Volkswagen Passat 2011 Maintenance Manual Download Page 3

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Contents

Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Information about flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1

Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2

Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3

Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.4

Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.5

Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.6

Country overview for diesel not compliant with EN 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.7

Country overview for petrol not compliant with EN 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.8

Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.9

Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.10 Countries with hot climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.11 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.12 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.13 Shortened intervals for spark plug replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4

Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1

Swivel joints, axle mountings, coupling rod bearings and anti-roll bar rubber mounting:

inspecting for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.2

Activation of environment monitoring system (Front Assist): checking . . . . . . . . . . . . . . . . 39

4.3

Automatic headlight control and static cornering light: checking function . . . . . . . . . . . . . . 39

4.4

Front passenger front airbag: checking key switch and “ON/OFF function” . . . . . . . . . . . . 40

4.5

Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 42

4.6

Battery: checking with battery tester (always refer to workshop manual) . . . . . . . . . . . . . . 45

4.7

Status of battery: reading, sending diagnosis protocol online . . . . . . . . . . . . . . . . . . . . . . 45

4.8

Reducing agent (AdBlue®/DEF): replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.9

Reducing agent (AdBlue®/DEF): changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.10 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 51

4.11 Brake and clutch system: changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.12 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 81

4.13 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . .

4.14 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.15 Diesel particulate filter: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.16 Dual clutch gearbox 02E: changing gear oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.17 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 86

4.18 Natural gas tank: renew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.19 Natural gas filler connection and sealing cap: check condition, clean if necessary and check

seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.20 Fault memory of all systems: reading with vehicle diagnostic tester , correcting possible faults

according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.21 Bonnet catch hook: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.22 Gearbox, final drive and drive shaft boots: inspect for leaks and damage. . . . . . . . . . . . . 88

4.23 All-wheel drive coupling: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.24 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 93

4.25 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.26 Poly V-belt: check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.27 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 95

4.28 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.29 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.30 Multi-purpose additive for diesel fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.31 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.32 Memory seat: initialising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Passat 2011 ➤ , Passat Variant 2011 ➤

Maintenance - Edition 01.2019

Contents

Summary of Contents for Passat 2011

Page 1: ...Maintenance Passat 2011 Passat Variant 2011 Edition 01 2019 Service Service Department Technical Information ...

Page 2: ... the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicle road worthiness and safety In addition the normal basic safety precautions for working on motor vehicles must as a matter of course be observed Service All rights reserved No reproduction without prior agreement from publisher Copyright 2019 Volkswagen AG Wolfsburg D3E8031B2B4...

Page 3: ... 4 9 Reducing agent AdBlue DEF changing 51 4 10 Tyres checking condition wear pattern tyre pressure and tread depth 51 4 11 Brake and clutch system changing brake fluid 77 4 12 Brake system and shock absorbers inspecting for leaks and damage 81 4 13 Brakes front and rear checking thickness of brake pads and condition of brake discs 82 4 14 Brake fluid level checking 84 4 15 Diesel particulate filt...

Page 4: ...7 4 50 Headlight adjustment checking gas discharge headlights with DLA 141 4 51 Headlight adjustment checking fog lights 147 4 52 Sliding sunroof drains checking for blockage cleaning if necessary 149 4 53 Service interval display resetting 149 4 54 Service interval display recoding 152 4 55 Sunroof checking function cleaning and greasing guide rails 154 4 56 Track rods checking clearance attachme...

Page 5: ...TSI turbocharger Motronic MED 17 5 TSI turbocharger Motronic MED 17 5 TSI turbocharger RON unleaded at least 98 95 95 95 Camshaft drive Chain Chain Chain Chain Engines Petrol engine Petrol engine Petrol engine Petrol engine Displacement I 1 8 1 4 1 4 1 4 Engine code CDAB CDGA CKMA CTHD No of cylinders valves per cylinder 4 4 4 4 4 4 4 4 Power kW at rpm 112 4300 to 6200 110 5500 118 5800 118 5800 T...

Page 6: ...iculate filter can be identified by PR No 7GG 7MB 7ME 7MG or 7MQ on the vehicle data sticker Engines Diesel engine Diesel engine Diesel engine Displacement I 2 0 2 0 2 0 Engine code CFGB CFGC CLLA No of cylinders valves per cylinder 4 4 4 4 4 4 Power kW at rpm 125 4200 130 4200 125 4200 Torque Nm at rpm 350 1750 to 2500 380 1750 to 2500 350 1750 to 2500 Bore mm 81 0 81 0 81 0 Stroke mm 95 5 95 5 9...

Page 7: ...rs only denote whether an engine oil level sensor is installed or not and no longer have an influence on the oil change interval 2 1 2 Flexible service The flexible service enables long service intervals depending on individual driving style and the conditions under which the vehicle is used Note For the flexible service a special LongLife engine oil is required page 7 Vehicles with PR number QG1 ...

Page 8: ...rvice Fixed service intervals apply for maintenance Vehicles with PR number QG2 The PR number is valid only to 2012 For these vehicles the flexible service is not factory activated Therefore these vehicles have a fixed service interval display page 5 and for maintenance the fixed service intervals rigid service intervals apply These vehicles are fitted with the follow ing components Fixed service ...

Page 9: ...eterioration of the oil due to thermal loading The oil deterioration is the deciding factor concerning the dis tance that can still be driven to the next service Note For vehicles with a flexible service but which are serviced ac cording to fixed service intervals the service interval display must be recoded to non flexible page 152 Fixed service interval display only vehicles with a fixed service...

Page 10: ...ing indications appear spanner symbol and km with the distance that can be driven until the next service is due After 10 seconds the display changes A clock symbol appears with the number of days to the next service On vehicles with text messages on dash panel insert display the following appears Service in km or days The service information disappears after a few seconds or if en gine is running ...

Page 11: ... multifunction steering wheel Vehicles without text messages on the dash panel insert dis play an overdue service is indicated by a minus sign in front of the kilometre mileage or day information On vehicles with text messages on dash panel insert display the following appears if service is overdue Service since km or days Reading service information using function buttons on dash panel insert The...

Page 12: ...fied torque Wiper blade protection remove Tyre Pressure Loss Indicator calibrate after tyre pressure has been corrected Vehicle inspect for leaks and damage from above and below Brake system inspect for leaks and damage Transportation devices remove if fitted Vehicle underside underbody inspect for damage Windscreen wash wipe system and headlight washer system check function and settings Engine oi...

Page 13: ...eadliner luggage compartment and glove compartment lights X Horn check function X Charging cable check that cable is present and check its condition Applies only to BEV X High voltage battery check charge level charge as necessary Applies only to BEV Vehicle exterior X Headlight washer system check function X Front lighting check function X Static cornering light cornering light check function X A...

Page 14: ... rails and lubricate with special grease Underside of vehicle X Drain engine oil and renew oil filter X Engine and components in engine compartment inspect for leaks and damage from below X Gearbox final drive and drive shaft boots inspect for leaks and damage X Brakes front and rear check thickness of pads linings and condition of brake discs X Poly V belt check condition X Swivel joints axle mou...

Page 15: ...d level dependent upon brake pad lining wear checking X Cooling system check frost protection and coolant level X Window wash wipe system check anti freeze protection replenish wash er fluid X Hybrid components inspect for damage to high voltage components and wires Applies only to HEV and PHEV X High voltage components and high voltage cables inspect for damage and correct routing and securing of...

Page 16: ...me conditions page 28 the shortest interval for an oil change service is 7 500 km or 1 year However other intervals apply for other countries Your im porter will inform you about this Passat 36 2012 Service intervals From to Engine Engine code PR No Remarks Service events Intervals Indicated on service interval display includes oil change From intro duction 2012 Diesel in countries where the sulph...

Page 17: ... every 10 000 mi or 1 year YES QI1 QI2 QI3 QI4 QI7 Interval service fixed every 30 000 km or 2 years YES QI6 Interval service flexible from 15 000 km or 1 year up to max 30 000 km or 2 years YES QI1 QI2 QI3 QI4 QI6 QI7 Inspection service after 3 years or max 60 000 km then every 2 years or 60 000 km NO 2 2 4 Service intervals as of model year 2014 Scope of work Climate and traffic condi tions usua...

Page 18: ... year 1 QI3 every 10 000 km or 1 year 1 QI4 30 000 km or 2 years then every 30 000 km or 1 year 1 QI4 every 15 000 km or 1 year 1 QI6 30 000 km or 2 years then every 30 000 km or 1 year 1 QI7 Every 20 000 mi or 2 years 1 1 Whichever occurs first Scope of work Climate and traffic condi tions usual for passenger vehicles operated on fuels compliant with EN 228 or EN 590 For operation with fuels that...

Page 19: ...ears 1 Max 1 year or 30 000 km 1 Dust and pollen filter cabin filter renew Every 60 000 km or 2 years 1 Max 1 year or 30 000 km 1 1 Whichever occurs first 2 2 7 Panoramic sliding sunroof Scope of work Climate and traffic conditions usual for passenger vehicles Countries with high levels of dust page 30 Panoramic sliding sunroof If the lubricating paste is grey clean and grease guide rails and clea...

