vehicles with sport suspension locking pieces are installed in springs of front axle These models can be identified by a tag attached at the mirror arrow Note Locking pieces should prevent vehicle from bouncing when being driven on to an automobile Page 35...

Page 83: ...ove the wheels Be careful not to damage surface of coil springs Relieve load on coil spring by raising vehicle on lifting platform Press locking piece arrow from coil spring Underbody protection perform visual check for damage During visual check observe floor pan wheel housings and sills Note Malfunctions found must be rectified repair measure This inhibits corrosion and rusting through Clock set...

Page 84: ...th buttons on windshield wiper lever Switch ignition on Press button 2 for 2 seconds to go to main menu Select Settings menu with button 2 and confirm with button 1 Select Clock menu with button 2 and confirm with button 1 Now mark menu time Hours by pressing button 1 set correct hour with button 2 and then confirm with button 1 Do the same with menu item Minutes You can leave the Settings menu us...

Page 85: ...ton 3 and set correct hour with buttons 2 and 4 Confirm again with button 3 and change to minute setting which is done the same as when setting the hour You can leave the menu again with button 1 Switch ignition off Toothed belt for camshaft drive Replacing 2 0 L TFSI only Note Generally it is not necessary to replace the belt before reaching the next replacement interval In particular cracks on t...

Page 86: ... a visual inspection for any damages to upholstered cover 1 Warning Adhesive from tape stickers etc and other residues or unauthorized work on airbag units can affect airbag function So that future airbag function is ensured make certain the customer is aware of this Upholstered cover of steering wheel may only be cleaned with a dry or damp cloth Front passenger side airbag Identification of airba...

Page 87: ...ction So that future airbag function is ensured make certain the customer is aware of this Upholstered cover of steering wheel may only be cleaned with a dry or damp cloth Spark plugs replacing Replacing spark plugs 2 0 L TFSI engine 01 5 Replacing spark plugs 2 0 L TFSI engine Special tools testers and auxiliary items required Spark plug wrench 3122 B Page 40 46 Description of work part 2 of 2 ...

Page 88: ... Torque wrench V A G 1331 Puller T40039 Puller T10094 Page 41 46 Description of work part 2 of 2 ...

Page 89: ... Puller T10095 Removal installation tool T10029 Puller T10112 Page 42 46 Description of work part 2 of 2 ...

Page 90: ...g work procedure Note To pull off spark plugs place ignition coil puller T40039 on topmost thick rib arrow of ignition coils with power output stages If lower ribs are used these can be damaged Remove engine covers 01 4 Upper engine cover removing and installing Page 43 46 Description of work part 2 of 2 ...

Page 91: ...coils with power output stages Remove both bolts 1 Pull all ignition coils approx 30 mm out of cylinder head in direction of arrow using ignition coil puller T40039 Push connector in direction of ignition coils with power output stages press catch down by hand and disconnect Page 44 46 Description of work part 2 of 2 ...

Page 92: ...ification and tightening torque Repair Manual 2 0 Liter 4 Cyl 4V Turbo Engine Mechanical Fuel Injection Ignition Engine Code s BPY Repair Group 28 Observe waste disposal regulations Installing Install new spark plugs using spark plug wrench 3122 B Page 45 46 Description of work part 2 of 2 ...

Page 93: ...ut stages into designated recesses of cylinder head cover Connect all connectors to ignition coils arrows Press ignition coils with power output stages onto spark plugs by hand until stop They must engage audibly Secure wiring using bolts 1 Install engine cover Page 46 46 Description of work part 2 of 2 ...

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