SM 37 PDF

Service
Maintenance
CC 2010 ➤ , CC 2012 ➤ ,
Passat 2006 ➤ , Passat CC 2009 ➤ ,
Passat Variant 2006 ➤
Edition 11.2016
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Service Department. Technical Information

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1. Engine list
2. Service work
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3. General information
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4. Descriptions of work:
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5. Exhaust emissions test

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Technical information should always be available to 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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg K0059021420

CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC 2009 ➤ , Passat Vari ...
Maintenance - Edition 11.2016
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Information about flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Service tables for market group A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Service tables for market groups B and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.8 Countries with hot climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9 Countries where diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.10 Allocation of countries to market groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.11 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.12 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.13 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Removable towing bracket: checking and cleaning if necessary . . . . . . . . . . . . . . . . . . . . 44
4.2 Swivel joints and suspension link mountings: AGVisual
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4.3 Front passenger front airbag: Checking olksw key switch and “ON/OFF not function” . . . . . . . . . . . . 47
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4.4 Automatic gearbox: Check ATF ed level . . . . . . . . . . . . . . . . . . . . . . u. a.ra. . . . . . . . . . . . . . . . . .
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Battery: Checking batteryauterminal clamps for secure seating . . . . . . . e.o.r a. . . . . . . . . . . . . 49
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4.6 Battery: Checking with sbatterys
tester and printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . 53
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4.7 Status of battery: Read, send diagnosis protocol online . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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4.8 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 53
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4.9 Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ab 72

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4.10 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wit 76

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4.11 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 78
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4.12 Checking thickness of brake pads/linings and condition of front and rear brake discs . . . . 78
4.13 6-speed dual clutch gearbox (DSG) 02E: Changing gear oil and filter . . . . . . . . . . . . . . . . 80
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4.14 Electric windows: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . . . 81

4.15 Reading fault memory of all systems with vehicle diagnostic tester , correcting possible faults
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according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.16 Front lid catch hook: grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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4.17 Boots: visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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4.18 Interior and exterior body: Carry out visual check for corrosion with doors and flaps open .
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4.19 Poly V-belt: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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4.20 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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4.21 Cooling system: Checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 84

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4.22 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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4.23 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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4.24 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cop py
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4.25 Removing and installing engine compartment cover -bottom- (noise insulation) . . . . . . . . 108
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4.26 Engine and components in engine compartment (from above and below): Visual check for
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4.27 Engine oil level: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.28 Engine oil: draining or extracting, renewing oil filter and replenishing engine oil . . . . . . . . 110
4.29 Engine oil: capacities and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.30 Tyre repair set: Check bottle for damage and if used; check and enter use-by date of tyre
sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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4.31 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 129
4.32 Wheel securing bolts: tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.33 Reading radio code using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.34 Radio/navigation system: entering PIN of anti-theft coding and storing local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.35 Tyre pressure loss indicator: performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.36 Dust and pollen filter: clean housing and renewing filter element . . . . . . . . . . . . . . . . . . . . 136
4.37 Headlight adjustment: Checking halogen headlights and fog lights, adjust if necessary,
Passat/Passat Estate 2006► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.38 Headlight adjustment: Checking halogen headlights, Passat CC and CC 2010► . . . . . . . . 139
4.39 Headlight adjustment: Checking gas discharge headlights without DLA, adjust if necessary,
Passat/Passat Estate 2006► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.40 Headlight adjustment: Checking gas discharge headlights without DLA, Passat CC and CC
2010► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.41 Headlight adjustment: Checking
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4.42 Headlight by
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4.43 Window ut
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4.44 Wiper
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4.45 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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4.46 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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4.47 Sunroof: Checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 171
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4.48 Sliding sunroof drains: Checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 171
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4.49 Track rod ends: check clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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4.51 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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4.52 Transport locks: Remove blocking pieces from springs on front axle . . . . . . . . . . . . . . . . 175
4.53 Underbody: visual check for damage to underbody sealant, underbody panels, routing of
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lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.54 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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4.55 Camshaft drive toothed belt: renewing (diesel engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.56 Toothed belt and toothed belt tensioning roller: renewing (TDI unit injector) . . . . . . . . . . . . 178
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4.57 Camshaft drive toothed belt: renewing (petrol engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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4.58 Camshaft drive toothed belt: checking (1.6 l, 4-cyl. petrol engines) . . . . . . . . . . . . . . . . . . 178
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4.59 Camshaft drive toothed belt: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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4.60 Coolant pump toothed belt: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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4.61 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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4.62 Compass module: Activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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4.63 Static cornering light (cornering light) and driving light assist: Check function . . . . . . . . . .
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4.64 All-wheel drive coupling: Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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4.65 Front and rear final drive: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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4.66 Auxiliary heater: Setting weekday in menu of dash panel insert . . . . . . . . . . . . . . . . . . . . 202
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4.67 Multi-purpose additive for petrol fuel: Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

4.68 Memory seat: Perform initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.69 Checking diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.70 Automatic gearbox: Change ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.71 Reducing agent (AdBlue®/DEF): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.72 Reducing agent (AdBlue®/DEF): Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4.73 Transport locks: Removing fastening rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4.74 Natural gas system: visual check of natural gas tank for corrosion and leakage . . . . . . . . 212
4.75 Natural gas system: check wax layer between natural gas fuel tank and fuel tank shut-off
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.76 Checking condition of natural gas filler neck, cleaning if necessary and checking seal . . . . 217
4.77 Natural gas tank: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.78 Activation of environment monitoring system (Front Assist): Check . . . . . . . . . . . . . . . . . . 218
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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iv Contents
1 Engine list
(VIGG000950; Edition 11.2016)
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This chapter provides information on the following subjects: lkswage es n
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Passat Petrol engines ⇒ page 1 ir se tee
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Diesel engines ⇒ page 3 ss
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Passat CC ►2009 Petrol engines ⇒ page 5
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To ease the search for an engine, the engine codes are listed in
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Engines: ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
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Displacement I 2.0 3.2 1.6 2.0
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Engine code AXX AXZ BLF BLR
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No. of cylinders/valves per cylin‐ 4/4 6/4 4/4 4/4
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Power kW at rpm 147/5700 184/6250 85/5800 110/6000

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Torque Nm at rpm 280/2000 330/3200 155/4000 200/3500

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Bore Diameter, mm 82.5 86.0 76.5 82.5
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Stroke mm 92.8 90.89 86.9 92.8
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Compression ratio 10.5 12.0 Prote
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Injection/ignition Motronic MED Motronic MED Motronic MED Motronic MED

9.1 9.1 9.5.10 9.5.10
TFSI FSI FSI FSI
RON unleaded, at 95 95 95 95
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Camshaft drive Toothed belt Chain Chain Toothed belt

Engine code BLV BLX BLY BPY
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Power kW at rpm 206/6200 110/6000 110/6000 147/5700
Torque Nm at rpm 360/2800 200/3500 200/3500 280/2000
Bore Diameter, mm 89.0 82.5 82.5 82.5
Stroke mm 95.9 92.8 92.8 92.8
Compression ratio 12.0 11.5 11.5 10.5
9.1 9.5.10 9.5.10 9.1
FSI FSI FSI TFSI
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Camshaft drive Chain Toothed belt Toothed belt Toothed belt
1. Engine list 1

Engine code BSE BSF BVX BVY
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Power kW at rpm 75/5600 75/5600 110/6000 110/6000
Torque Nm at rpm 148/3800 148/3800 200/3500 200/3500
Bore Diameter, mm 81.0 81.0 82.5 82.5
Stroke mm 77.4 77.4 92.8 92.8
Injection/ignition SIMOS 7.1 SIMOS 7.1 Motronic MED Motronic MED
IDI IDI 9.5.10 9.5.10
FSI FSI
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Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt
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Engine code BVZ BWA BWS BZB
der
Power kW at rpm 110/6000 147/5100 to 220/6500 to 118/5000 to 6200
6000 6700
Torque Nm at rpm 200/3500 280/1800
AG. Volkswagto
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Engines: ⇒ Petrol engine Petrol engine Petrol engine

Displacement I 1.4 2.0 2.0
ss
Engine code CAXA CAWB CCTA

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No. of cylinders/valves per cylinder 4/4 4/4 4/4

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2 1. Engine list

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Engine code ksw
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Power kW at rpm 125/5500 to 6200 147/5100 to 6000 118/4500 to 6200
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Stroke mm 92.8 92.8 84.2
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nform
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Injection/ignition Motronic MED 17.5 Motronic MED 17.5 Motronic MED 17.5
TSI turbocharger TSI turbocharger TSI turbocharger
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Power kW at rpm 112/4300 to 6200 110/5500 112/5000 to 6200
Stroke mm 84.2 75.6 84.2
Injection/ignition Motronic MED 17.5 Motronic MED 17.1 Motronic MED 17.5
TSI turbocharger CNG/TSI twincharg‐ TSI turbocharger
er
RON unleaded, at least 95 Natural gas and 95 95
RON Ethanol 85 Chain --- ---
Camshaft drive Chain Chain Chain
Passat diesel engines

Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine
Engine code BKC BKP BLS BMA
der
Power kW at rpm 77/4000 103/4000 77/4000 103/4000
Torque Nm at rpm 250/1900 320/1750 to 250/1900 320/1750 to
2500 2500
Bore Diameter, mm 79.5 81.0 79.5 81.0
1. Engine list 3

Engine code BKC BKP BLS BMA
Stroke mm 95.5 95.5 95.5 95.5
Injection/ignition TDI TDI TDI TDI
unit injector unit injector unit injector unit injector
Diesel particle filters No No Yes No

Engine code BMP BMR BUZ BVE
der
Power kW at rpm 103/4000 125/4200 120/4200 90/4000
cardiagn.com
Torque Nm at rpm 320/1750 to 2500 350/1800 350/1800 320/1750
Bore Diameter, mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
unit injector unit injector unit injector unit injector
Diesel particle filters Yes Yes Yes No
Camshaft drive Toothed belt Toothed belt Toothed belt
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Toothed belt
AG en AG
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Engines: ⇒ Diesel engine Diesel tho
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Bore Diameter, mm 81.0 79.5 79.5 81.0
Stroke mm 95.5 95.5 80.5 95.5
rrectness of i

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unit injector unit injector common rail common rail
nform
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Diesel particle filters No No Yes Yes

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tion in
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4 1. Engine list

Engine code CBAB CBAC CBBB CBDC
No. of cylinders/valves per cylinder 4/4 4/4 4/4 4/4
Power kW at rpm 103/1750 to 2500 105/1750 to 125/1750 to 2500 81/1500 to
2500 2500
Torque Nm at rpm 320/4200 320/4200 320/4200 250/4200
Bore Diameter, mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
common rail common rail common rail common rail
Diesel particle filters yes/no1) Yes Yes Yes
can be identified by the production control number 7GG, 7MB or
cardiagn.com
7ME on the vehicle data sticker.
. Volkswagen AG
gen AG does
Passat CC ►2009 and CCV2010►
olks
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Engines: ris ⇒ Petrol engine Petrol nengine
tee Petrol engine Petrol engine
utho or
Displacement ss a I 3.6 3.6 ac 1.8 2.0
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Engine code BLV BWS BZB CAWB

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Power kW at rpm 206/6200 220/6500 to 118/5000 to 6200 147/5100 to

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Torque Nm at rpm 360/2800 350/3500 to 250/1500 to 4200 280/1700 to

es, in part or in w
3750 5000
t to the co
Bore Diameter, mm 89.0 89.0 82.5 82.5

Stroke mm 95.9 96.4 84.2 92.8
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Engine code CBFA CCTA CCZA CCZB
der
Power kW at rpm 147/5100 to 6000 147/5100 to 147/5100 to 6000 155/5300 to
6000 6200
Torque Nm at rpm 280/1700 to 5000 280/1700 to 280/1700 to 5000 280/1700 to
5000 5200
Bore Diameter, mm 82.5 82.5 82.5 82.5
1. Engine list 5

Engine code CBFA CCTA CCZA CCZB
Stroke mm 92.8 92.8 92.8 92.8
17.1 17.5 17.5 17.5
TSI turbocharger TSI turbo‐ TSI turbocharger TSI turbo‐
charger charger
least . Volkswage
AG n AG d
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Camshaft drive Vol
ksw Chain Chain
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Engine code CDAA CDAB CGYA CKMA
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Power kW at rpm 118/4500 to 6200 112/4300 to 112/5000 to 6200 118/5800
es, in part or in w
6200
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Torque Nm at rpm 250/1500 to 4500 250/1500 to 250/1500 to 4500 240/1500 to
4500 4500
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Bore Diameter, mm 82.5 82.5 82.5 76.5
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Stroke mm 84.2 84.2 84.2 75.6

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Injection/igni‐ Motronic MED Motronic MED Motronic MED Motronic MED

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RON unleaded, at least 95 95 95 95