Page 20: ...y to Polo 6R1 6C1 and Touareg Every 60 000 km Every 30 000 km Diesel fuel filter renewing Every 90 000 km Every 30 000 km 2 2 12 Spark plugs Scope of work Petrol engine compliant with EN 228 E100 Petrol engine not compli ant with EN 228 page 31 Spark plugs renewing Every 60 000 km or 4 years 1 Every 40 000 km or 4 years 1 Every 30 000 km 20 000 km or 2 years 1 and every 15 000 km 10 000 km or 1 ye...

Page 21: ...na to model year 2013 Note This chapter contains only the time or mileage dependent ad ditional work up to model year 2013 for the Indian Russian and Chinese markets For information for other markets refer to the chapter Service tables page 7 Indian market Applies up to 2013 Interval Description of work Interval service QG0 QG2 QG3 2 QI4 Every 15 000 km or 1 year 1 Mainte nance tables Inspection s...

Page 22: ...se additive for petrol fuel adding At every service page 104 Dust and pollen filter cabin filter renew Every 15 000 km or 1 year 1 page 155 Spark plugs renewing Applies only to 1 4 l TSI Every 30 000 km or 2 years 1 page 162 Diesel fuel filter renewing Every 30 000 km page 97 Air filter element check renew as needed and clean housing Every 30 000 km or 2 years 1 page 99 Panorama tilting sliding ro...

Page 23: ...of checking function cleaning and greasing guide rails and cleaning wind de flector Every 10 000 km or 1 years 1 page 116 Spark plugs renewing Applies only to 1 4 l TSI 1 8 l TSI 2 0 l TSI and 3 6 l FSI engines Every 20 000 km or 2 years 1 page 162 Air filter element renew and clean housing every 30 000 km or 2 years 1 page 99 1 Whichever occurs first 2 2 17 Country specific additional work depend...

Page 24: ...d leakage Europe only except for Italy 3 years after initial registration then every 2 years Natural gas filler connection and sealing cap check condition clean if necessary and check seal Europe only except for Italy 3 years after initial registration then every 2 years Reducing agent AdBlue DEF changing Applies only to vehicles driven less than 15 000 km in 4 years Every 4 years Natural gas tank...

Page 25: ...31 3 1 Raising vehicle with lifting platform or trolley jack 3 1 1 Safety instructions and work prepara tion WARNING Before driving onto a lifting platform make sure that there is sufficient clearance between bottom components and lifting platform Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the per missible lifting capacity of the pla...

Page 26: ...er tical reinforcement of floor pan arrow 3 2 Stickers In this chapter there are stickers which apply for the German market The stickers determined for your country can be obtained from your importer Attach Your next service sticker page 22 Attach vehicle data sticker in customer service schedule page 23 Entries in service schedule page 23 3 2 1 Attaching Your next service sticker Note For vehicle...

Page 27: ...er of the two vehicle data stickers arrow in the service schedule 3 2 3 Entries in service schedule If a component is changed which has a change interval prescribed by the manufacturer e g the toothed belt the new change inter val begins at the time the component is changed Therefore it is very important every time a component is changed to document this in the service schedule This also applies t...

Page 28: ...otion Perform the following procedure Connect diagnostic line connector to diagnostic connection Switch on vehicle diagnostic tester Switch on ignition Now follow information given on screen to start desired functions 3 4 Vehicle identification number Vehicle identification number on lower edge of windscreen page 25 Vehicle identification number on bulkhead above coolant ex pansion tank page 25 Si...

Page 29: ...mber is located on the bulkhead above the coolant expansion tank arrow 3 4 3 Interpretation of vehicle identification number WVV ZZZ 3C Z B Y 000 001 Manufacturer code Filler charac ters Model Filler charac ters Model year 2011 Production lo cation Serial number 3 5 Vehicle data sticker The vehicle data sticker arrow is located in luggage compart ment on right in spare wheel recess The vehicle dat...

Page 30: ...mount of water in diesel Abu Dhabi Gambia Malawi Sierra Leone Afghanistan Georgia Malaysia Zimbabwe Egypt Ghana Mali Singapore Algeria Guatemala Morocco Somalia Angola Guinea Mauritania Sri Lanka and the Mal dives Equatorial Guinea Guinea Bissau Mauritius South Africa Argentina Guyana Macedonia Sudan Armenia Haiti Mexico South Sudan Azerbaijan Honduras Moldova Surinam Ethiopia India Mongolia Swazi...

Page 31: ...t compli ant with EN 228 Examples in fuel inadequacies that can lead to shortened main tenance exchange intervals Petrol contaminated with diesel High sulphur content Poor boiling point evaporation Metallic components Octane Booster Additive Contaminants in petrol Abu Dhabi Georgia Mauritius Syria Afghanistan Ghana Mexico Tajikistan Egypt Guatemala Mongolia Taiwan Algeria Guinea Mozambique Tanzani...

Page 32: ...and engine number are located On vehicle data sticker page 25 On type plate Or Rep gr 00 Identification Engine number engine features 3 9 Severe operating conditions If the vehicle is used under severe operating conditions some work will have to be performed before the next service is due or at shorter service intervals Regular short trips or stop and go operation in urban traffic High percentage ...

Page 33: ...ar USA Abu Dhabi Lebanon United Arab Emirates Algeria Libya West Sahara Egypt Liberia Zimbabwe Afghanistan Mexico Central African Republic Angola Malaysia Equatorial Guinea Mauritius Ethiopia Morocco Bahrain Madagascar Brunei Mali Benin Mozambique Burkina Faso Malawi Botswana Mauritania Burundi Nigeria China Niger Dubai Oman Democratic Republic of the Congo Puerto Rico Djibouti Palestine Ivory Coa...

Page 34: ...nmar Burma Togo Bangladesh Iraq Namibia Chad Belize Israel Nepal Indian subconti nent Tunisia Benin Dahomey Yemen Nicaragua Turkey Bhutan Jordan Niger Turkmenistan Bolivia Cambodia Nigeria Uganda Botswana Cameroon North Korea Uruguay Brazil Cape Verde Oman Ukraine Brunei Kazakhstan Pakistan Uzbekistan Burkina Faso Upper Vol ta Qatar Palestine Venezuela Chile Kenya Panama United Arab Emirates China...

Page 35: ... intervals are necessary if fuel not compliant with DIN EN 228 are used Examples in fuel inadequacies that can lead to shortened main tenance exchange intervals Petrol contaminated with diesel High sulphur content Poor boiling point evaporation Metallic components Octane Booster Additive Contaminants in petrol Country 30 000 km 2 years 20 000 km 2 years 15 000 km 1 year 10 000 km 1 year Abu Dhabi ...

Page 36: ...ador X Ivory Coast X Eritrea X Fiji X Gabon X Gambia X Georgia X Ghana X Guatemala X Guinea X Guinea Bissau X Haiti X Honduras X India X Indonesia X Iraq X Iran X Jamaica X Yemen X Jordan X Cameroon X Cape Verde X Caribbean left hand traffic X Kazakhstan X Qatar X Kenya X Kyrgyz Republic X Columbia X Cuba X Kuwait X Laos X Lebanon X Liberia X Libya X Passat 2011 Passat Variant 2011 Maintenance Edi...

Page 37: ... seas territories Aru ba Curacao Sint Maarten Dutch X Niger X Nigeria X North Korea X Oman X Pakistan X Panama X Papua New Guinea X Paraguay X Peru X Philippines X Republic of Congo X Rwanda X Russian Federation X Zambia X Saudi Arabia X Senegal X Seychelles X Sierra Leone X Singapore X Somalia X Sri Lanka X South Sudan X Sudan X Suriname X Syria X Tajikistan X Taiwan X Tanzania X Passat 2011 Pass...

Page 38: ...go X Trinidad and Tobago X Chad X Tunisia X Turkey X Turkmenistan X Uganda X Ukraine X Uruguay X Uzbekistan X Venezuela X United Arab Emi rates X Vietnam X West Sahara X Central African Re public X Zimbabwe X Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 34 3 General information ...

Page 39: ...Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 35 ...

Page 40: ...ondition of brake discs page 82 Diesel fuel filter renewing page 97 Diesel particulate filter checking page 85 Dual clutch gearbox 02E changing gear oil and filter page 85 Window regulators checking positioning open and close func tions page 86 CNG tank renewing page 87 Natural gas system inspecting natural gas tank for corrosion and leakage page 170 Natural gas system checking wax layer between n...

Page 41: ... of anti theft coding and storing local radio stations to station buttons page 124 Radio code reading using vehicle diagnostic tester page 123 Reducing agent AdBlue DEF replenishing page 46 Reducing agent AdBlue DEF changing page 51 Tyre Pressure Loss Indicator performing basic setting page 124 Tyre repair set checking page 127 Window wash wipe system and headlight washer system check ing function...

