Volkswagen Touareg 2003 Скачать руководство пользователя страница 13

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TOUAREG

SERVICE INTERVALS 2008►

From - to

Engine/Engine code/

PR No./Remarks

Service/intervals

Indicated on

service interval display SID

(includes oil change)

Since in‐

troduc‐

tion

Diesel, in countries with ele‐

vated sulphur content in fuel

⇒ page 23

Oil change service

every 7,500 km or 1 year

YES

2008► Petrol and diesel:

QG0/QG2 or QG1 vehicles

coded to non-flexible interval

Oil change service

every 15,000 km or 1 year

YES

Interval service:

every 30,000 km or 2 years

YES

Petrol and diesel:

QG1 vehicles

Interval service:

flexible according to SID from

15,000 km or 1 year up to max.

30,000 km or 2 years

YES

Petrol and diesel:

all vehicles

Inspection service:

after 3 years or max 60,000 km,

then every 2 years or 60,000 km

VW engine oil standards

Caution

Only engine oils approved by VW may be used, for up-to-date

information see ⇒ ServiceNet, Technical information, Inspec‐

tions and Servicing, Approved oils , or ask your importer.

TOUAREG

VW ENGINE OIL STANDARDS

PETROL ENGINES

With LongLife service (QG1)

Without LongLife service (QG0, QG2, QG3)

VR6, V8 engines without FSI

504 00

alternative

503 00

VR6, V8 engines without FSI ►2007 501 01/502

VR6, V8 engines without FSI 2008►

502 00

VR6 FSI, W12-cylinder

504 00

alternative

503 01

VR6 FSI, W12 engines ►2007

502 00/505

VR6 FSI, W12 engines 2008►

502 00

V8 FSI engine

504 00

alternative

503 01

V8 FSI engine

502 00

DIESEL ENGINES

V10 engines

with and without diesel particu‐

late filter

►2006

506 01

V10 engines

with and without diesel particulate fil‐

ter

►2006

506 01

R5 with engine codes BPD and

BPE

with diesel particulate filter

►2006

507 00

R5 with engine codes BPD and BPE

with diesel particulate filter

►2006

507 00

R5 engines without diesel par‐

ticulate filter

506 01

R5 engines without diesel particulate

filter

506 01

V10 engines without diesel par‐

ticulate filter

2007►

507 00

alternative

506 01

V10 engines without diesel particulate

filter

2007►

507 00

al‐

ternative

506 01

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work

Содержание Touareg 2003

Страница 1: ...r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t...

Страница 2: ...b y V o l k s w a g e n A G Maintenance Heading 1 Engine list 2 Service work 3 General 4 Descriptions of work 5 Exhaust emissions test 6 Glossary Technical information should always be available to t...

Страница 3: ...Check using battery tester with printer VAS 5097A or VAS 6161 47 4 10 Reducing agent AdBlue Replenish 47 4 11 Reducing agent AdBlue Change 56 4 12 Checking tyres Condition wear pattern tyre pressure...

Страница 4: ...uide rails 124 4 45 Sliding sunroof drains Check not blocked clean if necessary 124 4 46 Window wash wipe system and headlight washer system Checking operation and checking for damage if necessary rep...

Страница 5: ...00 300 4000 Bore mm 84 5 84 0 84 0 Stroke mm 93 95 9 95 9 Compression ratio 11 11 25 11 25 Injection ignition Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE RON min 98 unleaded 1 95...

Страница 6: ...7 1 1 SRE Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE RON min 98 unleaded 1 95 unleaded 95 unleaded Leakage diagnosis system e g USA vehicles no no no Onboard diagnosis OBD no no yes Camshaft drive C...

Страница 7: ...Gear train Chain Gear train Engines Diesel engine Diesel engine Diesel engine Diesel engine Capacity I 4 9 2 5 2 5 2 5 Engine code BLE BPD BPE BLK No of cylinders valves per cyl inder 10 2 5 2 5 2 5 2...

Страница 8: ...is system e g USA vehicles no no no no Onboard diagnosis yes yes yes yes Camshaft drive Gear train Chain Chain Chain Engines Diesel engine Diesel engine Diesel engine Capacity I 3 0 3 0 4 9 Engine cod...

Страница 9: ...dicates LongLife service QG0 or QG2 indicates time or distance dependent service 2 1 2 LongLife service Vehicles with PR number QG1 The LongLife service enables long service intervals depending on ind...