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Displace‐ l 3.6 1.4 1.4
ment
Engine code CNNA CTHD CZDA
No. of cylinders/valves 6/4 4/4 4/4
per cylinder
Power kW at rpm 206/6200 118/5800 92/5000-6000
Torque Nm at rpm 360/2800 240/1500 to 4500 200/1400-4000
Bore Diameter, 89.0 76.5 74.5
mm
Stroke mm 95.9 75.6 80.0
Injection/ Motronic MED 9.1 Motronic MED 17.5 Motronic MED17.5
ignition FSI TSI twin charger TSI turbocharger
RON unleaded, at 98 95 95
least
RON Ethanol 85 --- --- ---
6 1. Engine list

Displace‐ l 3.6 1.4 1.4
ment
Engine code CNNA CTHD CZDA
Camshaft drive Chain Chain Toothed belt
Passat CC ►2009 and CC 2010► diesel engines

Displacement I 2.0 n AG. 2.0
Volkswagen AG
does 2.0 2.0
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Engine code CBAA db
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No. of cylinders/valves per cyl‐ ut
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Power kW at rpm 100/1750 to 2500 103/1750 to 105/1750 to 125/1750 to 2500

un
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2500 2500
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Torque Nm at rpm 320/4200 320/4200 320/4200 320/4200
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Bore Diameter, mm 81.0 81.0 81.0 81.0
wit
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h re
Stroke mm 95.5 95.5 95.5 95.5
hole
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Diesel particle filters Yes yes/no1) Yes Yes
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nform
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can be identified by production control number 7GG, 7MB, 7MQ,
m
a
7ME or 7MM on the vehicle data sticker.
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tion in
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Engine code CFFA CFFB CFGB CFGC
t. C rig
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Power kW at rpm 100/4200 103/4200 125/4200 130/4200

Torque Nm at rpm 320/1750 to 2500 320/1750 to 2500 350/1750 to 2500 380/1750 to 2500
Bore Diameter, mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Diesel particle filters Yes yes/no1) Yes Yes
can be identified by production control number 7GG, 7MB, 7MQ,
7ME or 7MM on the vehicle data sticker.
1. Engine list 7
Engines: ⇒ Diesel engine Diesel engine

Displacement I 2.0 2.0
Engine code CUVC CUWA
No. of cylinders/valves per cylinder 4/4 4/4
Power kW at rpm 110/3500 135/3500-4000
Torque Nm at rpm 340/1750-3000 380/1750-3000
Bore Diameter, mm 81.0 81.0
Stroke mm 95.5 95.5
Compression ratio 16.2 15.8
Injection/ignition TDI TDI
common rail common rail
Diesel particle filters ksw
age Yes es n Yes
Vol ot g
Camshaft drive d by Toothed belt ua
ran Toothed belt
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Vehicles with factory-fitted dieselau particulate filter can be identified ac
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by production control number 7GG, 7MB, 7MQ, 7ME or 7MM on
ce
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nl
the vehicle data sticker.
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8 1. Engine list
2 Service work
Information reference flexible or fixed service ⇒ page 9
Service tables for market group A ⇒ page 11
Service tables for market group B and C ⇒ page 19
Countries listed by market groups ⇒ page 37
. Volkswagen AG
gen AG does
Delivery inspection
Vol
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swapage 19 not
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Scopes of oservice
ris
e ⇒ page 21 nte
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2.1 ss Information about flexible or fixed serv‐ c
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Service identification ⇒ page 9
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Service interval display ⇒ page 11
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2.1.1 Service identification
rrectne
– Referring to vehicle data sticker ⇒ page 34 , check if vehicle
is equipped with following PR numbers:
The PR number is decisive for the service intervals ss o
cial p
f
⇒ page 11 .
inform
mer
Model year PR number Service

atio
om
► 2012 QG1 Flexible service

c
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► 2012 QG0, QG2, QG3 Fixed service

t
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2013 ► QI6 Flexible service

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2013 ► QI1, QI2, QI3, QI4, QI7 Fixed service

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In the past, the PR numbers QG0, QG1 and QG2 determined the
agen
Prote AG.
type of service.
With immediate effect, these PR numbers 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, special LongLife engine oil is required.

⇒ page 12
Vehicles with PR number “QG1” or “QI6” are set up for flexible

service when they leave the factory. This means, these vehicles
have a flexible service interval display and are fitted with the fol‐
lowing components:
♦ Flexible service interval display in dash panel insert
♦ Engine oil level sensor
2. Service work 9
♦ Brake pad wear indicator (if fitted)

For vehicles with flexible service the service interval is determined
by the control unit and is indicated on service interval display
(SID) ⇒ page 11 .
Therefore the service intervals are flexible.
2.1.3 Fixed service

For vehicles with a fixed service, fixed services are calculated.
This means that the mileage or time values are already set by
Volkswagen. For normal operating conditions achieving these
service intervals is technically assured.
Therefore the service intervals are fixed.
For vehicles
♦ Which have not been delivered with extended servicing inter‐
vals (ESI) (PR numbers “QG0”, “QG2”, “QI1”, “QI2”, “QI3”,
“QI4”, “QI7”.
♦ or for which the extended servicing interval (ESI) was stopped
♦ or for which no LongLife engine oil was used
cardiagn.com
fixed service applies.
These non-flexible service intervals apply to all types of service
including an engine oil change.
Vehicles with PR number “QG0”
The vehicles are “not” factory-fitted with components for flexible
service. Fixed service intervals apply for maintenance.
The PR number is valid only to ►2012.
. Volkswagen AG
gen AG does
For these vehicles the flexible service is not factory-activated. Vol
ksw
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not
Therefore, these vehicles have a fixed service interval edisplay
d by gu
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⇒ page 11 and for maintenance the fixed service intervals
ho
ris (rigid nte
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service intervals) apply. These vehicles are fittedswith
au
t
the follow‐ ra
c
ing components: s
ce
e
nl
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♦ Fixed service interval display in dash panel insert

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The PR number is valid only to ►2012.

t to the co
For these vehicles the flexible service is not factory-activated.

Therefore, these vehicles have a fixed service interval display
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⇒ page 11 and for maintenance the fixed service intervals apply.

These vehicles are fitted with the following components:
l purpos
♦ Fixed service interval display in dash panel insert

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10 2. Service work
2.1.4 Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 11
Flexible service interval display (only vehicles with a flexible serv‐
ice) ⇒ page 11
Fixed service interval display (only vehicles with a fixed service)
⇒ page 11
Service interval display: Resetting ⇒ page 167
Service interval display: Recoding ⇒ page 166
Introduction of extended servicing intervals (ESI) agen

AG. Volkswagen AG d
oes
olksw not
V gu
Ask your importer if the extended servicing interval (ESI)edis avail‐
by ara
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able for your country. horis
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Flexible service interval display (only vehicles withs a flexible serv‐
s c
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un
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Calculation of service intervals:
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♦ The service intervals on vehicles with a flexible service is cal‐
ot
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culated. Input values such as, distance travelled, fuel con‐
, is n
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sumption, oil temperature and loading on diesel particulate
hole
spec
filter are evaluated by the control unit.
es, in part or in w
t to the co
♦ The result of the evaluation is a value for the deterioration of
the oil due to thermal loading.
♦ The oil deterioration is the deciding factor concerning the dis‐
rrectness of i
tance that can still be driven to the next service.
l purpos
Note
nform
mercia
For vehicles with a flexible service but which are serviced ac‐
a
com
tio
cording to fixed service intervals, the service interval display must
n in
be recoded to “non-flexible” ⇒ page 166 .
r
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Fixed service interval display (only vehicles with a fixed service)
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Calculation of service intervals:
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lated in fixed service intervals. This means that the mileage or
co Vo
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time values have been previously determined and specified by
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Prote AG.
Volkswagen.
♦ For normal operating conditions achieving these service in‐
tervals is technically assured.
2.2 Service tables for market group A

Delivery inspection ⇒ page 19
Scopes of service ⇒ page 21
The following chapter contains the service tables with the service
specifications of the Volkswagen Passenger Cars brand.
2. Service work 11
Note
♦ For combined kilometre and time display applies: whichever

occurs first.
♦ Depending on conditions under which the vehicle is used
⇒ page 35 and on vehicle equipment, extra service work
must be performed in addition to the interval service, inspec‐
tion service, inspection or inspection with extended scope.
AG. Volkswagen AG d
agen oes
♦ It is also possible, to perform additional work outside the serv‐ y Volksw not
gu
ice intervals with regard to the entries in the service scheduleise d b ara
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(or sticker: your next service). uthor eo
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2.2.1 Service tables for market group A
nl
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Service intervals ⇒ page 12
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VW engine oil standards ⇒ page 14
wit
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Filter change intervals ⇒ page 15
hole
spec
Toothed belt change intervals ⇒ page 16
es, in part or in w
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Spark plug change intervals ⇒ page 17
Other additional work based on time and distance ⇒ page 17
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Service intervals
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Caution
nform
mercia
Applies only to diesel engines
at
om
ion
c
• In some countries, diesel has a higher sulphur content.
in t
or
his
ate
• The high sulphur content leads to excessive wear of cyl‐
do
priv
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inders and it considerably reduces the cleanliness of pis‐
um
for
tons.
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♦ Therefore change the engine oil every 7,500 km in coun‐ t. C rig
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♦ Countries where diesel has a high sulphur content.
agen
Prote AG.
⇒ page 36
Note
♦ If an extremely uneconomical driving style is adopted or the

vehicle is used in extreme conditions ⇒ page 35 , the short‐
est 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 the required intervals.
PASSAT 3C ►2007
Service intervals ►2007
from-to Engine/Engine code/ Service/intervals Indicated on
PR No./Remarks service interval display SID
(includes oil change)
Since intro‐ Diesel in countries Oil change service YES
duction where sulphur content every 7,500 km or 1 year
in fuel is high
⇒ page 36
12 2. Service work
PASSAT 3C ►2007
Service intervals ►2007
From intro‐ QG0/QG2/QG3 or Oil change service YES
duction ►2007 QG1 vehicles coded to every 15,000 km or 1 year
non-flexible interval Interval service: YES
every 30,000 km or 2 years
QG1 vehicles Interval service: YES
flexible from 15,000 to max.
30,000 km or max. 2 years
For all vehicles Interval service inspection: YES
PASSAT 3C, Passat CC ►2009 and CC 2010►2012

Service intervals 2008►2012
cardiagn.com
G. Volkswagen AG d
Since intro‐ Diesel in countries Oil change service
ksw
agen
A
oes
not YES
duction where sulphur content Vol or 1 year
every 7,500bykm gu
ara
in fuel is high ed nte
oris
⇒ page 36 au
th eo
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s
2008►2012 QG0/QG2/QG3 or Oils change service YES
ce
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QG1 vehicles coded to every 15,000 km or 1 year

un
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non-flexible interval
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Interval service: YES
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QG1 vehicles Interval service: YES
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from 15,000 km or 1 year up to
ole,
max. 30,000 km or 2 years
spec
For all vehicles Inspection service: NO
t to the co
after 3 years or max 60,000 km,
then every 2 years or 60,000 km
rrectness
CC (35) 2013
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cial p
f i
Service intervals 2013

nform
mer
From - to PR No. Service events: Indicated on

atio
m
Intervals service interval display

o
n
c

i
or
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sd
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2013 QI1 Oil change service (fixed): YES

iv
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every 5,000 km or 1 year

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QI2 Oil change service (fixed): YES

t.
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every 10,000 mi or 1 year
QI1, QI2, QI3, QI4, QI7 Interval service (fixed): YES
2. Service work 13
AG. Volkswagen AG d
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Service intervals 2013
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QI6 Interval service (flexible): YES
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from 15,000 km or 1 year up to
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QI1, QI2, QI3, QI4, QI6, QI7 Inspection service: NO
after 3 years or max 60,000
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km, then every 2 years or
60,000 km
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Service intervals
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2014► QI1 Oil change service (fixed): *) YES
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every 5,000 km/1 year

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QI3 Oil change service (fixed): *)
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YES
QI4 Oil change service (fixed): *) YES
QI6 Oil change service (flexible): *) YES
max. 30,000 km/2 years
QI7 Oil change service (fixed): *) YES
every 10,000 mi/1 year
QI7 Inspection: YES
every 20,000 mi or 2 years
QI1, QI2, QI3, QI4, QI6 Inspection: YES
after 30,000 km or 2 years,
then every 30,000 km or 1 year
Note
*)Depending on the software version of the dash panel insert or

communication system, the term “Oil change service” or “Oil serv‐
ice” is displayed.
VW engine oil standards
Caution
Only engine oils approved by VW may be used; for up-to-date

information refer to ⇒ InfoNet, Service, Service work, Inspec‐
tion and maintenance, Approved oils , or ask your importer.
PASSAT 3C, Passat CC ►2009 and CC 2010►

VW ENGINE OIL STANDARDS
With flexible service With fixed service
14 2. Service work