Page 42: ... upper swivel joints for leaks and dam age Check also suspension link mountings arrow for following damage Large cracks perforating cracks or cuts in rubber material Complete separation of rubber and metal parts Large play between mounting and suspension link which has a considerably negative effect on the function of the mounting Note Superficial cracks and cuts as well as minor separations of th...

Page 43: ...t Maintenance point is dis played in maintenance list depending on PR number If system is not active proceed as follows Switch on ignition Select menu Assist Systems in dash panel insert menu There mark Front Assist entry and set tick and confirm with OK Switch off ignition System is now active 4 3 Automatic headlight control and static cornering light checking function Automatic headlight control...

Page 44: ...tside of windscreen by hand or with a suitable object arrow This measures the light incidence and the headlights are switched on Turn light switch 4 to position O 1 and switch off ignition Static cornering light Static cornering light integrated into fog light Start engine Switch on dipped beam or driving light assist Switch on turn signal Check cornering light Repeat procedure on other side 4 4 F...

Page 45: ...BAG OFF arrow must al so light up after self test passenger airbag deactivated Switch off ignition Using the ignition key turn switch 1 to AIRBAG ON position arrow B Switch on ignition Warning lamp PASSENGER AIRBAG OFF arrow goes out after self test passenger airbag activated Switch off ignition Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 41 ...

Page 46: ...nal 4 5 1 Battery in engine compartment Carry out following procedure Open battery cladding cover if fitted Check whether battery terminal clamps are secure on battery terminals by moving battery positive cable and battery nega tive cable back and forth WARNING If the battery terminal clamp is not seated securely on the bat tery positive terminal first disconnect battery terminal clamp on battery ...

Page 47: ...VE terminal clamp and tighten it to 6 Nm using torque wrench V A G 1331 and ratchet V A G 1331 1 If battery terminal clamp is NOT seated securely on negative ter minal Tighten NEGATIVE terminal clamp on battery terminal to 6 Nm using torque wrench V A G 1331 and ratchet V A G 1331 1 Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 43 ...

Page 48: ...hat several cross references are not directed to the correct chapter In this case select the pro cedure manually in the information 4 5 2 Battery in luggage compartment Carry out following procedure Open left cover in luggage compartment 1 If necessary pull inserted storage compartment out upwards Pull positive terminal cover upwards Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 44 4...

Page 49: ...ighten it to 6 Nm as well If battery terminal clamp is NOT seated securely on negative ter minal Tighten battery terminal clamp 1 on negative battery terminal to 6 Nm Fit the storage box in luggage compartment Note After the battery has been reconnected Electrical system Rep gr 27 Battery Disconnecting and connecting battery 4 6 Battery checking with battery tester al ways refer to workshop manual...

Page 50: ...el vehicles with SCR process selective catalytic reduction Additional information on the SCR process and reducing agent AdBlue DEF can be found in the glossary page 181 General notes page 46 Health endangerment and cleaning page 48 Disposal instructions page 49 Work preparation for filling reducing agent tank page 49 Filling reducing agent tank page 50 Work after filling reducing agent tank page 5...

Page 51: ...signation according to ISO 22241 1 The reducing agent AdBlue DEF is contained in a separate tank in the vehicle It is NOT therefore mixed with diesel fuel A refill container approved by Volkswagen must be used for replenishing the reducing agent AdBlue DEF The part numbers for available sizes of containers is available in ETKA Insufficient reducing agent If the level of reducing agent is low one o...

Page 52: ...coming into contact with the eyes and skin wash off immediately with plenty of water for at least 15 minutes and seek medical assistance In the event of skin contact with this fluid immediately wash off with plenty of water In the event of AdBlue DEF ingestion rinse out the mouth immediately with plenty of water for at least 15 mi nutes Do not induce vomiting unless instructed to do so by a doctor...

Page 53: ...nce with environmental regulations 4 8 4 Work preparation for filling reducing agent tank Note Ensure that vehicle stays on an even ground The reducing agent tank s filler aperture is located under the floor covering in the luggage compartment Raise floor covering 1 and push it back or hook it in Remove spare wheel 2 if available by unscrewing wing nut 3 Remove foam part if fitted Remove tank fill...

Page 54: ...nk filler neck with a water soaked lint free cotton cloth Insert filler nozzle of filling device for AdBlue VAS 6960 into filler neck of tank for reducing agent and start filling the tank for reducing agent Note The filler nozzle of the filling device for AdBlue VAS 6960 stops automatically when the required reducing agent level has been attained Remove filler nozzle 4 8 6 Work after filling reduc...

Page 55: ...tem selective catalytic reduction Draining reducing agent tank 4 10 Tyres checking condition wear pattern tyre pressure and tread depth Checking condition of tyre page 51 Checking wear pattern page 52 Tread depth including spare wheel check page 52 General notes page 52 Tyre pressures Passat Saloon page 54 Tyre pressures Passat Estate page 63 Tyre pressures Passat Estate Alltrack page 74 Special t...

Page 56: ...check ing alignment repair measure 4 10 3 Tyre tread depth including spare wheel checking Check tyre tread depth Minimum tread depth 1 6 mm Note This figure may vary according to legislation in individual coun tries Your importer will inform you about this The minimum tread depth is reached when the tyres have worn down level with the 1 6 mm high tread wear indicators arrows positioned at interval...

Page 57: ...mended winter tyres can be found in Wheels and Tyres Guide Standard Rep gr 44 Rec ommended winter tyres If winter tyres are fitted a sticker visible for the customer and indicating the speed limit must be applied in the interior of the vehicle For winter tyres the tyre pressure does not have be increased However this only applies if the winter tyre used corresponds exactly to the standard summer t...

Page 58: ...or VAS 5216 correct if necessary Part number 3AA 010 800 H Passat Saloon Part number 3AA 010 800 J Part number 3AA 010 000 S Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 220 2 2 32 220 2 2 32 250 2 5 36 280 2 8 41 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 836 C Passa...

Page 59: ... Rear All 1 230 2 3 33 230 2 3 33 250 2 5 36 280 2 8 41 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 800 Passat Saloon Part number 3AA 010 802 Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 260 2 6 38 260 2 6 38 260 2 6 38 280 2 8 41 1 Valid for all authorised wheel tyre ...

Page 60: ...7 235 40 R18 Part number 3AA 010 836 F Passat Saloon Part number 3AA 010 836 J Part number 3AA 010 000 B Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 240 2 4 35 240 2 4 35 260 2 6 38 290 2 9 42 235 45 R17 205 55 R16 270 2 7 39 270 2 7 39 290 2 9 42 310 3 1 45 205 50 R17 235 40 R18 Part number 3AA 010 801 E Passat Saloon Part number 3AA 010 000 P Half...

Page 61: ...5 45 R17 94W 260 2 6 260 2 6 280 2 8 300 3 0 235 40 R18 95W 280 2 8 280 2 8 310 3 1 330 3 3 Part number 3AA 010 801 L Passat Saloon Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 93W 220 2 2 220 2 2 280 2 8 300 3 0 235 45 R17 94W 235 40 R18 95Y 250 2 5 250 2 5 280 2 8 300 3 0 Part number 3AA 010 801 A Passat Saloon Half payload kPa bar Full payload kPa bar Tyr...

Page 62: ... kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 93W 240 2 4 240 2 4 260 2 6 290 2 9 235 45 R17 94W 205 55 R16 91V 250 2 5 250 2 5 280 2 8 300 3 0 235 40 R18 95Y Part number 3AA 010 844 C Passat Saloon Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 97W 240 2 4 240 2 4 260 2 6 290 2 9 235 45 R17 94W 205 55 R16 91V 250 2 5 250 2 5 280 2 8...

Page 63: ... Front Rear Front Rear All 1 230 2 3 33 230 2 3 33 250 2 5 36 290 2 9 42 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 705 D Passat Saloon Part number 3AA 010 705 T Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 240 2 4 35 240 2 4 35 260 2 6 38 300 3 0 44 1 Valid for all a...

Page 64: ...r psi Tyre size Front Rear Front Rear All 1 270 2 7 39 270 2 7 39 290 2 9 42 300 3 0 44 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 705 K Passat Saloon Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 260 2 6 38 260 2 6 38 280 2 8 41 320 3 2 46 1 Valid for all authorised w...

Page 65: ...5 R Passat Saloon Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 235 35 R17 260 2 6 260 2 6 280 2 8 320 3 2 235 40 R18 95Y 280 2 8 280 2 8 310 3 1 340 3 4 235 35 R19 91Y Part number 3AA 010 705 N Passat Saloon Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 93W 240 2 4 240 2 4 260 2 6 300 3 0 235 45 R17 94W 235 40 R18 95Y 260 2 6 260 ...