Страница 10: ...these vehicles the LongLife service is not factory activated Therefore these vehicles have a non flexible service interval dis play SID page 6 and for maintenance the time or distance dependent interv...

Страница 11: ...hicles with time or distance dependent service PR number QG0 QG2 Calculation of service intervals To calculate the service interval for vehicles with time or dis tance dependent service the non flexib...

Страница 12: ...reme conditions page 24 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 TOUAREG SERVIC...

Страница 13: ...every 2 years or 60 000 km NO VW engine oil standards Caution Only engine oils approved by VW may be used for up to date information see ServiceNet Technical information Inspec tions and Servicing Ap...

Страница 14: ...ith LongLife service QG1 According to flexible service interval display All remaining vehicles Every 15 000 km or 1 year AIR FILTER page 86 All engines except V6 TDI 2006 Every 120 000 km or 4 years 2...

Страница 15: ...Engine type Engine code Model year Change interval Tensioning roller 4 2 l AXQ Since introduction Every 120 000 km 120 000 km Spark plug change intervals Spark plug designation and specified torque P...

Страница 16: ...0 000 km page 137 Elastic drive coupling and alternator drive freewheel Renew Only valid for R5 TDI engine codes BAC and BLK Every 150 000 km page 137 Diesel particulate filter Read ash load Only vali...

Страница 17: ...chapter only provides information on market specific devia tions This means that all maintenance points that are not shown here are to be found in the normal service tables Indian market Interval Desc...

Страница 18: ...l part of the interval service North American market Interval Description of work Sliding sunroof drains Check not blocked clean if necessary Every 60 000 km page 124 Diesel particulate filter Renew O...

Страница 19: ...h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Interval Description of work Air filter element Ren...

Страница 20: ...page 24 Type plate page 24 Jacking up mode Switching self levelling suspension off and on page 24 3 1 Raising vehicle with lifting platform or trolley jack Note When raising the vehicle the jacking u...

Страница 21: ...on vertical stiffener of side member Rear lifting point Position support plate at reinforcement of floor pan near rear axle mounting arrow WARNING Ensure that support plate of raising platform is cen...

Страница 22: ...change service or inspection service or legal check such as legislative inspection or gas system check next serv ice due and enter date and mileage Note The new sticker is applied gradually from week...

Страница 23: ...ed 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...

Страница 24: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Vehicle diagnosis and service information system VAS 5052 or subsequent units Diagnosis cable 2 m VAS 5052 3 A N...

Страница 25: ...diagnosis tester Switch on vehicle diagnosis tester Switch on ignition Now follow screen display to start desired functions 3 4 Vehicle identification number Location windscreen The vehicle identifica...

Страница 26: ...el trim in the footwell on driver side The vehicle data sticker is also found in the service schedule for the customer On the left side of left hand drive vehicles on the right side of right hand driv...

Страница 27: ...ius Tajikistan Brazil Cambodia Mongolia Tanzania Brunei Cameroon Myanmar Burma Trinidad and Tobago Dominican Republic Kazakhstan Nigeria Tunisia Ecuador Qatar Pakistan Uruguay Ivory Coast Kenya Paragu...

Страница 28: ...jobs will have to be performed before the next service due or at shorter service intervals Severe operating conditions Regular short trips or stop and go operation in urban traffic High percentage of...

Страница 29: ...y V o l k s w a g e n A G Switch on ignition Press button LOCK in centre console arrow and hold for 5 seconds The jacking up mode is displayed in the combi instrument a warning lamp flashes in LOCK bu...

Страница 30: ...em and shock absorbers Perform visual check for leaks and damage page 62 Changing brake fluid page 63 Brake fluid level dependent upon lining wear Check page 66 Thickness of brake pads linings and con...

Страница 31: ...ding radio code using vehicle diagnosis tester page 112 Radio navigation system Activate anti theft coding page 113 Reducing agent AdBlue Replenish page 47 Reducing agent AdBlue Change page 56 Storing...

Страница 32: ...s w a g e n A G Spark plugs Renew page 140 Static cornering light cornering light and driving light assist Check function page 151 4 1 Removable towing bracket Check and clean if necessary This chapt...

Страница 33: ...it has only to be in agreement with the customer A repair must be charged separately Repair procedure Check contact surfaces arrows of ball head mounting for corrosion If contact surfaces are corroded...

Страница 34: ...cating the control motor linkage includes 1 Turbocharger 1 control motor V280 for cylinder bank 1 right engine side 2 Turbocharger 2 control motor V281 for cylinder bank 2 left engine side Remove engi...