VW ENGINE OIL STANDARDS
PETROL ENGINES
4-cylinder engine incl. FSI 504 001) 4-cylinder engine incl. 502 00
FSI ►2007
4-cylinder engine incl. 502 00
FSI 2008►
VR6 FSI 504 001) VR6 FSI ►2007 502 00/505 01
VR6 FSI 2008► 502 00
AG. Volkswagen AG
4-cylinder TSI 4-cylinder TSI 502 00
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Vehicles with retrofitted diesel particulate filter are allocated in the

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or
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by PR No. 7GG, 7MB, 7MQ, 7ME or 7MM on the vehicle data

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FILTER CHANGE INTERVALS
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ENGINE OIL FILTER: 1) 2) ⇒ page 110

With flexible service According to service interval display
All other vehicles up to ►2012 Every 15,000 km or 1 year
All other vehicles as of 2013► According to service interval display for oil change service / interval serv‐
ice
AIR FILTER: ⇒ page 94
All engine types Every 90,000 km or 6 years
DIESEL FUEL FILTER: ⇒ page 86
All diesel engines Diesel conforming to EN 590 Diesel not conforming to EN 590
Every 90,000 km Every 30,000 km
Draining water is deleted.
DUST AND POLLEN FILTER: ⇒ page 136
All engine types Every 60,000 km or 2 years
OIL FILTER OF DUAL CLUTCH GEARBOX (DSG): ⇒ page 80
All with gearbox type 02E Every 60,000 km
2. Service work 15
1)A new engine oil filter must be installed at every engine oil
change.
2) Only applies to diesel engines: in some countries, diesel has a
high sulphur content. The high sulphur content leads to excessive
wear of cylinders and it considerably reduces the cleanliness of
pistons. Therefore change the engine oil every 7,500 km in coun‐
tries where the diesel has a high sulphur content. Countries where
diesel has a high sulphur content. ⇒ page 36
Toothed belt change intervals

• If the engine is fitted with toothed belt or timing chain can be
found in the engine list.
Note
The camshaft drive with timing chain is maintenance-free!
cardiagn.com
TOOTHED BELT CHANGE / TENSIONING ROLLER CHANGE INTERVALS
Diesel engines
Engine type Engine code Model year Toothed belt Tensioning roller
n AG. Volkschange
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TDI-PD BKC, BKP, BMA, by ►2006
V Every 120,000guarEvery 240,000 km
BMP, BLS, BVE ed km te⇒ page 178
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⇒ page 178 ra
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TDI-PD BKC, BKP, BMA, 2007► Every Every 300,000 km
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BMP, BLS, BVE 150,000 km ⇒ page 178
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BMR, BUZ, BWV, BXE ⇒ page 178

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All TDI CR CBAA, CBAB, CBAC, CBBB, Since introduction Every Every 120,000 km
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CAYC, CFFA, CFFB, CFGB, ⇒ page 178 diesel engines

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CFGC, CUVC, CUWA • Applies only operated in

to diesel en‐ countries with spec
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tries with high
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⇒ page 39
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2.0 l TDI CR CBAA, CBAB, CBAC, CBBB, Since introduction Every 360,000 km
CBDC ►2009 180,000 km
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⇒ page 178
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All TDI CR CBAA, CBAB, CBAC, CBBB, 2010► Every 210,000 km

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CBDC, 210,000 km
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1.4 l TSI CZDA Since introduction No prescribed
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change interval,
toothed belt drive
with test interval,
see “other addi‐
tional work based
on time and dis‐
tance”
⇒ page 17
16 2. Service work

TOOTHED BELT CHANGE / TENSIONING ROLLER CHANGE INTERVALS
1.6 l BSE, BSF Since introduction No prescribed
change interval,
toothed belt drive
with test interval,
see “other addi‐
tional work based
on time and dis‐
tance”
⇒ page 17
Spark plug change intervals

• Spark plug designation and specified torque ⇒ Rep. gr. 28 ;
Ignition system; Test data, spark plugs
•
Spark plug change intervals
cardiagn.com
Engine type Engine code Change intervals Description
of work
2.0 l FSI 110 kW, BLR, BLX, BLY, BVX, BVY, BVZ EVERY 60,000 km ⇒
1.6 l indirect inj. BLF, BLP, BSE, BSF • Mileage more than 60,000 km in 4 years page 182
and FSI CAXA, CDGA, CKMA, CTHD,
1.4 l TSI engines CZDA EVERY 4 years
• Mileage less than 60,000 km in 4 years
2.0 l TFSI AXX, BPY, BWA EVERY 90,000 km

V6 FSI AXZ, BLV CNNA • Mileage more than 90,000 km in 6 years
1.8 l and 2.0 l TSI BZB, CAWB, CBFA, CCTA,swagen AG. Volkswagen AG does
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– Reducing agent (AdBlue®/DEF): Replenish At every service ⇒ page 204

spec
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• Only upon customer request and as a separate charge
– Dual clutch gearbox (DSG) 02E: renewing gear oil and filter Every 60,000 km ⇒ page 80
rrectne
• Not valid for 7-speed dual clutch gearbox 0AM

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– ATF: change Every 60,000 km ⇒ page 203

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• Applicable for 1.8 l TSI engine with gearbox group 09G in 6-speed
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automatic gearbox as of model year 2008

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2. Service work 17
Additional work based on time and distance Interval Description of

work
– Inspection with expanded scope After 60,000 km → Maintenance
or 3 years, tables
• Applies only in conjunction with regular inspection then every
60,000 km or
2 years
– Camshaft drive toothed belt: Checking At 90,000 km, ⇒ page 178
then every
• Applicable for 4-cylinder petrol engines without prescribed change 30,000 km
interval
– Diesel particulate filter: Check At 150,000 km, ⇒ page 203

then every
• Applicable for vehicles up to model year 2009 only 30,000 km there‐
after
• Vehicles with factory-fitted diesel particulate filter

then every
• Applicable for vehicles as of model year 2010 only 30,000 km there‐
after
cardiagn.com
then every
• Applicable for engine codes CUVC, CUWA only 30,000 km there‐
after
– Camshaft drive toothed belt: Checking At 240,000 km, ⇒ page 179

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• Applicable for vehicles without olksw prescribed change interval not and en‐ 30,000 km
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– Coolant pump stoothed
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– Exhaust emissions test (EET): Perform Every 12 months ⇒ page 219

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• Applicable for Germany only

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– Brake and clutch system: Change brake fluid Every 2 years ⇒ page 72
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• Only applies to vehicles ►2007

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– All-wheel drive coupling: Change oil Every 3 years ⇒ page 197

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• Valid for vehicles with 4MOTION

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– Brake and clutch system: Change brake fluid First after 3 ⇒ page 72
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• Only applies to vehicles 2008► then every 2

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– Natural gas system: visual check of natural gas tank for corrosion First after 3 ⇒ page 212
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WARNING: May only be carried out by specially trained personnel!
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18 2. Service work
AG. Volkswagen AG d
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Additional work based on time and distance Volksw Interval
not
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Description of
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work
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– Checking condition of natural gas filler connection
au
th and sealing cap, First after 3 or ⇒ page 217
ac
cleaning if necessary and checking sealss years,
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then every 2
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– Natural gas system: check wax layer between natural gas fuel tank 3 years after ini‐ ⇒ page 216
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spec
• Applicable for Germany only
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– Exhaust emissions test (EET): Perform First after 3 ⇒ page 219
years,
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• Applicable for Germany only then every 2
years
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– Reducing agent (AdBlue®/DEF): Changing Every 4 years ⇒ page 210
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• Applicable for vehicles driven less than 15,000 km in 4 years
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– Natural gas tank: renewing Every 20 years ⇒ page 217
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• Applicable for Passat EcoFuel only

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2.3 Service tables for market groups B and cted agen
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Since in several markets there are market-specific service spec‐
ifications, the latter are listed as time or mileage dependent
additional work and are grouped by the respective market group.
Delivery inspection ⇒ page 19
Scopes of service ⇒ page 21
Engine oil: capacities and specifications ⇒ page 126
Time or mileage dependent additional work up to model year
►2013 ⇒ page 24
Time or mileage dependent additional work as of model year
2014► ⇒ page 26
2.3.1 Delivery inspection

Work to be completed:
– Battery: Check battery terminal clamps for secure seating.
– Transportation mode: switching off
– Service interval display: resetting
– Status of battery: reading
– Event memories of all systems: reading
– Radio/radio navigation system: storing local radio stations to station buttons
– Time and date: setting
– All switches, electrical consumers, sockets, gauges and other controls: checking function
– Front passenger airbag: Check key switch and ON/OFF function
– Window regulators: initialising (activation)
2. Service work 19
Work to be completed:
– Vehicle interior: checking for cleanliness
– Seat and carpet protective coverings: removing
– All equipment which has been packed inside vehicle (if part of original equipment): installing
– Two safety hammers: installing according to installation instructions
– Edge protection on doors (plastic film): removing
– Vehicle exterior: checking for cleanliness
– Tyre pressure: Check
– Wheel bolts: tightening to specified torque
– Wiper blade protection: removing AG. Volkswagen AG d
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– Tyre pressure monitoring system: Calibrate after by Vtyre pressure has been corrected
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– Vehicle: visual check for leaks and damage horifrom
s
above and below nte
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– Brake system: visual check for leaks and s damage
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– Transportation devices: removing (if fitted)

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– Vehicle underside (underbody): carrying outing visual check for damage
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– Windscreen wash/wipe system and headlight washer system: Check function and settings
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– Engine oil level: checking; observe oil specification when topping up!
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– Coolant level: checking
spec
es, in part or in w
– For vehicle older than 6 months, the brake fluid must be renewed.
t to the co
– Brake fluid level: checking that it is at maximum
– Number, operation and cleanliness of keys: checking
rrectness of i
– Service schedule: entering delivery inspection
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– Owner's literature: checking literature is complete and preparing for delivery to customer
– Carry out road test.
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– Warning stickers: ensuring they are present

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– Charging cable: ensuring cable is present and checking its condition
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• Applies only to BEV and PHEV his

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– High-voltage battery: charge

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– Special rubber care set: hang on interior rear view mirror by c lksw
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– Storage compartments for roof side member, felt in rear longitudinal members and hydraulic pump noise
insulation: checking for moisture
– Dash panel insert: adapt language version (not applicable for German speaking countries)
– Onboard computer: reset with front information display and control unit
20 2. Service work
2.3.2 Scopes of service
Note
♦ Depending on the time elapsed and on the mileage since the

last service, service events may be combined (inspection with
oil change).
♦ An extended scope of inspection is carried out in combination
with an inspection.
♦ The scopes of service work are generally applicable and differ
according to vehicle model and equipment level. There is no
relation between individual vehicles and identified VINs.
♦ Scopes of service work for individual vehicles can be found
only in the maintenance tables. ⇒ Maintenance tables
Oil Inspec‐ Exten‐ Scope of work

change tion ded
service scope of
inspec‐
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X – Interior lights in headliner, luggage compartment and glove compartment

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lights: checking function

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X – Horn: checking function

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X – Charging cable: ensuring cable is present and checking its condition

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• Applies only to BEV
X – High-voltage battery: checking charge level, charge as necessary

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X – Sliding/tilting sunroof: checking function

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X – Headlight washer system: checking function

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X – Front lighting: checking function

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X – Static cornering light (cornering light): checking function

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X – Automatic headlight control: checking function

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– Rear lighting: checking function
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X – Windscreen wash/wipe system: checking function, spray jet settings and
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X – Wiper blades: moving blades to service position and checking for dam‐
age; checking park position and adjust
X – Interior and exterior of body: visual check for corrosion
X – Windscreen: visual check for damage
X – High-voltage charging socket in radiator grille: visual check for soiling and
damage
• Applies only to PHEV
2. Service work 21

change tion ded
service scope of
inspec‐
tion
(applies
only in
addition
to regu‐
lar in‐
spec‐
tion)
X – High-voltage charging socket in radiator grille and tank cap: visual check
for soiling and damage
X – Reducing agent (AdBlue®): replenishing; only on customer request
• If provided
X – Plenum chamber: check for dirt
cardiagn.com
• Applies only to up! and e-up!
X – CSC roof: Check for damage and function, clean wind deflector and seals
and apply special lubricant on rubber seals
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• Applies only to EOS

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X – Front lid catch hook: grease

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• Does NOT apply to: Polo 6C1, up!, e-up!, Passat (NMS-US) A32, Golf
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5G1, Golf estate BA5, Golf SV AM1, e-Golf, Beetle, Jetta and Scirocco
spec
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X – Door arrester: lubricating

• Only applies to Touran 1T, EOS, Golf Cabriolet, CC and Phaeton
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X – Convertible top: clean and grease locking element

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• Applies only to Golf Cabriolet and Beetle Cabriolet

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X – Convertible top: water test

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• Applies only to Golf Cabriolet and Beetle Cabriolet

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X – Sliding sunroof seal: lubricating