Page 66: ...load kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 230 2 3 33 230 2 3 33 250 2 5 36 280 2 8 41 235 45 R17 205 50 R17 250 2 5 36 250 2 5 36 270 2 7 39 300 3 0 44 235 40 R18 Part number 3AA 010 802 H Passat Saloon Part number 3AA 010 802 M Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 240 2 4 35 240 2 4 35 260 2 6 38 290 2 9 42 235 45 R17 205 5...

Page 67: ...sticker is fitted If the sticker is missing order a new sticker through ETKA The mandatory tyre pressures for the respective model can be found on a sticker attached to the inside of tank flap or to the B pillar If the inflation pressure sticker is missing proceed as follows Locate correct part number for respective vehicle in ETKA Using part number determine respective inflation pressures in tyre...

Page 68: ...215 55 R16 240 2 4 35 240 2 4 35 250 2 5 36 300 3 0 44 235 45 R17 205 55 R16 240 2 4 35 240 2 4 35 260 2 6 38 300 3 0 44 205 50 R17 235 40 R18 Part number 3AA 010 800 T Passat Estate Part number 3AA 010 000 N Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 220 2 2 32 220 2 2 32 250 2 5 36 300 3 0 44 235 45 R17 205 50 R17 250 2 5 36 250 2 5 36 280 2 8 41...

Page 69: ...R17 205 55 R16 250 2 5 36 250 2 5 36 270 2 7 39 300 3 0 44 205 50 R17 235 40 R18 Part number 3AA 010 836 M Passat Estate Part number 3AA 010 836 R Part number 3AA 010 000 A Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 230 2 3 33 230 2 3 33 260 2 6 38 300 3 0 44 235 45 R17 205 55 R16 250 2 5 36 250 2 5 36 280 2 8 41 300 3 0 44 205 50 R17 235 40 R18 Pa...

Page 70: ...payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 220 2 2 32 220 2 2 32 250 2 5 36 300 3 0 44 235 45 R17 205 50 R17 250 2 5 36 250 2 5 36 280 2 8 41 300 3 0 44 235 40 R18 Part number 3AA 010 821 B Passat Estate Part number 3AA 010 000 K Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 205 50 R17 M S 260 2 6 38 260 2 6 38 280 2 ...

Page 71: ... 45 R17 94W 260 2 6 260 2 6 280 2 8 320 3 2 235 40 R18 95Y 280 2 8 280 2 8 310 3 1 340 3 4 Part number 3AA 010 844 G Passat Estate Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 235 45 R17 94W 260 2 6 260 2 6 280 2 8 320 3 2 235 40 R18 95W 280 2 8 280 2 8 310 3 1 340 3 4 Part number 3AA 010 801 M Passat Estate Half payload kPa bar Full payload kPa bar Tyre size Front Rea...

Page 72: ...re size Front Rear Front Rear 215 55 R16 93W 230 2 3 230 2 3 260 2 6 300 3 0 235 45 R17 94W 205 55 R16 91V 250 2 5 250 2 5 270 2 7 300 3 0 235 40 R18 95Y Part number 3AA 010 804 F Passat Estate Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 93W 230 2 3 230 2 3 260 2 6 300 3 0 235 45 R17 94W 205 55 R16 91V 250 2 5 250 2 5 280 2 8 300 3 0 235 40 R18 95Y Part num...

Page 73: ...yre size Front Rear Front Rear All 1 240 2 4 35 240 2 4 35 260 2 6 38 300 3 0 44 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 705 E Passat Estate Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 240 2 4 35 240 2 4 35 260 2 6 38 300 3 0 44 235 45 R17 205 50 R17 M S 260 ...

Page 74: ...bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 260 2 6 38 260 2 6 38 280 2 8 41 320 3 2 46 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Part number 3AA 010 705 L Passat Estate Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear All 1 280 2 8 41 280 2 8 41 300 3 0 44 340 3 4 49 1...

Page 75: ...state Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 215 55 R16 93W 240 2 4 240 2 4 260 2 6 300 3 0 235 45 R17 94W 235 40 R18 95Y 260 2 6 260 2 6 280 2 8 300 3 0 235 35 R19 91Y Part number 3AA 010 705 M Passat Estate Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 205 55 R16 91V 240 2 4 240 2 4 260 2 6 300 3 0 215 55 R16 93W 235 45 R17 94W 235 4...

Page 76: ...e size Front Rear Front Rear 215 55 R16 220 2 2 32 220 2 2 32 250 2 5 36 300 3 0 44 235 45 R17 205 50 R17 250 2 5 36 250 2 5 36 280 2 8 41 300 3 0 44 235 40 R18 Part number 3AA 010 804 J Passat Estate Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 230 2 3 33 230 2 3 33 260 2 6 38 300 3 0 44 235 45 R17 205 50 R17 250 2 5 36 250 2 5 36 270 2 7 39 300 3 0...

Page 77: ...oad kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 230 2 3 33 230 2 3 33 260 2 6 38 300 3 0 44 235 45 R17 205 50 R17 260 2 6 38 260 2 6 38 280 2 8 41 320 3 2 46 235 40 R18 Part number 3AA 010 802 D Passat Estate Part number 3AA 010 802 N Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 215 55 R16 230 2 3 33 230 2 3 33 260 2 6 38 300...

Page 78: ...re not shown for a part number then a uniform pressure is valid for all authorised wheel tyre combinations Wheels and Tyres Guide Rep gr 44 Wheel and tyre combinations Check tyre pressure using tyre inflator VAS 5216 correct if necessary Part number 3AA 010 819 G Passat Estate Alltrack Part number 3AA 010 819 K Part number 3AA 010 000 G Half payload kPa bar psi Full payload kPa bar psi Tyre size F...

Page 79: ...rack Part number 3AA 010 830 M Part number 3AA 010 000 D Part number 3AA 010 800 P Half payload kPa bar psi Full payload kPa bar psi Tyre size Front Rear Front Rear 225 50 R17 240 2 4 35 240 2 4 35 260 2 6 38 300 3 0 44 225 45 R18 205 50 R17 M S 270 2 7 39 270 2 7 39 290 2 9 420 330 3 3 48 215 55 R161 340 3 4 49 1 Spare wheel Part number 3AA 010 819 H Passat Estate Alltrack Part number 3AA 010 819...

Page 80: ...819 P Passat Estate Alltrack Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 225 50 R17 94V 230 2 3 230 2 3 250 2 5 290 2 9 225 45 R18 95W 215 55 R16 97W 1 340 3 4 1 Spare wheel Part number 3AA 010 801 Passat Estate Alltrack Half payload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 225 50 R17 98V 220 2 2 220 2 2 240 2 4 280 2 8 225 45 R18 95W 215 55 R16 97...

Page 81: ...ayload kPa bar Full payload kPa bar Tyre size Front Rear Front Rear 225 50 R17 98V 230 2 3 230 2 3 250 2 5 290 2 9 225 45 R18 95W 215 55 R16 97W 1 340 3 4 1 Spare wheel 4 11 Brake and clutch system changing brake fluid Special tools and workshop equipment required Torque wrench VAS 6854 Brake filling and bleeding equipment VAS 5234 Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Desc...

Page 82: ...dition due to its corrosive nature it must not come into contact with paint Brake fluid is hygroscopic which means it absorbs mois ture from the ambient air and should therefore always be stored in air tight containers Rinse off spilled brake fluid using plenty of water Do not reuse extracted used brake fluid Observe relevant disposal regulations Extracting brake fluid Unscrew cap 1 from brake flu...

Page 83: ...bleeding equipment Note The bleeder hose must be firmly seated on bleeder valve so that no air can enter the brake system There must always be sufficient brake fluid in the brake res ervoir so that no air can enter the brake system through the reservoir Front axle Remove cap 1 from bleeder valve of front left brake caliper Push collector bottle bleeder hose 1 onto front left bleeder valve open ble...

Page 84: ...ter assembly overview Push bleeder hose onto bleeder valve arrow of clutch slave cylinder 1 Open valve and allow approx 50 ml of brake fluid to flow out Close valve and depress clutch pedal 10 to 15 times quickly in succession Open valve again and allow approx 50 ml of brake fluid to flow out Close valve remove bleeder hose and depress clutch pedal several times Install air filter housing accordin...

Page 85: ...on cap 1 of brake fluid reservoir Reinstall rear wheels if removed previously page 120 Perform functional check during road test 4 12 Brake system and shock absorbers in specting for leaks and damage Check following components for leaks and damage Brake master cylinder Brake servo for anti lock brake system hydraulic unit Brake pressure regulator and Brake caliper Shock absorbers during inspection...

Page 86: ...ds checking thickness page 83 Brake discs checking condition page 84 Special tools and workshop equipment required Torque wrench V A G 1332 Electric hand torch and mirror Carry out following procedure Note The adapter to loosen and tighten the anti theft wheel bolts can be found in the vehicle tool kit 4 13 1 Front disc brake pads checking thick ness For better evaluation of remaining pad thicknes...