Страница 35: ...s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Fitting location Front left between steering and housing of front final drive above coolant hoses arrow A Lubricate rotating point of co...

Страница 36: ...health and environ ment Protective and hygiene measures Behaviour in case of danger ServiceNet Genuine parts safety data sheets and operating instructions Diesel fuel additive for particulate filter...

Страница 37: ...on Collect fluid in a container e g when lines are drained empty etc Route lines of all types e g fuel lines additive lines as well as electrical wires so that the cable guide is in original condition...

Страница 38: ...ocated on tank filler neck arrow A Note Always note safety measures when working on additive contain er First pull sealing plug off VENTILATION arrow B page 34 Then pull sealing plug off EXTRACTION FI...

Страница 39: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 4 5 Extracting and replenishing with fluid Special tools testers measuring instruments and auxiliary items required Extraction...

Страница 40: ...prox 2 3 full see arrow 5 If necessary repeat extraction process Do not reuse extracted used additive fluid Dispose of extracted used additive fluid according to op erating instructions ServiceNet HSO...

Страница 41: ...disconnect filling hose using e g hose clamp 3094 Separate filling device VAS 6277 2 and overflow protection VAS 6277 3 from additive container connections arrows A B Connect both sealing plugs onto c...

Страница 42: ...dry and well ventilated area 4 5 Diesel particulate filter Reading the ash load Note When checking the diesel particulate filter read the ash load limit Connect vehicle diagnosis tester page 19 Switc...

Страница 43: ...Engine does not start transportation device active Procedure The battery cut off relay is located in the footwell in front of driver seat The battery cut off relay is screwed to the earth point of ba...

Страница 44: ...and tighten earth cable to 20 Nm Note When battery earth cable has been reconnected Electrical sys tem Rep gr 27 Disconnecting and connecting battery Route connector and relay cable at position shown...

Страница 45: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Battery under left front seat checking battery terminal clamps for secure seating Switch off ignition and all electrical c...

Страница 46: ...eated securely on positive terminal The following procedure must be followed without exception Disconnecting battery under front left seat WARNING The battery under the front left seat is equipped wit...

Страница 47: ...hten securing bolt on battery positive terminal clamp to 6 Nm Only after the positive terminal clamp 2 is secure may the negative terminal clamp 1 be placed on the battery negative terminal Tighten se...

Страница 48: ...l tools and workshop equipment required V A G 1331 Torque wrench 5 50 Nm Tighten battery clamp 1 on battery negative terminal to 6 Nm Reinstall engine cover panel Renew securing bolts arrows of seat f...

Страница 49: ...battery positive wire 1 and battery negative wire 2 back and forth WARNING If the battery clamp is not seated securely on the positive ter minal first disconnect battery clamp from battery negative te...

Страница 50: ...erminal clamp arrow to 6 Nm Only after the positive terminal clamp is secure may the neg ative terminal clamp arrow be placed on the battery negative terminal Tighten securing bolt on battery negative...

Страница 51: ...Checking battery 4 10 Reducing agent AdBlue Replenish Note To prevent the descriptions from becoming unclear the NOx re ducing agent AUS 32 AdBlue is merely called reducing agent AdBlue in the followi...

Страница 52: ...nd gearbox jack VAG 1383 A Adapter plate VAG 1383A 1 4 10 1 General Properties The reducing agent AdBlue is not a diesel additive and must not be poured into the diesel fuel tank The reducing agent Ad...

Страница 53: ...e reducing agent tank is located in the luggage compart ment A refill container approved by Volkswagen must be used for replenishing the reducing agent AdBlue The reducing agent tank has a capacity of...

Страница 54: ...ult finding 4 10 2 Health endangerment and cleaning WARNING The reducing agent AdBlue may irritate the skin eyes and respiratory organs Protect your hands In the event of skin contact with this fluid...

Страница 55: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 10 4 Work preparation for filling reducing agent tank Note Ensure that vehicle stays on an even ground The reduc...

Страница 56: ...pen Lever points in direction of hose cut off tap closed Lever positioned transverse to direction of hose 4 Quick release coupling on breather hose 5 Filling hose 6 Cut off tap for filling hose cut of...

Страница 57: ...ose 9 Engine and gearbox jack VAG 1383 A 4 Place filling device VAS 6542 onto reducing agent con tainer ETKA turn union nut COUNTER clockwise until both threads engage with each other Turn then union...