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X – Sliding sunroof drains: Check not blocked, clean if necessary
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Underside of vehicle
X – Draining engine oil and renewing oil filter
X – Engine and components in engine compartment (from below): visual
check for leaks and damage
X – Gearbox, final drive and drive shaft boots: visual check for leaks and
damage
22 2. Service work

change tion ded
service scope of
inspec‐
tion
(applies
only in
addition
to regu‐
lar in‐
spec‐
tion)
X – Brake pads/linings: checking thickness and condition of brake discs, front
and rear
X – Poly V-belt: checking condition
X – Swivel joints, axle mountings, coupling rod bearings and anti-roll bar rub‐
ber mounting: visual check for damage
X – Track rod ball joints: checking clearance, firm seating and boots
X – Brake system: visual check for leaks and damage
X – Exhaust system: visual check for leaks, firm seating and damage
cardiagn.com
X – Underbody: visual check for damage to undercoating, underbody covers,
routing of lines, plugs
X – Front and rear coil springs and rubber buffers: visual check for damage
X – Warning stickers: ensure they are present
• Applies only to high-voltage vehicles
X – Removable original towing bracket: Check

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• Applies only to Touareg and Phaeton
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X – Sunroof: checking function, cleaning guide rails and lubricating with spe‐
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X – Automatic gearbox: Check ATF level

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• Applies only to Phaeton

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Tyres
X – Tyre pressure: Check
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X – Tyre mobility set: checking for damage and use

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X – Tyres: checking condition and wear pattern of tyre; enter tread depth
Engine compartment
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X – Engine oil: replenishing

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X – Oil level: checking

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X – Battery and, if fitted, second battery: checking with battery tester

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X – Engine and components in engine compartment (from above): visual

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X – Brake fluid level (dependent upon brake pad/lining wear): Check

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X – Cooling system: checking frost protection and coolant level
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X – Window wash/wipe system: Check anti-freeze protection; replenish
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2. Service work 23

change tion ded
service scope of
inspec‐
tion
(applies
only in
addition
to regu‐
lar in‐
spec‐
tion)
X – Hybrid components: visual check for damage to high-voltage components
and wires
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• Applies only to HEV and PHEV
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X – High-voltage components
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and high-voltage cables: visual check foreedam‐
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X – Power assisted steering: Check fluid level
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• Applies only to Touareg and Phaeton
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spec
Final checks
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X – Service interval display: Reset
X – Headlight adjustment: checking and adjusting as necessary
rrectness of i
X – Tyre pressure monitoring system: Calibrate after tyre pressure has been
corrected
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X – Carry out road test.

X – High-voltage battery: charging
nform
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• Applies only to PHEV
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2.3.3 Time or mileage dependent additional

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work up to model year ►2013
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♦ This chapter contains only the time or mileage dependent ad‐

ditional work up to model year ►2013 for Chinese, Russian and
USA markets.
♦ For information for other markets, refer to the chapter “Service
tables for market group A” ⇒ page 11 .
Russian market
Applies up to ►2013 Interval Description of
work
Interval service (fixed) Every 15,000 km → Mainte‐
♦ (QG0/QG2/QG3) 2) or 1 year 1) nance tables
♦ QI4
(appears on service interval display)
Inspection service Every 30,000 km → Mainte‐
(does not appears on service interval display) or 2 years 1) nance tables
24 2. Service work

work
– Multi-purpose additive for petrol fuel: Add At every service ⇒ page 202
– Dust and pollen filter (cabin filter):
swa
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– Spark plugs: renew ho
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ut
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• Only valid for 2.0 1.6 l indirect injection and FSI,
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1.4 TSI engines

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– Diesel fuel filter: renew Every 30,000 km ⇒ page 86
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ility
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– Air filter element: renewing and cleaning housing Every 30,000 km ⇒ page 94
wit
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or 2 years 1)
h re
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spec
– Spark plugs: Renew Every 60,000 km ⇒ page 182
or 4 years 1)
t to the co
• Only valid for V6 FSI, 1.8 l and 2.0 l TSI engines
– Camshaft drive toothed belt: Renew Every 90,000 km ⇒ page 178
rrectne
• Only applies for 2.0 l FSI
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– Camshaft drive toothed belt: Renew Every 120,000 km ⇒ page 178
inform
mer
• Only valid for 1.6 l TDI and 2.0 l TDI Common Rail engines
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North American market
Prote AG.
Interval Description of
work
Sliding sunroof drains: Checking
– for blockage, cleaning if necessary Every 60,000 km ⇒ page 171
China market
Note
In the Chinese market no engine oils to VW standard 504 00/507

00 may be used because of poor fuel quality. ⇒ page 14

work
Oil change service (fixed) Once after 5,000 km → Mainte‐
♦ (QG0/QG2/QG3) nance tables
Oil change service (fixed) Every 10,000 km → Mainte‐
♦ (QG0/QG2/QG3) or 1 year 1), and then nance tables
every 10,000 km / 1
♦ QI3 year
Interval service (fixed) Every 20,000 km → Mainte‐
(appears on service interval display) or 2 years 1) nance tables
2. Service work 25

work
Inspection service After 30,000 km → Mainte‐
(does not appears on service interval display) or 3 years 1), and nance tables
then every
30,000 km or 2 years
– Multi-purpose additive for petrol fuel: Add At every service ⇒ page 202
– Dust and pollen filter (cabin filter): renewing Every 10,000 km ⇒ page 136
or 1 year 1)
– Spark plugs: Renew AG. Volkswagen km
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• Only valid for 1.4 l TSI, 1.8 l TSI, 2.0 l TSI and 3.6 l FSI rengines ran
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– Air filter element: renewing and cleaning housing ss Every 30,000 km ⇒ page 94c
or 2 years 1)
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2.3.4 Time or mileage dependent additional work as of model year 2014►
spec
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Note
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♦ The time or mileage-dependent additional measures are uni‐
versally applicable and vary according to vehicle model and
s
equipment level. There is no relation between individual vehi‐
s o
cles and identified VINs.
cial p
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♦ Vehicle-specific time and mileage dependent additional work
mer
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can only be found in the ⇒ maintenance tables .
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Scope of work Market group A Market group B Market group C

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Oil change service --- QI1
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every 5,000 km or 1 year (fixed) 1)

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QI4
QI6 --- ---
(flexible) 1)
QI7 --- ---
every 10,000 mi or 1 year
(fixed) 1)
Inspection After 30,000 km or 2 years, Every 15,000 km Every 10,000 km
then every 30,000 km or or 1 year 1) or 1 year 1)
1 year 1)
Inspection with expanded After 60,000 km or 3 years Every 30,000 km Every 20,000 km
scope then every 60,000 km or or 2 years 1) or 2 years 1)
• Applies only in con‐ 2 years 1)
junction with regular
inspection
– Multi-purpose addi‐ --- At every service At every service

tive for petrol fuel: Add
26 2. Service work

– Reducing agent At every service At every service At every service
(AdBlue®/DEF): Re‐
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• Only upon customer byV gu
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request and as a sep‐ thoris nte
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– Dust and pollen filter Every 30,000 km Every 15,000 km Every 10,000 km
pt
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(cabin filter): renewing or 2 years 1) or 1 years 1) or 1 years 1)

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• Applies only to Polo
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and up!
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– Dust and pollen filter Every 60,000 km Every 15,000 km Every 10,000 km
es, in part or in w
(cabin filter): renewing or 2 years 1) or 1 years 1) or 1 years 1)
t to the co
– Renew rubber buffer Every 30,000 km Every 30,000 km Every 30,000 km
for air filter housing or 2 years 1) or 2 years 1) or 2 years 1)
rrectness of i
• Applies only to Sciroc‐
l purpos
co R and Golf R Cab‐
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riolet
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– Diesel fuel filter: re‐ Every 60,000 km Every 30,000 km Every 20,000 km
m
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– Diesel fuel filter: re‐ Every 90,000 km Every 30,000 km Every 20,000 km
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and up!
– Air filter: Clean hous‐ Every 90,000 km Every 30,000 km Every 20,000 km
ing and renew filter el‐ or 6 years 1) or 2 years 1) or 2 years 1)
ement
– Spark plugs: Renew Every 60,000 km Every 30,000 km Every 20,000 km
or 4 years 1) or 2 years 1) or 2 years 1)
– Spark plugs: Renew Every 90,000 km Every 30,000 km Every 20,000 km
or 6 years 1) or 2 years 1) or 2 years 1)
• Only applies to CC
V6, Passat NMS-US
V6 and Touareg V6
– Panorama sliding After 60,000 km or 3 years Every 30,000 km Every 10,000 km

sunroof: checking then every 60,000 km or or 2 years 1) or 1 year 1)
function, cleaning and 2 years 1)
lubricating guide rails
and cleaning wind de‐
flector
– Automatic gearbox: Every 60,000 km or Every 60,000 km Every 60,000 km
Change ATF every 80,000 miles
• Applicable for gear‐

box 09G in countries
with hot climate only
2. Service work 27

– 6-speed dual clutch Every 60,000 km Every 60,000 km Every 60,000 km
gearbox: changing
gear oil and renew fil‐
ter
– Dual clutch gearbox‐ Every 60,000 km Every 60,000 km Every 60,000 km
es 0DD, 0DL and
0BH: changing gear
oil
– Poly V-belt: Renew --- Every 60,000 km Every 60,000 km
– Idler roller for poly V- Every 120,000 km Every 120,000 km Every 120,000 km
belt: renewing
• Applies only to V8 pet‐ agen

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– Toothed belt and ut
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ra
Every 120,000 km
camshaft drive ten‐ ss a c
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• Applicable for all pet‐
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ab
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– Toothed belt drive for --- Every 120,000 km Every 120,000 km
hole
spec
cooling pump: Renew
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• Applicable for all pet‐
rol engines with tooth‐
ed belt for coolant
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– Gearbox mounting: Every 150,000 km Every 150,000 km Every 150,000 km

renew nf
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• Applies only to Phae‐

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– Diesel particulate fil‐ At 180,000 km/ At 180,000 km/ At 180,000 km/

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ter: Check 210,000 km, 210,000 km, 210,000 km,

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then every 30,000 km then every 30,000 km then every 30,000 km

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– All-wheel drive cou‐ Every 3 years Every 3 years Every 3 years
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pling: Change oil
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– Front differential lock: Every 3 years Prote Every 3 years
AG.
Every 3 years
change oil
– Brake and clutch sys‐ 3 years after initial regis‐ 3 years after initial regis‐ 3 years after initial regis‐
tem: Change brake tration, tration, tration,
fluid then every 2 years then every 2 years then every 2 years
– Natural gas system: 3 years after initial regis‐ 3 years after initial regis‐ 3 years after initial regis‐
visual check of natural tration, tration, tration,
gas tank for corrosion then every 2 years then every 2 years then every 2 years
and leakage
– Checking condition of 3 years after initial regis‐ 3 years after initial regis‐ 3 years after initial regis‐
natural gas filler con‐ tration, tration, tration,
nection and sealing then every 2 years then every 2 years then every 2 years
cap, cleaning if neces‐
sary and checking
seal
28 2. Service work

– Reducing agent Every 4 years Every 4 years Every 4 years
(AdBlue®/DEF):
Changing
• Only valid for vehicles

driven less than
15,000 km in 4 years
– Natural gas tank: re‐ Every 20 years Every 20 years Every 20 years
newing
1) Whichever occurs first
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2. Service work 29
3 General information Vo lksw

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Raising vehicle with lifting platform orortrolley
ise jack ⇒ page 30 nte
h eo
ut ra
Sticker ⇒ page 31 ss a c
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nl
Entries in service schedule ⇒ page 32
pt
du
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Connecting vehicle diagnosis tester ⇒ page 32
erm
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Vehicle identification number ⇒ page 34
wit
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Vehicle data sticker ⇒ page 34 .
hole
spec
Severe operating conditions ⇒ page 35
es, in part or in w
t to the co
Countries with hot climate ⇒ page 35
Countries where diesel has a high sulphur content ⇒ page 36
rrectness of i
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Engine code and engine number ⇒ page 39
nf
ercia
Countries with high levels of dust ⇒ page 39
orm
m
Type plate ⇒ page 40
atio
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3.1 Raising vehicle with lifting platform or

or
thi
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sd
a
trolley jack
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Safety notes ⇒ page 30 yi

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Lifting points for lifting platform and trolley jack ⇒ page 30
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3.1.1 Safety notes:
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WARNING
♦ Before driving onto a lifting platform, ensure that there is

sufficient clearance between low-lying vehicle compo‐
nents 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 platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine and engage a gear with vehicle lifted
as long as even one driven wheel has contact with the
floor! Disregarding these warnings risks the danger of an
accident!
♦ If work is to be performed under vehicle, it must be sup‐
ported by suitable jack stands.
3.1.2 Lifting points for lifting platform and trol‐

ley jack
Note
The Passat R36 is fitted with a side member trim. Remove the
respective covers to reach the lifting points.
30 3. General information
Front lifting point:

– Position support plate, in area of side member marking
-arrow A-, at vertical reinforcement of floor pan -arrow B-.
WARNING AG. Volkswagen AG d

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Ensure that side member reinforcement ed by seats centrally on ara
nte
support plate of hoist mounting. tho ris
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Rear lifting point:
wit
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– Position support plate, in area of side member marking
hole
spec
-arrow A-, at vertical reinforcement of floor pan -arrow B-.
es, in part or in w
t to the co
WARNING
rrectness of i
Ensure that side member reinforcement seats centrally on
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support plate of hoist mounting.
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3.2 Stickers
or c
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sd
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In this chapter there are stickers which apply for the German
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market. The stickers determined for your country can be obtained
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from your importer.