Page 87: ...tem Rep gr 46 Front brake Assembly overview front brake Note For technical reasons it is possible that several cross references are not directed to the correct chapter In this case select the pro cedure manually in the information Install wheel in marked position Tighten wheel bolts diagonally and alternately specified tor que page 120 Place adapter in vehicle tool kit after completing work Fit wh...

Page 88: ...te For technical reasons it is possible that several cross references are not directed to the correct chapter In this case select the pro cedure manually in the information 4 13 3 Brake discs checking condition Check all brake discs for the following damage pattern Cracks Scoring Rust no surface rust Burrs on circumference of brake disc Note Inform customer if brake disc damage is similar to these...

Page 89: ...exceeded Brake fluid level at inspection service The fluid level must always be judged in conjunction with lining pad wear When vehicle is in use fluid level tends to drop slightly due to lining pad wear and automatic adjustment Recommended brake fluid level if brake pads are almost at wear limit At MIN marking or just above 2 REPLENISHING IS NOT REQUIRED Recommended brake fluid level when brake p...

Page 90: ...e been disconnected and reconnected the roll back function of the electric window regulators is disabled Severe pinching injuries could result Carry out the following procedure to reactivate the automatic functions of the window regulators Note The following work description applies to the front left window regulator Reactivate the other window automatic functions in the same manner by operating t...

Page 91: ...y and check seal Special tools and workshop equipment required Lint free cloth Open tank flap and remove protective cap from natural gas filler neck Check if seal is fitted and its condition arrow Check natural gas filler neck for dirt damage and surface corrosion Clean natural gas filler neck ONLY from outside If the filler neck is dirty clean off dirt using compressed air The filler neck will no...

Page 92: ... and workshop equipment required Universal oil spray G 000 115 A2 Note Vehicle must be at least at room temperature Lubricate bonnet arrester with universal oil spray G 000 115 A2 at points marked with arrows Operate moving parts several times so that universal oil is able to penetrate Remove any excess lubricant using a lint free cloth 4 22 Gearbox final drive and drive shaft boots inspect for le...

Page 93: ... fitting can cause the all wheel drive coupling and the final drive to fail The all wheel drive coupling and the final drive are one system with separate oil systems 1 Sealing plug for filler hole of all wheel drive coupling oil 2 Drain plug for all wheel drive coupling oil 3 Sealing plug for gear oil filler hole 4 Drain plug for gear oil Special tools and workshop equipment required Temperature g...

Page 94: ... VAS 6291 1 Drip tray for workshop hoist VAS 6208 Draining oil Raise vehicle with lifting platform and position used oil collec tion and extraction unit VAS 6622A under all wheel drive coupling Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 90 4 Descriptions of work ...

Page 95: ...te hose above drive shaft to prevent sagging Place drip tray for workshop hoist VAS 6208 under final drive The vehicle can be lowered as soon as the hose above the rear left wheel leads away from the vehicle Note The prescribed temperature range for oil during oil level check is 20 C to 40 C Observe the temperature of oil container when topping up oil After topping up oil the temperature gauge VAS...

Page 96: ...it to specified torque Specified torque Nm Oil filler plug 15 Ensure adherence to prescribed temperature range during oil level check if oil temperature was not within prescribed tempera ture range of 20 C to 40 C when topping up oil The oil temperature can be measured using temperature gauge VAS 6519 If the oil temperature is not between 20 and 40 C adherence to prescribed temperature range must ...

Page 97: ... belt pulley end Removing and installing poly V belt Note For technical reasons it is possible that several cross references are not directed to the correct chapter In this case select the pro cedure manually in the information 4 26 Poly V belt check condition Carry out following procedure Remove bottom engine compartment cover noise insula tion page 109 Use a suitable socket to turn the engine at...

Page 98: ...lutely necessary to renew the poly V belt In the case of diesel engines toothed belts which came into contact with oil brake fluid fuel or reducing agent must always be renewed In the case of petrol engines toothed belts which came into contact with oil brake fluid fuel or coolant must al ways be renewed This can avoid breakdowns and malfunctions The replacement of a poly V belt is a repair measur...

Page 99: ...s engine reliability under heavy loads particularly in countries with trop ical climates Use ONLY refractometer T10007A for determining current anti freeze value Frost protection must be guaranteed down to 25 C as a min imum and in countries with arctic conditions down to approx 36 C Increasing the frost protection is permissible only if cli matic conditions require stronger frost protection It ma...

Page 100: ...in coolant and supplement coolant additive page 96 Note If the currently used coolant additive cannot be determined precisely use the scale 2 for coolant additive G13 Please observe disposal instructions Check coolant additive concentration after road test again 4 27 2 Coolant level checking replenishing coolant if necessary Check coolant level in expansion tank when engine is cold Delivery inspec...

Page 101: ...prox 40 approx 60 36 C approx 50 approx 50 4 28 Diesel fuel filter renewing Special tools and workshop equipment required Diesel extractor VAS 5226 Angled screwdriver VAS 6543 Removing Caution Ensure that no diesel fuel contacts other components in the engine compartment Clean immediately if necessa ry Remove engine cover panel page 106 Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4...

Page 102: ...emove diesel fuel filter element 4 from lower part of fuel filter Note Please observe disposal instructions Caution Remove all diesel dirt and water residues from fuel filter lower part using diesel extractor VAS 5226 Installing Caution The seals 2 and 3 and diesel fuel filter element 4 must be renewed Always moisten new seal 2 slightly with diesel fuel to avoid malfunctions Passat 2011 Passat Var...

Page 103: ...engine to run for several minutes at mid revs then switch engine off again Read event memory and erase if necessary Carry out a leakage test of the fuel system Note If there is still air in the fuel system the engine can change to emergency running mode during road test In this case switch engine off and erase fault memory Then continue with a road test 4 29 Air filter cleaning housing and renewin...

Page 104: ...n bolts of upper part of air filter housing 1 to 1 6 0 2 Nm Refit clamp and push on connector until it engages 4 29 2 Air filter element removing and instal ling diesel engines 1 4 l 1 8 l and 2 0 l TSI engines Unscrew bolts arrows Pull vacuum hose off air filter housing If necessary pull off connector from air mass sensor Caution To prevent damage to the connection and to vacuum hose do not use s...

Page 105: ...peratures above 12 C Note The warm air flap is not installed in all vehicles Clean upper part of air filter Insert new air filter element and install air filter upper part Tighten air filter upper part with bolts arrows to 1 6 Nm Connect vacuum hose to air filter housing If necessary connect connector to air mass sensor Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of ...

Page 106: ...30 2 Recommendation for using multi pur pose additive for diesel fuel Note In the following markets with a high risk of coke and deposit formation the addition of a multi purpose additive is recom mended owing to the lower concentration of additives in the diesel fuel Only additives compliant with VW 505 26 multi purpose ad ditive G 001 790 M3 may be used After adding the additive it is extremely ...

Page 107: ...th Africa Fiji Sudan Gambia South Sudan Georgia Surinam Ghana Syria Guatemala Thailand Guinea Togo Guinea Bissau Trinidad and Tobago Guyana Chad Haiti Turkmenistan Honduras Ukraine Indonesia USA Iraq Belarus Jamaica Venezuela Jordan Central African Republic Cambodia Zimbabwe Cameroon Canada Cape Verde Caribbean left hand traffic Columbia Laos Lebanon Liberia Passat 2011 Passat Variant 2011 Mainten...

Page 108: ...service Country China India Russia 4 31 2 Recommendation for using multi pur pose additive for petrol fuel Note In the following markets with a high risk of coke and deposit formation the addition of a multi purpose additive is recom mended owing to the elevated olefin content and aromatics in the petrol Only additives compliant with VW 507 53 B multi purpose ad ditive G 001 780 M3 may be used Obs...

Page 109: ... release switch and press again until a gong sounds after a few seconds 4 33 Engine and components in engine com partment inspecting for leaks and dam age from above and below Remove engine cover panel if necessary page 106 If necessary remove engine cover panel noise insulation bottom page 109 Inspect as follows Check engine and components in engine compartment for leaks and damage Lines hoses an...

Page 110: ...removing and installing 1 8 l TSI and 2 0 l TSI petrol direct injection engines page 108 Removing and installing engine cover 4 cylinder CR diesel en gines page 108 4 34 1 Engine cover panel removing and in stalling 1 4 l TSI engines Engine cover design type 1 TSI twincharger Removing If fitted pull hose off connection arrow A Disengage engine cover panel at securing points arrows B and raise Then...

Page 111: ...tion inserted into mountings Engine cover design type 2 TSI twincharger Removing Remove securing bolts 1 of engine cover panel Detach coolant hoses 2 on engine cover panel and pull en gine cover panel upwards Installing Attach coolant hoses 2 on engine cover panel and fit engine cover panel onto camshaft housing Tighten securing bolts 1 to 8 Nm Passat 2011 Passat Variant 2011 Maintenance Edition 0...