Страница 58: ...agent tank au tomatically has the correct fill level After replenishing switch on ignition for at least 20 seconds so that the replenished reducing agent AdBlue can be rec ognised by the system Cauti...

Страница 59: ...o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 10 6 Work after filling reducing agent tank Screw in tank cap 1 of...

Страница 60: ...through all parts of filling device VAS 6542 under flowing water 4 11 Reducing agent AdBlue Change Procedure Power unit Rep gr 26 SCR system selective catalytic re duction Draining reducing agent tank...

Страница 61: ...upping one sided wear porous side walls cuts and punctures Check tyre age We recommend not to use any tyres older than 6 years Inform customer WARNING The customer must be informed of any faults found...

Страница 62: ...ures for the relevant model can also be found on a sticker It is attached to the inside of tank flap or to B pillar Adjust the tyre pressure to suit the vehicle load The spare wheel should have the hi...

Страница 63: ...n pressure using tyre inflator VAS 5216 cor rect if necessary 4 13 Storing tyre pressure values Correct tyre pressure must be adjusted page 56 Tyres must be cold Switch on ignition Press button 1 to a...

Страница 64: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pliers 3314 Torque wrench 40 200 Nm V A G 1332 Electric hand torch and mirror Note The adapter to loosen and tighten the anti th...

Страница 65: ...without backplate Wear limit 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm without backplate and must be renewed repair meas ure Inform customer Note When replacing bra...

Страница 66: ...ssary replacing the brake discs is a repair measure Check brake disc for wear Brake system Rep gr 46 Repairing rear brakes Condition of brake discs Check Check all brake discs for the following damage...

Страница 67: ...r this purpose it can be mixed with the previous brake fluid WARNING Brake fluid must under no circumstances come into con tact with fluids containing mineral oils oil petrol cleaning solutions Minera...

Страница 68: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Brake filling and bleeding equipment VAS 5234 Brake bleeding wrench VAS 5519 Brake bleeding tool VAS 6564 Observe...

Страница 69: ...ning gear brake systems Rep gr 47 Bleeding brake system Bleeding brake system Place brake pedal depressor V A G 1869 2 between driver seat and brake pedal and tension it Screw adapter onto brake fluid...

Страница 70: ...on other side of vehicle at front Table Sequence and quantity of brake fluid Sequence Clutch slave cylinder wheel brake cylinder brake calipers Quantity of brake fluid which must flow out Bleeder valv...

Страница 71: ...the reservoir MAX marking 1 must not be 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 t...

Страница 72: ...batteries in luggage compartment and or left front seat have been disconnected and reconnected the one touch win dow operation is disabled Therefore with immediate effect before a new vehicle is de l...

Страница 73: ...rms a vehicle system test and reads all control units available for this vehicle type Press button Now all faults are listed Note At this point it is useful to change to operating mode guided function...

Страница 74: ...he front passenger Check activation deactivation Note There are vehicles which are fitted with automatic passenger air bag deactivation e g vehicles for the North American market This is performed by...

Страница 75: ...e 4 23 1 Protective bellows Visual check Carry out the following procedure Check outer bellows and inner bellows arrows for leaks and damage Note Also check protective bellows on rear axle 4 24 Dust a...

Страница 76: ...nks surface cracks Traces of oil and grease Install engine cover Note If faults are found it is absolutely necessary to renew the poly V belt This will avoid possible breakdowns or operating problems...

Страница 77: ...lter 5 cylinder diesel engines page 78 4 27 1 Renewing diesel fuel filter 6 cylinder diesel engines Note Please note for engine codes CASA CASB and CATA the fuel system must be bled after changing the...

Страница 78: ...r upper part arrows A Pull diesel fuel filter element 4 out of diesel fuel filter lower part on retainer 3 Note Observe disposal regulations Caution If necessary remove dirt and water residues from di...

Страница 79: ...bolts to 10 Nm torque Bleeding fuel system for engine codes CASA CASB and CATA Connect vehicle diagnosis tester page 19 Select Guided functions Perform vehicle identification Select respective engine...

Страница 80: ...k s w a g e n A G Diesel extractor VAS 5226 Remove engine cover page 106 Removing Remove plug arrow from water drainage connection of diesel fuel filter housing Extract diesel fuel from side water dr...

Страница 81: ...n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull filter elements 3...