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Attach “Your next service appointments” sticker. ⇒ page 31
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Attach “vehicle data sticker” in customer service schedule. by c lksw
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⇒ page 32
Prote AG.
3.2.1 Attaching “Your next service” sticker
Note
For vehicles from model year 2014►, no service sticker needs to

be attached.
3. General information 31
Service sticker valid for vehicles to model year ►2013

– Service sticker “Your next service”: Enter a cross in position
for next oil 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.
Service intervals ⇒ page 11
– Attach sticker to driver door pillar (B-pillar).
AG. Volkswagen AG d
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3.2.2 Attaching “vehicle data sticker” in cus‐

nl
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– Apply the lower of the two vehicle data stickers -arrow- in the
wit
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service schedule.
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spec
es, in part or in w
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3.3 Entries in service schedule

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If a component is changed which has a change interval prescribed
om
by the manufacturer, e.g. the toothed belt, the new change inter‐
n in
or c
val begins at the time the component is changed.

thi
te
sd
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• Therefore it is very important, every time a component is

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changed, to document this in the service schedule.

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Note
♦ When using “Genuine parts kits” it must be taken into account

whether it is technically necessary to change all the compo‐
nents included in the genuine parts kits.
♦ If more components are renewed than is technically necessa‐
ry, inform the customer before repair!
3.4 Connecting vehicle diagnostic tester

Special tools and workshop equipment required
♦ Diagnosis system - VAS 6160 A-
♦ Diagnosis system VCI - VAS 6150 C-
Note
Ensure that the selected vehicle diagnosis tester is only used with
the respective diagnosis cable.
cardiagn.com
WARNING
♦ Always secure testing and measuring equipment on the

rear seat during a road test.
♦ Only a passenger may operate these devices while the
vehicle is in motion.
– Carry out following procedure:

– Connect diagnosis cable connector to diagnostic connection.
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– Switch on vehicle diagnostic tester . y Volksw not
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– Switch on ignition. r ise nte
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Now follow information given on screen
ss to start desired functions. c
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CC 2010 ➤ , CC 2012 ➤ , Passatho2006 ➤ , Passat CC 2009 ➤ , Passat Varint...
ris ee
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Maintenance - Edition 11.2016 s au ac
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3.5 Vehicle identification number
an
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Location engine compartment
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The vehicle identification number is located on the extension of
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longitudinal member -arrow-.
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Significance of vehicle identification number
es, in part or in w
t to the co
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WVW ZZZ 3C Z 5 8 000 234
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Manufacturer Filler charac‐ Model Filler charac‐ Model year Production lo‐ Serial number
code ters ters 2005 cation
3.6 Vehicle data sticker

The vehicle data label -arrow- is located in back of vehicle in the
spare wheel well. The vehicle data sticker is also found in the
service schedule for the customer.
Note
In the Passat R36, the Passat CC ►2009 and CC 2010►, the ve‐
hicle data sticker -arrow- is located on the right-hand side of the
spare wheel recess.
The sticker in luggage compartment includes the following vehicle

data:
The sticker in service schedule includes the same data. The leg‐
end can be found below the sticker. AG. Volkswagen AG d
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3.7 Severe operating conditions
If the vehicle is used under severe operating conditions, some
rrectne
jobs will have to be performed before the next due service date
or between the specified service intervals.
s
Severe operating conditions
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• Regular short trips or stop and go operation in urban traffic
form
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• High percentage of cold starts
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• Vehicle is used in areas with winter temperatures over a long
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period
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• Regular long periods of idling (e.g. taxis) cum

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• Using diesel with elevated sulphur content
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• Regular operation in areas with high levels of dust
3.8 Countries with hot climate

Australia Qatar Thailand
Abu Dhabi Lebanon Tunisia
Algeria Libya Togo
Egypt Lesotho Tanzania
Afghanistan Liberia Chad
Angola Mexico Uganda
Equatorial Guinea Malaysia USA
Ethiopia Mauritius United Arab Emirates
Bahrain Morocco West Sahara
Brunei Madagascar Zimbabwe
Benin Mali Central African Republic
Maintenance - Edition 11.2016 AG. Volkswagen A n G do
wage es n
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Burkina Faso Mozambique by ua
ed ran
oris tee
Botswana Malawi au
th or
ac
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Burundi Mauritania
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China Nigeria
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Dubai Namibia
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Democratic Republic of the Congo Niger
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Djibouti Oman
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Ivory Coast Puerto Rico
es, in part or in w
t to the co
Eritrea Palestine
Gabon Pakistan
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Gambia Qatar
Ghana Republic of Congo l purpos
Guinea Rwanda
nform
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Guinea-Bissau South Africa

Iran Saudi Arabia
m
at
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ion
India Singapore
c
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or
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Indonesia Senegal
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Iraq Sudan
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Israel Zambia
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Yemen South Sudan
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Jordan Sierra Leone
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Kuwait Somalia
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Cameroon Swaziland
Kenya Syria
3.9 Countries where diesel has a high sul‐

phur content
Applies only to diesel engines, as diesel fuel in some countries
has a high sulphur content The high sulphur content leads to ex‐
cessive wear of cylinders and it considerably reduces the clean‐
liness of pistons. Therefore change engine oil every 7,500 km in
countries where the diesel has a high sulphur content.
Afghanistan Ghana Cuba Saudi Arabia
Egypt Guatemala Kuwait Senegal
Algeria Honduras Laos Zimbabwe
Angola Indonesia Lebanon Sri Lanka and the Mal‐
dives
Argentina Iraq Libya Sudan
Armenia Iran Madagascar Surinam
Bangladesh Jamaica Mali Syria
Bolivia Jordan Mauritius Tajikistan
Brazil Cambodia Mongolia Tanzania
Brunei Cameroon Myanmar (Burma) Trinidad and Tobago
Dominican Republic Kazakhstan Nigeria Tunisia
Ecuador Qatar Pakistan Uruguay
Ivory Coast Kenya Paraguay Uzbekistan
El Salvador Kyrgyz Republic Peru Venezuela
Gabon Columbia Russian Federation Vietnam

China Republic of Congo
AG. Volkswagen AG d
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3.10 Allocation of countries to market groups uthor eo
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Market group A Market group B Market group C
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Albania Abu Dhabi Angola
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Belgium Afghanistan Ethiopia
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Bosnia-Herzegovina Egypt Benin
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Bulgaria Algeria Botswana
hole
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Denmark Equatorial Guinea Brazil
es, in part or in w
t to the co
Germany Argentina Burkina Faso
Estonia Armenia Burundi
rrectness of i
Finland Azerbaijan China
l purpos
France Australia Democratic Republic of the Congo

Gibraltar Bahamas Djibouti
cardiagn.com
nform
ercia
Greece Bahrain Ivory Coast

m
at
Great Britain / Northern Ireland Bangladesh Eritrea
om
ion
c
Ireland Belize Gabon
in t
or
his
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Iceland Bhutan Gambia
do
priv
cum
or
Italy (San Marino, Vatican City) Bolivia Ghana

f
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Japan Bermudas Guinea
Co
Cop py
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Canada Cayman Islands Guinea-Bissau
gh ht
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Vo
co
Croatia Brunei Hong Kong
by lksw
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Liechtenstein Chile Cameroon
Croatia Costa Rica Cape Verde
Liechtenstein Dominican Republic Kenya
Latvia Dubai Lesotho
Lithuania Ecuador Liberia
Luxembourg El Salvador Libya
Malta Tahiti Madagascar
Macedonia Saint Martin (French part) Malawi
Monaco French Guiana Mali
Montenegro Fiji Morocco
New Zealand Georgia Martinique
Netherlands Guadeloupe Mauritania
Norway Guatemala Mauritius
Austria Guyana Mayotte
Poland Haiti Mozambique
Portugal Honduras Namibia
Romania India Niger
Sweden Indonesia Nigeria
Switzerland Iraq Pakistan
Serbia Iran Palestine
Slovakia Israel Republic of Congo
Slovenia Jamaica Rwanda

Spain (Andorra, Balearic Islands, Yemen Saint-Barthélemy
Canary Islands)
South Korea Jordan Zambia
South Africa Cambodia Senegal
Czech Republic Caribbean driving on the left Seychelles
Hungary Kazakhstan Sierra Leone
USA Qatar Zimbabwe
Cyprus Kyrgyz Republic Somalia
Columbia Sudan
Cuba Surinam
Kuwait Swaziland
Laos Tanzania
Lebanon Togo
Malaysia Trinidad and Tobago
Mexico Chad
Moldova Tunisia
cardiagn.com
Mongolia Uganda
Myanmar agen AG. Volkswagen AG do West Sahara
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ua African Republic
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Netherlands overseas territories Ar‐

nl
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uba, Curacao, Sint Maarten (Dutch)
itte
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North Korea
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Oman wit
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Papua New Guinea

es, in part or in w
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Paraguay
Peru
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Philippines
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Puerto Rico
Reunion
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Russia
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Saudi Arabia
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Singapore
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Sri Lanka and the Maldives

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Syria
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Turkey
Turkmenistan
Ukraine
Uruguay
Uzbekistan
Venezuela

United Arab Emirates (not including
Abu Dhabi and Dubai)
Vietnam
Belarus
3.11 Engine code and engine number

Engine code and engine number are located:
♦ On vehicle data sticker ⇒ page 34 .
♦ On type plate (4-digit engine code)
♦ On engine control unit (4-digit engine code)
♦ Or
♦ »Power unit« ⇒ Power unit; Rep. gr. 00 ; Technical data/
engine number »Technical data/engine number«.
3.12 Countries with high levels of dust
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Abu Dhabi Gabon Liberia Singapore
Afghanistan Gambia Macao Somalia
Egypt Georgia Madagascar Sri Lanka
AG. Volkswagen AG d
Algeria Ghana Malawi swagen South
oes Africa
k not
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Angola Greece riseMaldives
d South Korea ara
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Equatorial Guinea Guatemala s aut
Mali South Sudan or ac
s
Argentina Guinea Morocco Sudan
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nl
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du
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Armenia Guinea-Bissau Mauritania Suriname
itte
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Azerbaijan Guyana Mauritius Swaziland
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Ethiopia Honduras Mexico Syria
wit
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Australia Hong Kong Mongolia Tajikistan
hole
spec
Bahrain India Mozambique Tanzania
es, in part or in w
t to the co
Bangladesh Indonesia Myanmar (Burma) Thailand
Belize Iraq Namibia Togo
rrectness of i
Benin (Dahomey) Iran Nepal (Indian subconti‐ Chad
nent)
l purpos
Bhutan Israel Nicaragua Tunisia

Bolivia Yemen Niger Turkey
nform
ercia
Botswana Jordan Nigeria Turkmenistan

m
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Brazil Cambodia North Korea Uganda

n
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Brunei Cameroon Oman Uruguay

his
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Burkina Faso (Upper Vol‐ Cape Verde Pakistan Ukraine

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Chile Kazakhstan Palestine USA
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China Qatar yri
Panama Uzbekistan
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Costa Rica Kenya Papua New Guinea
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Venezuela
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Democratic Republic of Kyrgyz Republic Paraguay United Arab Emirates
the Congo
Djibouti Columbia Peru Vietnam
Dominican Republic Cuba Puerto Rico Belarus
Dubai Kuwait Rwanda Western Sahara
Ecuador Laos Russian Federation Central African Republic

El Salvador Lesotho Zambia
Ivory Coast Lebanon Saudi Arabia
Eritrea Liberia Senegal
French Guyana Libya Sierra Leone
Fiji Zimbabwe
3.13 Identification plate
Note
Vehicles for certain export countries have no type plate.
Type plate -arrow- is visible in lower area of B-pillar when front

left door is opened.
The type plate includes the following vehicle data:
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A - Vehicle identification number
B - Variable indications e.g. axle loads, gross vehicle weight rat‐
ing, gross combination weight
AG. Volkswagen AG d
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4. Descriptions of work: 41
4 Descriptions of work:
Removable towing bracket: checking and cleaning if necessary
⇒ page 44
Front and rear final drive: Checking oil level ⇒ page 201
Swivel joints and axle mountings: Visual check ⇒ page 46
Activation of environment monitoring system (Front Assist):
Checking ⇒ page 218
All-wheel drive coupling: changing oil ⇒ page 197
Automatic gearbox: Check ATF level ⇒ page 49
Automatic gearbox: Changing ATF ⇒ page 203
Battery: Checking battery terminal clamps for secure seating
⇒ page 49
Battery: Checking using battery tester with printer VAS 6161
⇒ page 53
Status of battery: reading, sending diagnosis protocol via online
connection ⇒ page 53
cardiagn.com
Filling vehicle with reducing agent (AdBlue®) ⇒ page 204
Front passenger airbag: Checking key switch and “ON/OFF func‐
tion” ⇒ page 47
Checking tyres: condition, wear pattern, tyre pressure and tread
depth ⇒ page 53 agen
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Brake and clutch system: changing brake fluid ⇒ page 72ed by V gu
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Brake fluid level: checking ⇒ page 76 ho eo
aut ra
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Brake system and shock absorbers: visual check for leaks and
ce
le
un
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damage ⇒ page 78
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Thickness of brake pads/linings and condition of brake discs, front
rm
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and rear: Checking ⇒ page 78
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Diesel fuel filter: renewing ⇒ page 86
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spec
Checking diesel particulate filter ⇒ page 203
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t to the co
6-speed dual clutch gearbox (DSG) 02E: Changing gear oil and
filter ⇒ page 80 rrectness of i
Window regulators: checking positioning (open and close func‐
tions) ⇒ page 81
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CNG tank: Renewing ⇒ page 217