Page 112: ... Push ball sockets of engine cover panel to correct installation position if necessary Fit engine cover panel at securing points arrows and press on until it engages 4 34 3 Engine cover panel removing and in stalling CR diesel engines Removing Disengage engine cover panel at securing points arrow and raise Installing Caution Before installing engine cover panel check the 4 securing el ements ball ...

Page 113: ...s so that the oil can flow back into the sump Pull out dipstick wipe with a clean cloth and push dipstick in again to limit stop Pull dipstick out again and read oil level Note Oil level must always be in area A for the delivery inspection This way you will achieve the greatest possible customer sat isfaction The oil change quantity in the service table was determined experimentally and is suffici...

Page 114: ... page 113 Oil filter renewing CR diesel engines page 114 Engine oil replenishing page 116 4 37 1 Engine oil draining or extracting Special tools and workshop equipment required Used oil collector and extractor VAS 6622A Oil spill cloth Engine oil draining or extracting Carry out following procedure Note For engines with standing oil filter the oil filter must be re newed before changing the engine...

Page 115: ...116 Engine oil capacity Maintenance tables Engine oil capacities and specifications page 116 Specified torques for oil drain plug M14 30 Nm M24 50 Nm WARNING Torque specifications must not be exceeded Excessive torque can cause leaks in the area of the oil drain plug or even damage 4 37 2 Oil filter renewing 1 4 l TSI engines Special tools and workshop equipment required Oil filter tool 3417 Passa...

Page 116: ...oil filter Caution When removing oil filter make certain that the old seal is also removed and is not stuck to the valve timing housing Ensure that no engine oil drips onto poly V belt or alternator Installing Note Observe fitting instructions on oil filter Please observe disposal instructions Clean oil filter sealing surface on valve timing housing Lightly oil seal on new filter Screw new oil fil...

Page 117: ... to flow back into sump Now unscrew filter completely Note Please observe disposal instructions Installing Clean sealing surface before installing oil filter cartridge Oil rubber seal lightly on new filter This ensures best possible sealing when the filter is tightened Tighten filter to 22 Nm using torque wrench V A G 1331 4 37 4 Oil filter on 6 cylinder petrol engine re newing Special tools and w...

Page 118: ...sposal instructions Renew O rings 1 3 5 and lightly oil them before installing Now insert new oil filter insert Tighten oil threaded cap 4 to 25 Nm The oil drain plug 6 is tightened to 10 Nm 4 37 5 Oil filter renewing CR diesel engines Removing Note Please observe disposal instructions Oil new O rings before installing Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 114 4 Descriptions ...

Page 119: ... out of filter housing Clean sealing surfaces on threaded cap and oil filter housing Installing Renew filter element 3 Renew O rings 2 and 4 Install threaded cap and tighten to 25 Nm Further assembly is basically a reverse of the dismantling se quence Ensure that the solenoid change over valve 1 audibly engages Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 115 ...

Page 120: ...Capacity output With flexible service With fixed service CAYC 1 6 l 77kW 4 3 507 00 507 00 CFFA 2 0 l 100kW 4 3 507 00 507 00 CFFB 1 2 0 l 103kW 4 3 507 00 507 00 CFFB 2 2 0 l 103kW 4 3 507 00 505 01 CFGB 2 0 l 125kW 4 3 507 00 507 00 CFGC 2 0 l 130kW 4 3 507 00 507 00 CLLA 2 0 l 125kW 4 3 505 01 1 With diesel particulate filter Vehicles with a factory fitted diesel particulate filter can be ident...

Page 121: ... and close glass panel and sliding headliner roller blind completely Open roof system and remove any excessive dirt Only grease stone VAS 6621 is allowed to be used for cleaning and lubricating Caution In order to prevent the vehicle interior from being soiled hold a cloth under the respective work area Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 117 ...

Page 122: ... near wind deflec tor 1 and turn it by 90 2 Move grease stone VAS 6621 as far as centre of guide rail in direction of arrow 3 Turn VAS 6621 by 90 4 and remove tool 5 Remove residual grease and dirt from inner area of guide rail using a lint free cloth if necessary remove sand and dust from the guide rail using a workshop vacuum cleaner The described procedure can be repeated several times de pendi...

Page 123: ... and wind deflec tor frame use a sponge and a soapy solution Mixing ratio for soapy solution 3 drops of washing up liquid to 1 litre of water Caution Do not use a commercially available insect remover or other solvents because these products have not been tested and approved Then remove insects and particles using a vacuum cleaner with a suitable nozzle Caution The net on the wind deflector could ...

Page 124: ...traight ahead level road Imbalance wheels drive shafts propshaft Noise vibration wheel bearing exhaust system Engine hot starting behaviour 4 41 Wheel securing bolts tightening to specified torque Pulling off wheel hub trim page 120 Pulling off wheel trim page 121 Pulling off wheel bolt caps page 121 Loosening tightening anti theft wheel bolts page 121 Tightening wheel bolts page 122 Installing wh...

Page 125: ...ve the cover caps is located with the ve hicle tool kit Place the puller hook through opening in cover cap Pull off cap using the puller hook Loosening tightening anti theft wheel bolts Note To loosen tighten the anti theft wheel bolts a special adapter located in vehicle tool kit is required To loosen the anti theft wheel bolts lockable wheel bolts do not use an impact screwdriver If the adapter ...

Page 126: ... the wheel bolt wrench onto adapter 2 onto stop Tightening wheel bolts Tighten the wheel bolts diagonally and alternately to the fol lowing torque setting 120 Nm WARNING Never use an impact screwdriver to tighten the wheel bolts Installing wheel centre cover wheel bolt cover caps and wheel cover Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 122 4 Descriptions of work ...

Page 127: ...requisites for vehicle diagnostic tester The vehicle diagnostic tester is connected via the Central Partner Network CPN with the central database Carport Fazit Available access for the user of the system GeKo secrecy and component protection Note The radio codes are also called security codes They can be read in the central database and displayed on the vehicle di agnostic tester For radio activat...

Page 128: ...time the unit must remain switched on the display extinguishes The electronic lock can be released as described above The cycle two attempts one hour lock applies again Procedure Communication Rep gr 91 Select radio and navigation system Determine anti theft code of anti theft coding via VAS tester and deactivate anti theft coding Vehicle electrics Communication Rep Gr 91 Select radio and navigati...

Page 129: ...e are loaded more heavily e g when towing a trailer or when driving in mountains Snow chains are fitted The temporary spare wheel is fitted One wheel per axle has been changed To model year 2011 The tyre pressure monitoring warning lamp has a yellow warning lamp in the dash panel insert arrow FLASHING LIGHT means that the INITIAL BASIC SET TING has not been performed A PERMANENT LIGHTING UP in con...

Page 130: ... button 5 Press OK button 5 to confirm tyre pressure Press OK button 5 again to confirm the confirmation prompt displayed Tyre pressure monitor display warning lamp lights up briefly in dash panel insert arrow to confirm that basic setting has been completed successfully Use corresponding buttons on windscreen wiper lever to perform basic setting Button 1 is used to confirm menu options Rocker lev...

Page 131: ... not be more than 4 years old Note If the tyre sealant has been used the container must be re newed Please observe disposal instructions 4 46 Window wash wipe system and head light washer system checking function Checking anti freeze protection of fluid topping up fluid page 127 Window wash wipe system check spray jet settings and adjust if necessary page 129 Headlight washer system checking spray...

Page 132: ... 4 of the refractometer is applicable for the anti freeze protection of the window wash wipe system Mixing ratio Frost protection to Genuine washer fluid ETKA Water 17 18 C 1 part 3 parts 22 23 C 1 part 2 part 37 38 C 1 part 1 part Top up fluid in window wash wipe system only if customer requests to do so Use genuine washer fluid ETKA throughout all year to fill win dow wash wipe system Depending ...

Page 133: ... The powerful cleanser easily removes wax and oil resi due from the glass Frost protection must be guaranteed to approx 25 C approx 35 C in countries with an arctic climate in the windscreen wash wipe system 4 46 2 Window wash wipe system checking spray jet settings and adjusting if nec essary Special tools and workshop equipment required Adjusting tool T10564 or adjusting tool T40187 Note If the ...

Page 134: ... the washer jet 3 by turning the adjuster 2 using a suitable screwdriver Clockwise lower Anti clockwise higher Rear window spray jet setting Adjust spray jet using adjusting tool T10564 or adjusting tool T40187 so that the water jet sprays onto the upper third of rear window 4 46 3 Headlight washer system checking spray jet settings Caution Only control function of spray jets but do not adjust the...

Page 135: ... arms Note Adjusting the wiper blades is a repair measure The repair measure is carried out subject to a separate charge 4 46 5 Rear window wiper blade checking park position Procedure Electrical system Rep gr 92 Rear window wiper system Adjusting wiper arm Note Adjusting the wiper blades is a repair measure The repair measure is carried out subject to a separate charge 4 47 Wiper blade protection...