Страница 82: ...engine starts immediately after changing the diesel fuel filter bleed the fuel system using vehicle diagnosis tester Connect vehicle diagnosis tester page 19 Switch on ignition Select Guided function...

Страница 83: ...ne identification on diesel fuel filter Return line marked blue 2 identified with RT return line to tank Supply line marked black 3 identified with VF supply line to filter Return line 9 identified wi...

Страница 84: ...nect vehicle diagnosis tester page 19 Switch on ignition Select Guided functions Perform vehicle identification Select Systems capable of self diagnosis Diesel direct in jection and glow plug system F...

Страница 85: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G With ignition switched on press button 3 Select the symbol N using the function buttons 2 in display 1 and confirm with OK To...

Страница 86: ...risedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p...

Страница 87: ...us protects the complete cooling system against corrosion and reduces the formation of sludge and corrosion G12 Plus Plus is suitable as a filled for life filling for cast iron and all aluminium engin...

Страница 88: ...to C Quantity to drain in litres Actual value Specified val ue 5 cylinder engine 5 cylinder en gine1 6 cylinder engine 6 cylinder engine1 0 25 3 5 5 5 4 0 6 0 35 4 0 7 0 4 5 7 5 5 25 3 0 4 5 3 5 5 0...

Страница 89: ...l k s w a g e n A G Mixture ratio Caution Only distilled water may be used for mixing Tap or well water does not have the required quality to ensure the functionality of coolant Frost protection to Co...

Страница 90: ...oolant if necessary Note Coolant additive G12 Plus Plus prevents frost and corrosion damage scaling and also raises boiling point of coolant For these reasons the cooling system must be filled all yea...

Страница 91: ...r i g h t b y V o l k s w a g e n A G 4 31 1 Removing and installing filter element on 10 cylinder engines Remove engine cover page 106 Removing Note The removal and installation of the left air filt...

Страница 92: ...r filter housing arrow as follows Press locking ring 1 off flange of line 3 using screwdriver C Press securing sleeve 2 in direction of arrow and pull line A off line B at the same time Pull air filte...

Страница 93: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Secure air filter housing with...

Страница 94: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert securing pins so that marking on pin 1 and marking on air filter housing...

Страница 95: ...h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Turn pin until marking 1 aligns with marking on air filter hous ing 3 Pull out securing pin upwards Pull off intake hose Disconnect...

Страница 96: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter element A If necessary blow out air filter housing with compressed air and install new air filter element...

Страница 97: ...s w a g e n A G Then press locking ring 1 onto flange of line 3 until it can be heard to engage Install intake hose Install intake hose securing pins as follows Insert securing pins so that marking on...

Страница 98: ...On the rear line press locking ring 1 off flange of line 3 using screwdriver C Press securing sleeve 2 in direction of arrow and pull line A off line B at the same time On front line press securing r...

Страница 99: ...w a g e n A G Secure air filter housing with spring clips 1 Bolt on throttle valve module 2 and tighten to 3 Nm Reconnect connector 3 Push line arrow together again Then press locking ring 1 onto flan...

Страница 100: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect lines to air filter housing arrow as fo...

Страница 101: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter element A If necessary blow out air filter housing with compressed air and install new air filter element Installing Install ai...

Страница 102: ...6 4 32 Engine oil level Check Please note the following After shutting off engine wait at least 3 minutes so that the oil can flow back into the sump Pull out dipstick and wipe with a clean cloth and...

Страница 103: ...l filter must be re newed before changing the engine oil page 100 When removing the filter element a valve is opened the oil in the filter housing automatically flows into crankcase For 8 cylinder and...

Страница 104: ...ne page 103 Renewing oil filter on 6 cylinder diesel engine page 105 Renewing oil filter on 8 cylinder petrol engine page 101 Renewing oil filter on 10 cylinder diesel engine page 102 Renewing oil fil...

Страница 105: ...O rings before installing Remove oil drain plug 1 of threaded cover and drain oil Loosen threaded cover 2 on hexagon 1 or along perimeter and remove Clean sealing surfaces on threaded cap and oil fil...

Страница 106: ...with oil filter element Separate oil filter element 3 from sealing cap 1 Clean sealing surfaces on threaded cap and oil filter housing Installing Renew oil filter element 3 Install sealing cap 1 with...

Страница 107: ...25 Nm 4 33 7 Renewing oil filter on 6 cylinder petrol engine Note Observe disposal regulations Oil new O rings before installing Prevent engine oil from dripping onto subframe Carry out the following...