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Natural gas system: performing visual check of natural gas tank

for corrosion and leakage ⇒ page 212
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Natural gas system: checking wax layer between natural gas fuel
n in
tank and fuel tank shut-off valve ⇒ page 216

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Checking condition of natural gas filler connection, cleaning if

r
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necessary and checking O-ring ⇒ page 217

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The fault memory of all systems must be read with vehicle diag‐
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Bonnet: Lubricating arrester ⇒ page 82 .
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Protective bellows: visual check ⇒ page 82

Interior and exterior body: visual check for corrosion when doors
and flaps are open ⇒ page 83
Poly V-belt: renewing ⇒ page 83
42 4. Descriptions of work:
Poly V-belt: checking condition ⇒ page 83

Compass module: Activating ⇒ page 195
Cooling system: checking frost protection and coolant level
⇒ page 84
Air filter: cleaning housing and renewing filter element
⇒ page 94
Multi-purpose additive for petrol fuels: adding ⇒ page 202
Memory seat: Perform initialisation ⇒ page 203
Removing and installing engine cover panel -top- ⇒ page 100
Removing and installing engine compartment cover (noise insu‐
lation) - bottom- ⇒ page 108
Engine and components in engine compartment (from above and
below): visual check for leaks and damage ⇒ page 108
Oil level: checking ⇒ page 108
Engine oil: draining or extracting; renewing oil filter and replen‐
ishing engine oil ⇒ page 110
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Engine oil: capacities and specifications ⇒ page 126 agen
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Tyre repair set: checking ⇒ page 129 d by gu
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Performing road test (driving behaviour, noises,
aut air conditioner
h eo
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etc.) ⇒ page 129 ss c
ce
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un
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Wheel securing bolts: tightening to correct torque setting
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⇒ page 130
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Radio code: reading using vehicle diagnostic tester ⇒ page 132
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Radio/navigation system: activate anti-theft coding ⇒ page 132
h re
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spec
Reducing agent (AdBlue®/DEF): Replenishing ⇒ page 204
t to the co
Reducing agent (AdBlue®/DEF): Changing ⇒ page 210
Tyre Pressure Loss Indicator: performing basic setting
rrectne
⇒ page 133
Dust and pollen filter: cleaning housing and renewing filter ele‐
ss
ment ⇒ page 136
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Headlight adjustment: Checking halogen headlights and fog
form
mer
lights, adjust if necessary, Passat/Passat Estate 2006►

atio
m
⇒ page 136
o
n
c
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Headlight adjustment: Checking halogen headlights, Passat CC

thi
te
sd
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and CC 2010► ⇒ page 139

iv
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Headlight adjustment: Checking gas discharge headlights without

en
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t.
DLA, adjust if necessary, Passat/Passat Estate 2006►
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⇒ page 142
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Headlight adjustment: Checking gas discharge headlights with

DLA, CC 2012► ⇒ page 151
Headlight adjustment: Checking fog lights, Passat CC and CC
2010► ⇒ page 157
Service interval display: Resetting ⇒ page 167
Service interval display: Recoding ⇒ page 166
Sunroof: checking function, cleaning and lubricating guide rails
⇒ page 171
CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC 2009AG➤. V,olPassat
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Sliding sunroof drains: Checking not blocked, cleaning ho if neces‐
ris
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sary ⇒ page 171 aut ra
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Window wash/wipe system and headlight washer system: check‐
nl
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du
ing function ⇒ page 159
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Wiper blade protection: removing ⇒ page 163
ility
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Track rod ends: checking clearance, security and boots
, is n
h re
⇒ page 173
hole
spec
Static cornering light (cornering light) and driving light assist:
es, in part or in w
t to the co
Checking function ⇒ page 196
Auxiliary heater: Setting weekday in menu of dash panel insert
⇒ page 202
rrectness of i
Door arrester: Lubricating ⇒ page 174
l purpos
Transportation mode: switching off ⇒ page 174
nf
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Transportation devices: removing blocking pieces from springs
orm
on front axle ⇒ page 175
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Transport locks: Removing fastening rings ⇒ page 210
or c
thi
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Underbody: visual check for damage to underbody sealant, un‐
sd
iva
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derbody panels, routing of lines, plugs ⇒ page 176

rp
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Clock: set to correct time ⇒ page 176

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Camshaft drive toothed belt: renewing (diesel engines)
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⇒ page 178 cop Vo
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Toothed belt and toothed belt tensioning roller: Renewing (TDI
AG.
unit injector) ⇒ page 178

Camshaft drive toothed belt: renewing (petrol engines)
⇒ page 178
Camshaft drive toothed belt: Checking (1.6 l 4-cylinder petrol en‐
gines) ⇒ page 178
Camshaft drive belt: Checking ⇒ page 179
Coolant pump toothed belt: Checking ⇒ page 180
Spark plugs: renewing ⇒ page 182
4.1 Removable towing bracket: checking

and cleaning if necessary
This chapter describes how to check and repair a removable tow‐
ing bracket.
Note
Note that checking towing bracket is included in the respective

service. However, a repair is charged separately and must be re‐
quired by the customer.
Check procedure
– Remove cover -1-.
– Push connector housing aside to allow for opening ball head
mounting.
– Insert ball head into mounting.
After ball head has been inserted, green mark on hand wheel
must be aligned with white mark on ball head. Hand wheel must
be entirely in contact. Afterwards, it must be possible to close the
towing bracket lock by removing the key. If this is not possible,
the following repair procedure must be performed.
cardiagn.com
Note
If a repair has to be performed, 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, eliminate corrosion with a tri‐
angular scraper and clean the treated areas with silicone
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– Apply a thin coat of lubricating
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on cleaned surfaces.thor tee
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– Check contact surfaces -arrows- of ball head for corrosion.

h re
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spec
– If contact surfaces are corroded, eliminate corrosion with a tri‐

es, in part or in w
angular scraper and clean the treated areas with silicone

t to the co
remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
rrectness of i
on cleaned surfaces.
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– Check again ball head seat in mounting ⇒ page 45 .

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– After checking, fit protective cap -1- into ball head mounting
-2-.
Note
If protective cap is damaged or not available, a new protective

cap must be fitted to protect ball head mounting against corrosion.
⇒ ETKA olks
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– Insert cover -1-.
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4.2 Swivel joints and suspension link
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mountings: Visual check
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– Check swivel joint boots -arrow- for leaks and damage.
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Prote AG.
– 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 the

rubber element from the metal part do not significantly affect
the operation of the elasto-kinematic mounting and do not
constitute a basis for a complaint.
♦ Damage to the thin rubber skin over cavities due to construc‐
tion is also permissible.
♦ Play between bearing and axle component is permissible as
long as there is no negative effect on the function of the bear‐
ing.
cardiagn.com
4.3 Front passenger front airbag: Checking
key switch and “ON/OFF function”
Passat/Passat Estate 2006 ►, Passat CC 2009 ►, CC 2010 ►
⇒ page 47
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CC 2012 ► ⇒ page 48
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CC 2009 ►, CC 2010 ►
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The “Airbag ON / OFF” switch -1- is located in the glove box.

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Front passenger front airbag: Check key switch and “ON/OFF

function”
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– Using ignition key, turn key switch -1- to position -arrow A-

“Airbag Off”.
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– Switch on ignition.
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– Warning lamp “Passenger airbag off” -arrow A- must also light

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up after self-test (passenger airbag deactivated).

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– Switch off ignition.

– Using ignition key, turn key switch -arrow 1- to position “Airbag
ON” -arrow B-.
– Warning lamp “Passenger Airbag Off” -arrow A- goes out after
self-test (passenger airbag activated).
cardiagn.com
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– Using the ignition key, turn switch -1- to “AIRBAG OFF” posi‐
es, in part or in w
tion (-arrow A-).
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– Warning lamp “PASSENGER AIRBAG OFF” -arrow- must al‐

so light up after self-test (passenger airbag deactivated).
– Using the ignition key, turn switch -1-AG

to. V“AIRBAG
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– Switch on ignition. rised ara
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– Warning lamp “PASSENGER AIRBAG OFF” -arrow- goes out
after self-test (passenger airbag activated).
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4.4 Automatic gearbox: Check ATF level
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Procedure
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– ⇒ Rep. gr. 37 ; Checking ATF level and topping up; Checking
ATF level
Or
– ⇒ Rep. gr. 37 ; ATF; Checking ATF level
4.5 Battery: Checking battery terminal

clamps for secure seating
Battery in engine compartment ⇒ page 50
Battery in luggage compartment ⇒ page 52
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
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♦ A securely seated battery terminal clamp ensures trouble free
function and long service life of the battery.
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♦ When securing terminal clamp, ensure that it is completely
seated on battery terminal.
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cardiagn.com
4.5.1 Battery in engine compartment
nform
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Carry out following procedure:

m
at
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ion
– Open battery cladding cover (if fitted).
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– 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 negative terminal to prevent possible accidents.
If the battery terminal clamp is NOT seated securely on positive

terminal:
– Loosen the -NEGATIVE- battery terminal clamp and remove.
AG. Volkswagen AG d
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– Tighten -POSITIVE- terminal clamp to 6 Nm using torque
an
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– Reconnect -NEGATIVE- terminal clamp and tighten it to 6 Nm
mer
using torque wrench - V.A.G 1331- and ratchet - V.A.G. atio

m
1331/1- .
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If the battery clamp is NOT seated securely on negative terminal:

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– Tighten -NEGATIVE- terminal clamp on battery terminal to

6 Nm using torque wrench - V.A.G 1331- and ratchet - V.A.G.
1331/1- .
– Install battery cladding cover (if fitted).

Carry out following procedures after connecting battery:
Procedure
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
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terminals by moving battery negative cable -1- and battery
positive cable -2- 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 negative terminal to prevent possible accidents.
If the battery terminal clamp is not seated securely on positive

terminal:
– Disconnect battery terminal clamp -1- from battery negative
terminal first.
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The battery status is read while the transportation mode is being
switched off ⇒ page 174 .
4.8 Tyres: checking condition, wear pattern,

tyre pressure and tread depth
Check condition of tyres ⇒ page 54 .
Check wear pattern ⇒ page 54 .
Tread depth (including spare wheel): check ⇒ page 55 .