Page 136: ...emoving transport wiper blade page 133 4 47 1 Wiper blade protection version 1 re moving Switch ignition on and off briefly with bonnet closed When engine is switched off move wiper lever down to touch wipe function within 10 seconds The wiper blades move to the service position Lift the wiper arm away from windscreen Caution When doing this do not touch the wiper blade to prevent dam age Remove u...

Page 137: ...from windscreen Caution When doing this do not touch the wiper blade to prevent dam age Pull protective strip off wiper blade upwards as shown in il lustration Carefully place wiper arm back onto windscreen Switch ignition on and briefly press the wiper lever to move the wipers back to park position Switch ignition off again 4 47 3 Wiper blade protection version 3 re moving transport wiper blade S...

Page 138: ... maintenance list as of model year 2014 In the US Canadian and Mexican markets SAE compliant headlights are used As of model year 2014 the headlight adjustment is subject to a separate charge Test and adjustment conditions page 134 Check headlight adjustment ECE page 134 Check headlight adjustment SAE page 135 Halogen headlights adjusting page 137 4 48 1 Test and adjustment conditions Tyre pressur...

Page 139: ... on the horizontal bright dark boundary contacts the dividing line 1 of the test area and Check whether the breaking point 2 between the horizontal part of the light dark border on the left and the rising part on the right lies on the vertical line of the central point 3 The bright core of the light beam must be to the right of the vertical line Note To simplify the determination of the breaking p...

Page 140: ...et according to the fuel level in the fuel tank Inclination for SAE VOL halogen headlights Fill level of fuel gauge Inclination 0 to 1 2 0 9 1 2 to 1 0 7 VOL Visual Optical Aim Left 1 Check whether the left horizontal light dark border touches the separating line 1 in the test area of the headlight adjustment unit Inclination for SAE VOR halogen headlights Fill level of fuel gauge Inclination 0 to...

Page 141: ...itional weights are no longer used Instead a different inclination setting on the headlight adjust ment unit is used If the maintenance tables are used the settings are displayed in the vehicle specific maintenance list as of model year 2014 In the US Canadian and Mexican markets SAE compliant headlights are used As of model year 2014 the headlight adjustment is subject to a separate charge Test a...

Page 142: ...rol are reset to dipped beam position The initialisation of the headlight range control is performed during vehicle start or after an on signal is applied to terminal 15 4 49 2 Headlight adjustment ECE adjusting Special tools and workshop equipment required Headlight adjustment unit VAS 5046 A Headlight adjustment unit VAS 5047 A Headlight adjustment unit VAS 621 001 Vehicle diagnostic tester The ...

Page 143: ...orizontal part of the light dark border on the left and the slope on the right should be on the vertical line passing through the centre mark Note To simplify the determination of the breaking point 2 cover and uncover left from driver perspective half of the headlight a few times Then check dipped beam again 4 49 3 Headlight adjustment SAE checking Special tools and workshop equipment required He...

Page 144: ...1 0 0 VOR Visual Optical Aim Right 2 Check whether the right horizontal light dark border touches the separating line 2 in the test area of the headlight adjust ment unit 4 49 4 Gas discharge headlights without Dy namic Light Assist dynamic main beam regulation adjusting Note As of model year 2014 the headlight adjustment is subject to a separate charge Carrying out basic setting of headlight rang...

Page 145: ...ific maintenance list as of model year 2014 In the US Canadian and Mexican markets SAE compliant headlights are used As of model year 2014 the headlight adjustment is subject to a separate charge DLA Dynamic Light Assist dynamic high beam regulation Conditions for testing and adjustment page 141 Check headlight adjustment ECE page 142 Check headlight adjustment SAE page 143 Gas discharge headlight...

Page 146: ...eadlight adjustment unit is set according to the fuel level in the fuel tank Inclination setting for ECE compliant gas discharge headlights LED headlights and DLA headlights Fill level of fuel gauge Inclination 0 to 1 2 1 0 1 2 to 1 1 0 Test pattern with dynamic main beam Note For dynamic main beam test pattern headlights need to be reset to basic settings using vehicle diagnostic tester The basic...

Page 147: ...carried out using the test pattern with dynamic main beam The controller only uses the DLA main beam distribution test program With the dipped beam switched on the lowest part of the hor izontal light dark border must touch the dividing line 1 of the test area The breaking point 2 between the horizontal part of the light dark border on the left and the slope on the right should be on the vertical ...

Page 148: ...Check the following Whether the horizontal light dark border touches the separat ing line 1 in the test area when the main beam is on Whether the breaking point 2 between horizontal part of the light dark border on the right and the rising part on the left lies on the vertical line of the central point 3 The bright core of the light beam must be to the left of the vertical line Note The setup patt...

Page 149: ... For dynamic main beam test pattern headlights need to be reset to basic settings using vehicle diagnostic tester The basic settings can only be reset using vehicle diagnostic tester After resetting DLA main beam distribution is actuated automatically Pay special attention to correct alignment of the adjustment sighting device on the headlight adjuster Only when this has been done can you adjust t...

Page 150: ...t necessary to use the ve hicle diagnostic tester Headlight adjustment on the other hand can only be carried out using the test pattern with dynamic main beam The controller only uses the DLA main beam distribution test program With the dipped beam switched on the lowest part of the hor izontal light dark border must touch the dividing line 1 of the test area The breaking point 2 between the horiz...

Page 151: ...eck headlight setting Adjust height setting of headlight if necessary Note Adjustment of the left headlight is carried out in the same se quence The adjustment bolts for the left headlight are a mirror image 4 51 Headlight adjustment checking fog lights Note Additional weights are no longer used Instead a different inclination setting on the headlight adjust ment unit is used If the maintenance ta...

Page 152: ...1 001 The inclination on the headlight adjustment unit is set according to the fuel level in the fuel tank Inclination setting for fog lights Fill level of fuel gauge Inclination 0 to 1 2 2 2 1 2 to 1 2 0 Fog lights Check whether the upper light dark border touches the setting line and runs horizontally over the entire width of the test screen Other additional lights Additionally retrofitted light...

Page 153: ...itions clean sunroof drains Note Cleaning of the sliding sunroof drains is a repair measure which is subject to a separate charge when performed 4 53 Service interval display resetting Resetting service interval display using vehicle diagnostic tester page 150 Resetting service interval display without vehicle diagnostic tester page 150 Additional information for service interval display page 5 Th...

Page 154: ...coded to fixed intervals This also modifies the adaptation channel for oil quality 4 53 1 Service interval display resetting using vehicle diagnostic tester Reset service interval display Vehicle diagnostic tester Select the respective service which is to be reset 4 53 2 Service interval display resetting with out vehicle diagnostic tester Only up to 2013 page 150 Applies from 2014 page 151 Applie...

Page 155: ...ition switched off press and hold button 3 Switch on ignition Release button 3 and press clock setting button 1 once briefly The service interval display is now in the resetting mode After a short time the display switches back to the original display Applies as of 2014 Oil change service interval display resetting With ignition switched off press and hold button 3 Switch on ignition Release butto...

Page 156: ... Release button 3 The service interval display is now in the resetting mode Reset inspection service interval display by pressing OK but ton 5 on multifunction steering wheel or OK button 1 on windscreen wiper lever After a short time the display switches back to the original display 4 54 Service interval display recoding Recoding from flexible to fixed intervals ODIS Service Connect vehicle diagn...

Page 157: ... Without task Select Control units Select Dash panel insert Select Guided Functions Select Oil change service fixed Follow instructions in Guided functions mode Reset 1 Oil change service fixed Follow instructions in Guided functions mode The current values for maximum distance to be driven km until next oil change service are shown in the display of the vehicle diagnostic tester Select No Select ...

Page 158: ...cified no clear ance Check that boots arrow are not damaged and are seated correctly Make sure that boots 1 of steering rack are not damaged and are seated correctly Perform visual inspection for leaks and damage in area of steering rack including track rods 4 57 Auxiliary heater setting weekday in menu of dash panel insert As the weekday in the menu for the auxiliary heater is not linked to the t...

Page 159: ...Select main menu Switch on ignition A vehicle symbol is displayed Press button 1 once To return to main menu press rocker switch 2 and hold for about one second Or select menu option Back and press button 1 Press rocker 2 up or down to mark a menu item The marked menu option is found between the two horizontal lines Additionally there is a triangle on the right Mark menu item Auxiliary heater and ...

Page 160: ...ttach ments and anti theft alarm systems which can produce faults during transportation Procedure Switch transportation mode off on Vehicle diagnostic tester 4 60 Transportation devices removing block ing pieces from springs on front axle Blocking pieces are fitted to front axle springs of vehicles with sports running gear These vehicles are identified by a warning tag on the mirror arrow Note The...

Page 161: ... Push blocking piece arrow off coil spring Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 157 ...

Page 162: ...y circumstances Externally towing eyes and fastening rings are distinguished by the fact that fastening rings 1 and 2 have no surface protection and are designed as welded parts The long version of the tie down ring 1 has the part number 3C0 802 994 A The short version of the tie down ring 2 has the part number 3C0 802 994 In contrast the towing eye 3 has surface protection and is a forged part i ...