Страница 108: ...o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench 5 50 Nm V A G 1331 Removing Note Observe disposal regulations Oil new O rings before installing...

Страница 109: ...aded cap 3 with new O ring 4 and tighten to 25 Nm Fit oil drain plug 1 with new seal 2 and tighten to 10 Nm The remaining assembly steps are basically a reverse of the dis mantling procedure 4 33 9 Re...

Страница 110: ...tling procedure 4 33 10 Replenishing engine oil Oil specifications see page 7 General notes Note Observe disposal regulations After replenishing with oil wait at least 3 minutes and then check oil lev...

Страница 111: ...ol engine Unclip engine compartment covers 1 and 2 and remove upwards Caution Do not push with the fist or a tool on the engine cover panel when it is installed or engaged at securing points it could...

Страница 112: ...ts observe oil filler neck and oil dipstick Caution Do not push with the fist or a tool on the engine cover when it is installed or engaged at securing points it could be damaged Press engine cover at...

Страница 113: ...Front and rear noise insulation Remove bolts A First remove front noise insulation 3 Then remove bolts B Pull rear noise insulation 2 out of spring tabs 1 Tighten bolts to 8 Nm torque 4 36 Engine and...

Страница 114: ...bottle has a limited expiry date Therefore the expiry date is indicated on the bottle arrow This example shows that the expiry date 05 2003 has been ex ceeded then the bottle has to be renewed Check t...

Страница 115: ...clicks at latest Free travel of operating lever until braking effect be gins 2 3 clicks ABS function Pulsing must be felt at the brake pedal during ABS regulated braking Steering Function steering fre...

Страница 116: ...180 Nm 4 40 Reading radio code using vehicle diag nosis tester Authorization prerequisites for vehicle diagnosis tester The vehicle diagnosis tester is connected via the Central Part ner Network CPN w...

Страница 117: ...ed from vehicle The anti theft codes are also called radio codes or security codes Security code means that each unit with an anti theft coding is programmed with its own code number This security cod...

Страница 118: ...tivate the fixed code as follows Switch radio on The unit automatically displays SAFE and then 1000 For this no buttons are used With the help of station buttons 1 to 4 enter code number ap plied on t...

Страница 119: ...removed If the diode flashes the radio navigation system is ready for use and the anti theft coding is activated Activate fixed code on radio navigation system MFD 2 and on radio navigation system MF...

Страница 120: ...ox 50 C Do not start engine but bring front wheels to straight ahead position Remove reservoir cap with built in dipstick arrow Wipe off dipstick using a clean cloth Screw cap on hand tight and unscre...

Страница 121: ...eflectors and bulbs OK The vehicle must be rolled forward or backward several metres or front and rear springs must be bounced fully several times so that springs settle The vehicle and the headlight...

Страница 122: ...driver seat and the vehicle otherwise unloaded unladen weight The unladen weight is the weight of vehicle ready for operation with a full fuel tank at least 90 including weight of all equip ment usua...

Страница 123: ...he vertical line Note To simplify finding the breaking point 2 cover and uncover left from driver perspective half of the headlight a few times Then check dipped beam again After correct adjustment of...

Страница 124: ...adlight are a mirror image Left headlight from model year 2007 Height adjustment of left headlight Adjust adjustment bolts using a hexagon key 1 Height adjustment for dipped beam main beam Turn vertic...

Страница 125: ...adlight B Lateral adjustment for dipped beam main beam and dynamic cornering light Turn lateral adjustment bolt B until correct setting is attained Height adjustment of left headlight Adjust adjustmen...

Страница 126: ...nt bolt 1 until correct setting is at tained Note Please check also that both headlights move evenly when head light range control is operated The adjustment bolts for the right headlight are a mirror...

Страница 127: ...on the headlight adjustment unit The inclination for fog lights is 2 0 Note Percentage given is based on a projection distance of 10 metres Remove cover 1 from fastenings in direction of arrow Perfor...

Страница 128: ...correct setting is attained using hexagon key arrow A lateral adjustment is not possible Other additional lights Additionally retrofitted lights of other systems must be checked and set according to...

Страница 129: ...tap water into sliding sunroof drains and check if almost the same quantity of water flows out of the wheel housings If this is the case the test is completed If only a small quantity of water or no w...

Страница 130: ...o check pour tap water again through the sliding sunroof drain holes Install in reverse order 4 46 Window wash wipe system and head light washer system Checking opera tion and checking for damage if n...