General notes ⇒ page 55 .
Tyre pressures for Passat CC/CC ⇒ page 56
Tyre pressures, Passat Saloon ⇒ page 68
Tyre pressures, Passat Estate ⇒ page 70
♦ Tyre inflator - VAS 5216-
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– Check tyre tread depth.
Minimum tread depth: 1.6 mm
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-arrows- positioned at intervals around the tyre.
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used.
♦ If no inflation pressure is shown for the spare wheel, then in‐
flate the spare wheel to the highest inflation pressure for the
vehicle.
♦ Please note that basic setting should be performed on vehicles
with tyre pressure monitoring after every pressure change
⇒ page 133 .
Winter tyres
Note
♦ Important information on recommended winter tyres can be

found in ⇒ Wheels and tyres guide; Rep. gr. 44 ; Wheels,
tyres, vehicle geometry; Wheel and tyre combinations .
♦ 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.
This only applies however if the winter tyre used corresponds
exactly to the standard summer tyre size and the speed index
is no higher than “H”. If this is not the case, please refer to the
recommendation of the tyre manufacturer.
4.8.5 Tyre pressures for Passat CC/CC
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235/35 R19
205/50 R17 M&S

235/45 R17 240/2.4/35 240/2.4/35 260/2.6/38 310/3.1/45
235/40 R18
235/35 R19
205/50 R17 M&S

235/45 R17 230/2.3/33 230/2.3/33 250/2.5/36 300/3.0/44
235/40 R18
Part number - 3C8 010 668 T- Passat CC/CC

235/45 R17 240/2.4/35 240/2.4/35 260/2.6/38 310/3.1/45
235/40 R18
Part number - 3C8 010 668 R- Passat CC/CC

235/45 R17 250/2.5/36 250/2.5/36 270/2.7/39 320/3.2/46
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235/45 R17 94W 240/2.4 240/2.4 260/2.6 310/3.1
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235/45 R17 94W 270/2.7 270/2.7 290/2.9 340/3.4

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235/40 R18 95W 290/2.9 290/2.9 320/3.2 350/3.5

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205/50 R17 260/2.6/38 240/2.4/35 --- --- 280/2.8/41 330/3.3/48
235/40 R18
235/35 R19

235/45 R17 250/2.5/36 230/2.3/33 --- --- 280/2.8/41 320/3.2/46
4.8.6 Tyre pressures, Passat saloon
Note
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.

necessary.
Passat saloon with petrol engines
Petrol engines Tyre pressure for vehicles up to Tyre pressure for vehicles as of model year
model year 2008 2009
Half load Full load Half load Full load
bar/psi bar/psi bar/psi bar/psi
Power Front Rear Front Rear Front Rear Front Rear
1.4 l/90 kW 2.1/30 2.1/30 2.3/33 2.8/41 2.1/30 2.1/30 2.3/33 2.8/41
1.4l/90 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 2.8/41
BlueMo‐
tion
1.4 l/ --- --- --- --- 2.5/36 2.5/36 2.7/39 3.0/44
110 kW
EcoFuel
1.6l/75 kW 2.0/29 2.0/29 2.3/33 2.8/41 2.0/29 2.0/29 2.2/32 2.7/39
1.6l/85 kW 2.1/30 2.1/30 2.3/33 2.8/41 2.1/30 2.1/30 2.3/33 2.8/41
1.8 l/112 2.3/33 2.3/33 2.5/36 3.0/44 2.3/33 2.3/33 2.5/36 3.0/44
cardiagn.com
and 118
kW
2.0l/ 2.2/32 2.2/32 2.6/38 3.0/44 2.2/32 2.2/32 2.6/38 3.0/44
110 kW
2.0l/110 2.2/32 2.2/32 2.6/38 3.0/44 2.2/32 2.2/32 2.6/38 3.0/44
kW
4-motion
2.0l/ 2.3/33 2.3/33 2.5/36 3.0/44 2.3/33 2.2/33 2.7/39 3.0/44
147 kW
3.2l/ 2.6/38 2.6/38 2.9/42 3.4/49 2.6/38 2.6/38 2.9/42 3.4/49
184 kW
4-motion
3.6l/ 2.7/39 2.7/39 2.9/42 3.4/49 2.7/39 2.7/39 2.9/42 3.4/49
202 kW n AG. Volkswagen AG
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Passat saloon with diesel engines

Diesel engines Tyre pressure for vehicles up to Tyre pressure for vehicles as of model year
rrectne

s

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inform
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1.6l/66 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 2.8/41

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1.9l/77 kW 2.1/30 2.1/30 2.3/33 2.8/41 2.1/30 2.1/30 2.3/33 2.8/41

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1.9l/77 kW 2.5/36 2.5/36 2.5/36 2.8/41 2.5/36 2.5/36 2.5/36 2.8/41

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Prote 4. Descriptions of work:
AG.
Diesel engines Tyre pressure for vehicles up to Tyre pressure for vehicles as of model year
2.0l/81 kW 2.3/33 2.3/33 2.5/36 3.0/44 2.1/30 2.1/30 2.3/33 2.8/41
2.0l/ 2.3/33 2.3/33 2.5/36 3.0/44 2.3/33 2.3/33 2.5/36 3.0/44
103 kW
2.0l/ 2.3/33 2.3/33 2.5/36 3.0/44 2.3/33 2.3/33 2.5/36 3.0/44
103 kW agen
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spec
2.0l/110 --- --- --- --- 2.2/32 2.2/32 2.6/38 3.0/44
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2.0l/ 2.4/35 2.4/35 2.6/38 3.0/44 2.4/35 2.4/35 2.6/38 3.0/44
120 kW
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2.0l/ 2.6/38 2.6/38 2.8/41 3.0/44 2.5/36 2.5/36 2.8/41 3.0/44
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4.8.7 Tyre pressures, Passat estate
om
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The mandatory tyre pressures for the respective model can be
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C py
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necessary.
Passat Variant with petrol engines
1.4 l/90 kW 2.3/33 2.3/33 2.5/36 3.0/44 2.1/30 2.1/30 2.6/38 3.0/44
1.4l/90 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 3.0/44
BlueMo‐
tion
1.4 l/110 --- --- --- --- 2.5/36 2.5/36 2.5/36 2.8/41
kW
1.4 l/ --- --- --- --- 2.5/36 2.5/36 2.7/39 3.0/44
110 kW
EcoFuel
1.6l/75 kW --- --- --- --- 2.0/29 2.0/29 2.5/36 3.0/44
1.6l/85 kW 2.1/30 2.1/30 2.6/38 3.0/44 2.0/29 2.0/29 2.5/36 3.0/44
1.8 l/112 2.3/33 2.3/33 2.7/39 3.0/44 2.3/33 2.3/33 2.7/39 3.0/44
and 118
kW
2.0l/ 2.3/33 2.3/33 2.7/39 3.0/44 2.2/32 2.2/32 2.6/38 3.0/44
110 kW
2.0l/110 2.3/33 2.3/33 3.0/44 3.0/44 2.2/32 2.2/32 2.6/38 3.0/44
kW
4-motion
2.0l/ --- --- --- --- 2.3/33 2.3/33 2.7/39 3.0/44
147 kW
3.2l/ 2.7/39 2.7/39 3.2/46 3.4/49 2.6/38 2.6/38 3.2/46 3.4/49
184 kW
4-motion
3.6l/ --- --- --- --- 2.7/39 2.7/39 3.2/46 3.4/49
202 kW
cardiagn.com
4-motion
3.6 l/ --- --- --- --- 2.7/39 2.7/39 3.2/46 3.4/49
220 kW
4-motion
18 inch
3.6 l/ --- --- --- --- 2.8/41 2.8/41 3.3/48 3.5/51
220 kW
4-motion
19 inch
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Diesel engines utho Tyre pressure for vehicles up to 2.8/Tyre
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1.6l/66 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 3.0/44

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1.9l/77 kW 2.2/32 2.2/32 2.5/36 3.0/44 2.1/30 2.1/30 2.4/35 3.0/44

t to the co
1.9l/77 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 3.0/44

BlueMo‐
tion
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2.0l/81 kW --- --- --- --- 2.5/36 2.5/36 2.5/36 3.0/44

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nf
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2.0l/90 kW 2.6/38 2.6/38 2.8/41 3.0/44 2.3/33 2.3/33 2.7/39 3.0/44

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2.0l/ 2.6/38 2.6/38 2.8/41 3.0/44 2.3/33 2.3/33 2.7/39 3.0/44

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Diesel engines Tyre pressure for vehicles up to 2.8/Tyre pressures for vehicles as of model year
2.0l/ --- --- --- --- 2.5/36 2.5/36 2.7/39 3.0/44
103 kW
BlueMo‐
tion
2.0l/110 --- --- --- --- 2.2/32 2.2/32 2.6/38 3.0/44
kW g en AG. Volkswagen AG d
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2.0l/ s 2.5/36 2.5/36 3.0/44 3.0/44 2.3/33 2.3/33 2.7/39 3.0/44
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2.0l/ 2.4/35 2.4/35 2.7/39 3.0/44 2.4/35 2.4/35 2.7/39 3.0/44
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120 kW
spec
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2.0l/ 2.6/38 2.6/38 2.9/42 3.0/44 2.4/35 2.4/35 2.7/39 3.0/44
t to the co
125 kW
2.0l/ 2.6/38 2.6/38 2.9/42 3.0/44 2.4/35 2.4/35 2.7/39 3.0/44
125 kW
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4-motion
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4.9 Brake and clutch system: Change brake

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fluid
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♦ Brake filling and bleeding equipment - VAS 5234-

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Prote AG.
♦ Brake filling and bleeding equipment - VAS 6860-
♦ Brake bleeding wrench - VAS 5519-
♦ Brake bleeding tool - VAS 6564-
cardiagn.com
WARNING
♦ Never allow brake fluid to come into contact with fluids that
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐
eral oils will damage seals and rubber grommets of brake
system.
♦ Brake fluid is poisonous. Also due to its corrosive effect
brake fluid must not come into contact with paintwork. wagen AG. Volkswagen AG doe
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♦ Brake fluid is hygroscopic, which means it absorbsed
by mois‐
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ara
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♦ Rinse off spilled brake fluid using plenty of water.
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♦ Do not reuse extracted (used) brake fluid!

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♦ Observe relevant disposal regulations.

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Extracting brake fluid

es, in part or in w
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– Unscrew cap -1- from brake fluid reservoir.

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cted 4. Descriptions of work:
agen
Prote AG.
– Using the suction hose from brake filling and bleeding unit ,
extract as much brake fluid -2- from the brake fluid reservoir
as possible through the strainer -1-.
Note
♦ The strainer in brake fluid reservoir must remain in place.

♦ Ensure that no brake fluid runs through the strainer after com‐
pleting the extraction (the brake fluid level in the reservoir must
be even with the lower edge of the strainer).
Connecting brake filling and bleeding equipment
– Screw adapter -1- onto brake fluid reservoir.

– Connect filler hose from brake filling and bleeding unit to
adapter -1-.
– Set correct pressure on brake filling and bleeding equipment
⇒ Operating Manual , and switch on brake filling and bleeding
equipment .
cardiagn.com
Note
. Volkswagen AG
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♦ The bleeder hose must be firmly seated on bleeder yV
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that no air can enter the brake system. ised b ara
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♦ There must always be sufficient brake s aufluid in the brake res‐ ra
c
ervoir so that no air can enter the brake system through the
s
ce
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reservoir.
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♦ Start with front right brake caliper on RHD vehicles.
rm
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Front axle
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– Remove cover cap -1- from bleed screw of front left brake cal‐
es, in part or in w
iper. t to the co
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– Push collector bottle bleeder hose -1- onto front left bleed
um
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screw, open bleed screw and let appropriate quantity of brake

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t.
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fluid run out (see table). Close bleed screw. Torque: Running . Cop py
gear → Brake systems ⇒ Rep. gr. 47 → Repairing front brake
ht rig
rig ht
by
caliper. copy Vo
by lksw
cted agen
Prote
– Fit again cover cap on bleed screw of front left brake caliper.
AG.
Repeat procedure on right-hand side of vehicle at front.

– If necessary, remove both wheels on rear axle to reach the
bleed screw.
– Remove cover cap -1- from bleed screw of rear left brake cal‐
iper.
– Push collector bottle bleeder hose -1- onto rear left bleed
screw.
– Open bleed screw and let appropriate quantity of brake fluid
run out (see table). Close bleed screw. Torque: Running gear
→ Brake systems ⇒ Rep. gr. 47 → Repairing rear brake caliper.
– Fit again cover cap on bleed screw of rear left brake caliper.
– Repeat procedure on right-hand side of vehicle at rear.
cardiagn.com
For vehicles with manual gearbox
Remove air filter housing.
Procedure
– Power unit ⇒ Rep. gr. 23 → Diesel direct injection system →
Assembly overview - air filter
Or
AG. Volkswagen AG d
agen o
– Power unit ⇒ Rep. gr. Vol 24 → Injection system → Removing
ksw es n
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installing air filter.
sed by ua
ran
ri tee
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aut or
ac
ss
Note
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un
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For technical reasons it is possible that several cross references

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rm
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are not directed to the correct chapter. In this case select the pro‐
pe
ility
cedure manually in the information.

ot
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spec
– Push bleeder hose onto bleeder valve -arrow- of clutch slave

es, in part or in w
cylinder -1-.
t to the co
– Open valve and allow approx. 100 ml of brake fluid to flow out.
rrectness of i
– Close valve and depress clutch pedal 10 to 15 times quickly

in succession.
l purpos
– Open valve again and allow approx. 50 ml of brake fluid to flow

out.
nform
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– Close valve, remove bleeder hose and depress clutch pedal

m
several times.
com
tion in
r
– Install air filter housing accordingly in reverse order.