Page 163: ...Caution When installing the cover make sure that the vehicle s paint work is not damaged Remove cover cap bond if fitted Fasten cover cap 4 61 3 Passat Estate Note One towing eye must remain with the vehicle if two towing eyes are used to secure the vehicle during transportation The addi tional towing eye can be scrapped Towing eye in front right bumper Unscrew towing eye arrow clockwise Caution W...

Page 164: ...p bond if fitted Fasten cover cap 4 62 Door arrester grease Perform the following procedure Lubricate door arrester at positions 1 2 3 and 4 with universal oil spray G 000 115 A2 Ensure universal oil penetrates by moving door several times over all detents Wipe off excess universal oil with a cloth Then lubricate door arrester rollers with lubricating paste G 000 150 at positions marked with an ar...

Page 165: ...underbody panels routing of lines plugs Caution During inspection also check floor pan wheel housings and sills Always ensure that all lines are secured in their mount ings all plugs are available and that there is no visible damage on the underbody Faults found must always be rectified repair measure This inhibits corrosion and rusting through 4 65 Camshaft drive toothed belt diesel en gines rene...

Page 166: ...ge 166 Spark plugs renewing 1 8 l TSI and 2 0 l TSI engines page 168 Spark plugs renewing 6 cylinder FSI engines page 170 Special tools and workshop equipment required Spark plug socket 3122 B Torque wrench V A G 1331 Puller T10094 A for 1 4 l TSI engines Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 162 4 Descriptions of work ...

Page 167: ...for 3 6 l FSI engines Assembly tool T10118 for 3 6 l FSI and 1 4 l TSI engines 4 66 1 Spark plugs renewing 1 4 l TSI en gines turbocharger Removing Remove engine cover panel page 106 Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 4 Descriptions of work 163 ...

Page 168: ... output stage arrow Slightly pull out ignition coil with output stage Fit assembly tool T10118 as illustrated Release connector locking device carefully and pull off con nector Unscrew spark plugs using spark plug socket VAS 3122B Installing Note When installing new spark plugs regrease ignition coils with output stage using silicone paste ETKA The applicable silicone paste is stated in the ETKA a...

Page 169: ...rk plugs Test data spark plugs Please observe disposal instructions Seat puller T10094 A on ignition coil with output stage Slide connector on ignition coil with output stage until it audibly engages Push ignition coil with output stage in direction of arrow into cylinder head Route cables properly in cable guide Secure cable guide clips arrows Connect hoses 1 and 2 Install engine cover panel page...

Page 170: ... ignition coil connectors can remain connected Note installation position of ignition coils with output stages Caution Ensure that the cables are not kinked or damaged Seat puller T10094 A on ignition coil with output stage Pull out ignition coil with output stage and connected wires and carefully place to side Unscrew spark plugs using spark plug socket VAS 3122B Installing Note When installing n...

Page 171: ...on system test data Please observe disposal instructions Place puller T10094 A on ignition coil with output stage Push ignition coil with output stage into cylinder head until they noticeably engage Route cables properly in cable guide Engage clamps of cable guide arrows Set hose with bracket and charge pressure control solenoid valve to original installation position Tighten bolts 1 10 Nm Push on...

Page 172: ... cover panels page 106 The spark plugs are located below the ignition coils with output stages 2 Note Note installation position of ignition coils with output stages Pull all ignition coils out of cylinder head approx 30 mm in direction of arrow using puller T40039 Press connectors in direction of ignition coils with output stages press onto catch by hand and pull connectors arrows off Passat 2011...

Page 173: ... with output stage using silicone paste ETKA The applicable silicone paste is stated in the ETKA along with the corresponding ignition coil and or spark plug Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage arrow Insert ignition coils with output stages into cylinder head Align ignition coils with output stages in respective recess...

Page 174: ...ng ignition coil and or spark plug Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage arrow Install new spark plugs using spark plug socket and extension VAS 3122B Screw in new spark plugs using spark plug socket and exten sion 3122 B Note Spark plug designation and specified torque Power unit Power unit Rep gr 28 Test data spark plu...

Page 175: ...m Inhaling natural gas can lead to light headedness and lung damage High concentrations may lead to suffocation due to lack of oxygen Natural gas is NOT odourless because a gas having a strong odour is added Condition for testing All parts of the natural gas system to be checked must be reached easily The exhaust gas warning lamp in the dash panel insert must not light up and there must be no entr...

Page 176: ...k and fuel tank shut off valve is sufficiently waxed page 175 Applicable procedure for assessment of steel and CFRP fuel tanks Gas engines general information Rep gr 20 Fuel tanks Damage assessment catalogue for natural gas tanks Check whether the natural gas tank cover in the luggage com partment arrow is damage free Testing for leaks Start engine to set pressures in gas system to operating state...

Page 177: ...is present in the air immediately surrounding the area being tested If the gas leak detector VAS 523 003 detects a leak a leak detector spray must be used to prove conclusively whether the gas is actually escaping from the vehicle system When a leak detector spray is used no bubbles may escape from the sprayed area within a test period of 3 minutes Should leaks occur these must be repaired after w...

Page 178: ...fully Coupling point for high pressure line arrow from natural gas tank 3 to high pressure valve for gas mode on underbody Tank shut off valves for natural gas tanks 1 and 2 with all con nections threaded connections and mechanical shut off valves arrows Passat 2011 Passat Variant 2011 Maintenance Edition 01 2019 174 4 Descriptions of work ...

Page 179: ...sor 2 installed and without removal of the exhaust gas turbocharg er pressure pipe see illustration view when removed Install underbody cover General body repairs exterior Rep gr 66 Natural gas tank covers 4 68 Natural gas system checking wax layer between natural gas fuel tank and fuel tank shut off valve Note Applies only to German market Special tools and workshop equipment required Wax ETKA Ma...

Page 180: ...emissions test only when all units of the emissions testing station are connected prop erly and joined to each other according to the operating in structions All work to be performed is displayed by the emissions testing station Conditions for testing All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine For bar code reading the EET ...

Page 181: ... the respective mask Manual specified data input for EET Note All test conditions and data required for exhaust emissions test can be found in the Data sheets for exhaust emissions test for respective engine Perform manual data input according to instructions on dis play Enter displayed values on EET data sheet in column Test values for exhaust emissions test on display as follows 1 Test speed idl...

Page 182: ...formed is displayed by the emissions testing station Conditions for testing All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine Automatic gearbox selector lever in P position Manual gearbox gear lever in neutral Parking brake applied 12V battery fully charged if battery charge is too low raise idling speed if necessary Perform exha...

Page 183: ...vation of idle speed limitation of Euro 6 vehicles with man ual gearbox Switch on ignition Switch on infotainment system Press Home function button Press Vehicle function button Press Setup function button Press ESC system function button and deactivate TCS Manual specified data input for EET Note For the relevant test requirements and all the necessary data for the exhaust emissions test refer to...

Page 184: ...LSA must be used If no value is indicated on the type plate and no opacity figure has been specified by the manufacturer the statutory opacity figures 2 5 m 1 or 1 5 m 1 depending on date of initial reg istration must be used The nominal speed can only be entered manually If the opacity figure of Euro 5 vehicles on the EET data sheet is different from the value indicated on the type plate enter th...

Page 185: ... tank in the vehicle ATF level Filling level of ATF in gearbox BEV Battery Electric Vehicle Electric vehicle CNG Compressed Natural Gas Compressed natural gas CO Carbon monoxide Produced when fuels containing carbon are not combusted com pletely Common rail CR This term refers to a common high pressure injection line the rail which supplies all cylinders of the relevant cylinder bank with fuel Die...

Page 186: ...ine emissions PMS Particulate reduction system QG0 Vehicles are not factory fitted with components for LongLife service For maintenance the intervals based on time and distance non flexible intervals apply QG1 Vehicles are factory fitted with active LongLife service This means vehicles have a flex ible service interval display and are fitted with the following components Flexible service interval ...

Page 187: ... upstream of a spe cial catalytic converter PFI Intake manifold injection system indirect injection system SULEV Super Ultra Low Emission Vehicle TSI TSI turbocharger Charging with turbocharger only TSI twincharger Charging with turbocharger and compressor TGI Charging with turbocharger and natural gas injection system TDI Turbo diesel engine direct injection ULEV Ultra low emission vehicle VDA Ge...

Page 188: ...rmance handling noises air conditioner etc carrying out page 119 Chapter updated Track rods checking clearance attachment and boots page 154 Chapter updated 23 02 2 018 Exhaust emissions test page 176 Chapter updated 22 12 2 017 Service tables page 7 Chapter updated Multi purpose additive for diesel fuel adding page 102 Chapter updated Protective bellows inspecting page 88 Checking clamps added to...

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Volkswagen Passat 2011, Maintenance Manual

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