Страница 131: ...e place a drop of water on the glass to improve the readability of the bright dark boundary The bright dark boundary can be clearly recognised on the WATERLINE Check concentration of anti freeze addit...

Страница 132: ...nsures that the fan type washer jets remain fully functional at low temperatures Use Genuine Volkswagen Windscreen Clear G 052 164 also in the warmer periods of the year The powerful cleanser re moves...

Страница 133: ...e for the left hand headlight right hand mirror image Check jet setting a 100 mm b 75 mm c 230 mm d 50 mm Switch on dipped headlight Operate windscreen washer system The headlights are washed if the w...

Страница 134: ...e 12 mm If necessary adjust park position by loosening cone and mov ing wiper arm Wiper arm tightening torque 32 Nm Windscreen of RHD vehicles Check park position The distance A between wiper blade an...

Страница 135: ...in service position This can be done by switching the ignition on and off once with bonnet closed Then operate wiper lever and the wipers will stop in service position Take the right hand wiper from...

Страница 136: ...the wipers will stop in service position Take the right hand wiper from windscreen and lift Caution To prevent damage ensure that the wiper is only touched at the wiper joint and do not pull on the w...

Страница 137: ...same procedure for the left hand wiper Carefully place wiper arm back onto windscreen Switch ignition on and briefly operate the wiper lever to move the wipers back to park position Switch ignition of...

Страница 138: ...dicated on display Press the GoTo button on display arrow Indicated on display Press the End button on display arrow Press End button in End menu Switch off ignition and separate diagnosis connections...

Страница 139: ...med correctly confirm with button Select one after the other Dash panel insert ARROW Adapting service interval extension Perform adaption according to the information of GUIDED FUNCTIONS Ending adapti...

Страница 140: ...A G Check mountings Check that boots arrow are not damaged and are seated correctly 4 51 Transportation mode Switch off Connect vehicle diagnosis tester page 19 Switch on ignition Indicated on displa...

Страница 141: ...button in End menu Switch off ignition Note The vehicle diagnosis tester must probably remain connected for further tests 4 52 Door arrester Grease Carry out the following procedure Grease door arrest...

Страница 142: ...rument Time The time can be set here and the choice can be made between the 12 and 24 hour display Language The language for the combi instrument can be set here Units The units of measurement for tem...

Страница 143: ...arning Time Convenience Language Units Reset Turn knurled wheel 2 until the menu point to be selected is shown Press knurled wheel The selected menu is called up Example setting clock via multifunctio...

Страница 144: ...ox and front and rear final drive Checking oil level replenishing if necessary Procedure Power transmission transfer box and final drive Power transmission transfer box and final drive Rep gr 34 Check...

Страница 145: ...Gdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g...

Страница 146: ...h t b y V o l k s w a g e n A G Spring type clip pliers VAS 6499 4 58 1 Vehicles with 6 cylinder petrol engine Removing Carry out the following procedure Unclip engine covers 1 and 2 and remove upward...

Страница 147: ...the flat side of igni tion coil with output stage arrows Slide puller T10095 a from the flat side of the connector in di rection of arrow onto ignition coil with output stage Pull out ignition coil w...

Страница 148: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Apply a thin bead of spark plug connector grease G 052 141 A2 on the circumference of the sealing...

Страница 149: ...h t b y V o l k s w a g e n A G 4 58 2 Vehicles with 8 cylinder petrol engine Removing Pull out dipstick Remove bracket for left engine cover 1 Unscrew bolts and retaining pin for engine cover arrows...

Страница 150: ...ling Screw in new spark plugs using spark plug socket and exten sion 3122 B Note Observe specified torque Current values Power unit Rep gr 28 Ignition system test data When renewing spark plugs grease...

Страница 151: ...c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Push on connectors A so that they engage Install left bracket f...

Страница 152: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull off hose 1 Remove bolts 1 and 2 and carefully pull off in...

Страница 153: ...n system test data Observe disposal regulations Carry out the following procedure Installing Screw in new spark plugs using spark plug socket and exten sion 3122 B Note When renewing spark plugs greas...

Страница 154: ...c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Reinstall int...

Страница 155: ...c cornering light cornering light and driving light assist Check function Static cornering light Switch on ignition and dipped beam Turn steering wheel from centre position one turn to the right and c...

Страница 156: ...ls Vehicles with regulated catalytic converter or vehicles with diesel engine 3 years after initial registration and then every 2 years Valid for Germany Vehicles for commercial passenger trans port e...

Страница 157: ...and combined with each other according to the instruction manual All work to be performed is displayed by the emissions testing station VAS 6300 Test prerequisites All test conditions and data requir...

Страница 158: ...ehicle registration document at posi tions 1 8 1 Vehicle manufacturer e g VOLKSWAGEN VW 2 Vehicle type e g Golf 3 Key number to 1 e g 11 4 Key number to 2 e g 0603 vehicle registration docu ment 4 Key...

Страница 159: ...CO content at increased idling speed 6 Lambda at increased idling speed 7 Idling speed 8 Select regulating probe type either step type probe or broad band probe item 1 9 Lambda probe value When all da...

Страница 160: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G Follow instructions on display Switch off ignition Connect diagnosis cable connector to EOBD connection Switch on ignition Perform visual check...

Страница 161: ...es are set to zero a regulating probe test is not performed If not all display values are set to zero a regulating probe test will be performed later Confirm condition of MI lamp arrow B Catalytic con...

Страница 162: ...utton and the test can be repeated Maintain engine speed in required engine speed range The remaining time to perform measurement is displayed arrow A Measuring idling speed and CO content It is autom...

Страница 163: ...ow A They will then be included in the test log When the exhaust emissions test is classed as passed select arrow B EET sticker issued in drop down menu and date Then confirm with Yes see arrow C Afte...

Страница 164: ...A G 1798 Or Data reader V A G 1799 Data sheets for exhaust emissions test Note All test conditions and data required for exhaust emissions test Data sheets for exhaust emissions test If possible the...

Страница 165: ...tions Note The engine speed adapter VAS 5087 A or the engine speed adapter VAS 6296 can be used instead of the TDC sender for engines where the hole of the TDC sender cannot be reached or cannot be re...

Страница 166: ...rt engine and run at idling speed Press F2 button for EET diesel on data reader If the following is indicated on display Please insert vehicle identity card Manual input with button Enter vehicle iden...

Страница 167: ...Continue test sequence by pressing the Q button If the following is indicated on display Idling speed Speed ACT xxxx rpm SPEC xxxx rpm Press button Idling speed not within specified range Note The id...

Страница 168: ...Speed ACT xxxx rpm SPEC xxx xxxx rpm Release accelerator pedal The data reader accepts the actual figures within 15 seconds If the following is indicated on display Data transfer to diesel tester Dep...

Страница 169: ...xx rpm Release accelerator pedal Press button If the following is indicated on display Average opacity figure ACT x xx rpm SPEC x x xx rpm Press button If the following is indicated on display Opacit...

Страница 170: ...hicles fitted with On board diagnosis OBD The OBD monitors all components and part systems influenc ing the exhaust emissions quality Special tools and workshop equipment required Emissions testing st...

Страница 171: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Manual gearbox Gear lever in neutral Handbrake pulled on Perform exhaust...

Страница 172: ...ehicle data input menu is displayed Note For new models the document previously known as the vehicle registration document is now called the vehicle registration certificate part 1 For new models the...

Страница 173: ...transmitted via the network to the respective mask Manual specified data input for EET Note All test conditions and data required for exhaust emissions test see Data sheets for exhaust emissions test...

Страница 174: ...splay 1 Press button arrow to continue the process Visual check Follow instructions on display Perform visual check If visual check is OK press OK button arrow Note When not OK button is pressed a che...

Страница 175: ...ormed Conditioning In the conditioning phase the engine and if necessary the emis sion control systems are brought to operating temperature by throttle bursts and are prepared for the exhaust emission...

Страница 176: ...An air quality check is carried out before starting the free accel eration When doing this no emission probe must be in the exhaust tail pipe Otherwise measuring errors or faulty signals could occur...

Страница 177: ...t can be assessed by the operator Further throttle bursts Follow instructions on display arrow B Now the next throttle burst follows starting with phase 1 of Free acceleration Many Free accelerations...

Страница 178: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Press button Close arrow B to close the menu P...

Страница 179: ...Carbon monoxide is produced when fuels containing carbon are not combusted com pletely CN Cetane number measurement unit for ignition quality of diesel fuel DIN Deutsches Institut f r Normung e V Germ...

Страница 180: ...to the exhaust system upstream of a special catalytic converter SD Naturally aspirated diesel engine SDI Naturally aspirated diesel engine direct injection TDI Turbo diesel engine direct injection DP...

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