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Sequence and quantity of brake fluid

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Sequence t. Cop py
Brake fluid quantity
bleeder valves: which must flow out of bleeder valves:
rig
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pyri by
Vo
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Brake caliper
lksw
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Prote AG.
Front left 0.20 l
Front right 0.20 l
Sequence Brake fluid quantity

bleeder valves: which must flow out of bleeder valves:
Wheel brake cylinder/brake caliper
Rear left 0.30 l
Rear right 0.30 l
Clutch slave cylinder 0.15 l
Total quantity for automatic gearbox including approx. 1.00 l
the quantity extracted from the n Abrake
G. Volksfluid
wageres‐
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ervoir lkswage oes
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Total quantity forrisemanual gearbox including the
d
nte approx. 1.15 l
quantity extracted
utho
from the brake fluid reservoir eo
r
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ss
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– Depress clutch pedal several times after completion of bleed‐
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ing process.
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– Switch off brake filling and bleeding unit .
, is n
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– Reinstall air filter housing in reverse order.
spec
es, in part or in w
– Take filler hose off adapter.
t to the co
cardiagn.com
– Unscrew adapter from brake fluid reservoir.
rrectness of i
– Check brake fluid level and adjust level if necessary. It must
be between position -1- and -2-.
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nform
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ate
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Cop py
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– Screw cap -1- onto brake fluid reservoir.
co lksw
by
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Prote AG.
– Reinstall rear wheels, if removed previously ⇒ page 130 .
– Perform functional check during road test.
4.10 Brake fluid level: Check

Note the following:
• The brake fluid is dependent on pad wear.
Caution
• For this vehicle a “new” special brake fluid has been in‐
troduced. It can only be identified by the part number brake
fluid VW 501 14 - B 000 750- .
• Use only the new brake fluid. The previous brake fluid with
the part number »B 000 700 A« must “not” be filled into
the brake system of the Passat.
WARNING
♦ Never allow brake fluid to come into contact with fluids that
contain mineral oilsn A(e.g.ooil,
lkswpetrol,
agen AGcleaning agents). Min‐
e G. V
eral oils damage
olkswagthe seals and bootsdoin
es the
no brake system.
V t gu
by
♦ Brake ris fluid is poisonous. Also due to its corrosive
tee effect
a
ed ran
brake
ut
ho
fluid must not come into contact with paintwork.or
a ac
ss
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
ce
e
nl
ture from the ambient air and should therefore always be

pt
du
an
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stored in air-tight containers.
itte
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♦ Rinse off spilled brake fluid using plenty of water. ab

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♦ Observe relevant disposal regulations. h re

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es, in part or in w
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Brake fluid level at delivery inspection:

– For the delivery inspection the fluid level must be at MAX.
marking -1-.
rrectness of i
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Note
nform
ercia
In order that brake fluid does not overflow the reservoir, MAX
m
marking -1- must not be exceeded.

at
om
ion
c
in t
or
Brake fluid level at inspection service

his
ate
do
riv
The fluid level must always be judged in conjunction with lining/

p
cum
or
pad wear.
f
en
ng
t.
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op
When vehicle is in use, fluid level tends to drop slightly due to
C py
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lining/pad wear and automatic adjustment.
gh ht
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by
• Recommended brake fluid level, if brake pads are almost at
cted agen
Prote AG.
wear limit:
“At MIN marking or just above” -2-, “REPLENISHING IS NOT

REQUIRED”.
• Recommended brake fluid level when brake pads are new or
well within pad wear limit:
“Between MIN and MAX marking”.
WARNING
If fluid level is below MIN. marking -2-, the brake system must
be checked before fluid is topped up “Repair measure”
4.11 Brake system and shock absorbers:

Perform visual check for leaks and dam‐
age
AG. Volkswagen AG d
agen oes
Check following components for leaks and damage: olksw not
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♦ Brake master cylinder horis nte
eo
aut ra
♦ Brake servo (for anti-lock brake system: hydraulic
ss unit) c
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nl
pt
♦ Brake pressure regulator and
du
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itte
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♦ Brake caliper
erm
ab
ility
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♦ Shock absorbers (during inspection only)
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♦ Presence of dust caps on brake fluid bleeder valves
hole
spec
es, in part or in w
– Ensure that brake hoses are not twisted.
t to the co
– Additionally ensure that brake hoses do not touch any vehicle
components when steering is at full lock.
rrectness of i
– Check brake hoses for abrasion, porosity and brittleness.
l purpos
– Check brake lines for corrosion.
cardiagn.com
– Check brake connections and fastenings for correct seating,
nform
ercia
leaks and corrosion.

m
at
om
– Check brake lines and brake hoses for proper seating, and
ion
c
make sure they are correctly secured in retainers.
in t
or
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ate
do
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WARNING
um
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Faults found must always be rectified (repair measure). Cop py
t. rig
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pyri by
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by c lksw
cted agen
4.12 Checking thickness of brake pads/lin‐
Prote AG.
ings and condition of front and rear

brake discs
Thickness of front disc brake pads: checking ⇒ page 79
Thickness of rear disc brake pads: checking ⇒ page 79
Condition of brake discs: checking ⇒ page 80
♦ Electric hand torch and mirror

The adapter to loosen and tighten the anti-theft wheel bolts can
be found in the vehicle tool kit ⇒ page 130 .
4.12.1 Front brake pads:

– For better evaluation of remaining pad thickness, use a test
mirror and, if necessary, remove the wheel on the side where
the brake pad wear indicator is installed.
– Pull off wheel bolt covers if necessary ⇒ page 130 .
– Mark position of wheel relative to brake disc.
– Unbolt wheel bolts and remove wheel.
Volkswa
– Measure thickness of inner
swa
genand
AG. outer pads.
gen AG
does
k not
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by
a - Pad thickness s“without” backplate ara
ed nte
ri
ho eo
Wear dimension:
au 2 mm
t ra
c
ss
The brake pads have reached their wear limit at a pad thickness
ce
e
nl
pt
du
of 2 mm (without backplate) and must be renewed (repair meas‐
an
itte
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ure). Inform customer!
erm
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ility
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Note
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spec
When replacing brake pads, always check brake discs as well for
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es, in part or in w
t to the co
wear! Checking and if necessary replacing the brake discs is a
repair measure.
rrectness of i
– Check brake disc for wear:
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Procedure
Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐ nform
ercia
nism → Repairing front brakes.

m
at
om
ion
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in t
Note
or
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ate
do
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p
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or
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Cop py
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– Install wheel in marked position. cop Vo
by lksw
cted agen
Prote AG.
– Tighten wheel bolts diagonally and alternately, specified tor‐
que ⇒ page 130 .
– Place adapter in vehicle tool kit after completing work.
– Fit wheel bolt covers if necessary .
4.12.2 Rear brake pads:

– Illuminate area behind hole in wheel using an electric hand
torch.
– Determine thickness of outer pad by checking visually.

– Illuminate inner pad with an electric hand torch and mirror.
– Determine thickness of inner pad by checking visually.
a - Inner and outer pad thickness without backplate
Wear dimension: 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 brake pads, always check brake discs as well for
wear! Checking and if necessary replacing the brake discs is a
repair measure.
– Check brake disc for wear:

Procedure
cardiagn.com
Running gear → Brake systems ⇒ Rep. gr. 46 → Brake mecha‐
agen
AG. Volkswagen AG d
oes
nism → Repairing rear brake. yV
olksw not
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ed ran
oris tee
th or
Note au ac
ss
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nl
pt
du
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itte
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ab
ility
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4.12.3 Condition of brake discs: checking
spec
es, in part or in w
t to the co
Check all brake discs for the following damage pattern:
♦ Cracks
♦ Scoring rrectness of i
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♦ Rust (no surface rust)

♦ Burrs on circumference of brake disc
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
Inform customer if brake disc damage is similar to these damage

sd
iva
o
r
patterns. Renewing the brake discs is a repair measure.

rp
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4.13 6-speed dual clutch gearbox (DSG) Cop py
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02E: Changing gear oil and filter pyri by
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Prote
Procedure: »Power transmission; Direct shift gearbox« ⇒ Power
AG.
transmission; Direct shift gearbox; Rep. gr. 34 ; Changing oil and

filter of direct shift gearbox »Changing oil and filter of direct shift
gearbox«.
4.14 Electric windows: Check positioning

(open and close functions)
Note
The automatic opening and closing features for the electric win‐
dows do not function after disconnecting and reconnecting the
battery. Therefore, before a new vehicle is delivered, the window
regulators must be reactivated. Once the windows have been re‐
activated, the battery must not be disconnected again.
WARNING
After batteries have 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:
cardiagn.com
Note
The following work description applies to the front left window

regulator. Reactivate the other window automatic functions in the
same manner by operating the respective switch in the driver
door.
wage es n
– Switch on ignition. yV
olks ot g
ua
d b ran
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– Close all doors and windows horis completely. tee
ut or
a ac
– Hold the front left side
ss window in “closed” position, by pulling
and holding switch (for longer than 1 second).
ce
le
un
pt
an
d
itte
– Pull switch again for 1 second. The side window must now go
y li
rm
ab
up or down by itself when switch is briefly pulled or pressed.

pe
ility
ot

wit
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hole
4.15 Reading fault memory of all systems with vehicle diagnostic tester , cor‐
spec
es, in part or in w
recting possible faults according to repair guidelines

t to the co
ODIS Service
rrectness of i
– Connect vehicle diagnostic tester ⇒ page 32 .

l purpos
– Carry out identification of vehicle.
nform
ercia
– Enter task data or select “Without task”.

m
– Select “Control units”.

com
tion in
– Select “Event memory list”.

r
te o
thi
s
– Repair all faults according to repair guidelines.

iva
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fo
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ng
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Cop py
ht. rig
rig ht
Caution py by
co Vo
by lksw
cted agen
Prote AG.
The vehicle must always be delivered to the customer with
event memory cleared.
Static faults
If one or more static faults are found in the event memory, we
recommend seeking agreement from the customer to rectify
these faults using Guided Fault Finding.
Sporadic faults
If only sporadic faults or notes are stored in the event memory
and the customer has no complaints regarding the electronic ve‐
hicle system, erase event memory.
4.16 Front lid catch hook: grease

♦ 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-.
cardiagn.com
– Operate moving parts several times so that universal oil is able
to penetrate.
– Remove any excess lubricant using a lint-free cloth.
4.17 Boots: visual check

Carry out following procedure: agen
AG. Volkswagen AG d
oes
olksw not
– Check outer bellows and inner bellows -arrows- for dleaks
by
V and gu
ara
damage. horise nte
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un
pt
an
d
itte
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ab
ility
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ole,
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t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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Cop py
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82
op Vo
by c lksw
4. Descriptions of work: Prote
cted AG.
agen
4.18 Interior and exterior body: Carry out vis‐

ual check for corrosion with doors and
flaps open .
Test locations
♦ Sliding roof frame
♦ Inner and outer door frame
♦ Area around trim strips
♦ Windscreen roof edge
♦ Outer and inner A-pillar
♦ Bonnet
♦ Wheel arches
♦ Inner and outer tailgate
cardiagn.com
4.19 Poly V-belt: Renew
Procedure
⇒ Rep. gr. 13 ; Cylinder block belt pulley end; Removing and AG. Volkswagen AG d
agen
installing poly V-belt Volksw
oes
not
by gu
ara
ed
4.20 Poly V-belt: Check condition thoris nte
eo
au ra
c
Carry out following procedure: ss
ce
le
un
pt
– Crank engine at vibration damper on pulley using a socket.
an
d
itte
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erm
ab
Check poly V-belt -1- for:
ility
ot p
♦ Sub-surface cracks (cracks, core ruptures, cross sectional

wit
is n
h re
breaks)
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spec
♦ Layer separation (top layer, cord strands) t to the co
♦ Eruptions on bottom cover

♦ Fraying of carcass
rrectne
♦ Flank wear (material wear, frayed flanks, flank brittleness -

glassy flanks-, surface cracks)
ss o
♦ Oil and grease marks

cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
If faults are found, it is essential for the poly V-belt to be renewed.

t
sd
va
This can avoid breakdowns and malfunctions. The replacement

i
o
pr
cum
r
of a poly V-belt is a repair measure.

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.21 Cooling system: Checking frost protec‐

tion and coolant level
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements. It
is therefore recommended to use distilled water when mixing
coolant for topping up or replacing coolant.
AG. Volkswagen
♦ Use only coolant additives which conform
lksw
agen with the ⇒ Elec‐
AG do
es n
tronic parts catalogue (ETKA) d.bOther
yV
o
coolant additives may ot g
ua
reduce corrosion protectionorisubstantially.
se The resulting dam‐ ran
tee
age could lead to loss ofaucoolant
th and subsequent severe or
ac
damage to the engine.ss
ce
le
un
pt
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
an
d
itte
rosion damage as well as scaling. Such additives also raise
y li
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ab
the boiling point of the coolant. Therefore, the cooling system
pe
ility
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must be filled all year round with a coolant additive.
ot
wit
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♦ Because of its high boiling point, the coolant improves engine
hole
reliability under heavy loads, particularly in countries with trop‐
spec
ical climates.
es, in part or in w
t to the co
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
rrectness of i
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
l purpos
-36°C. Increasing the frost protection is permissible only if cli‐

matic conditions require stronger frost protection. It may, how‐
nform
ercia
ever, be increased only to a maximum of -48 °C. Otherwise,

the cooling effect will be impaired.
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com
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♦ The coolant concentration must not be reduced by adding wa‐

n in
r
ter even in warmer seasons and in warmer countries. Frost

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thi
protection must be guaranteed down to at least -25°C.

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♦ Read off anti-freeze figures for respective replenished coolant

fo
en
ng
additives.
t.
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Cop py
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♦ The temperature read off the refractometer - T10007A- corre‐
ht ht
rig by
py
sponds to the »ice flocculation point«. Flakes of ice may start co Vo
by lksw
forming in the coolant below this temperature. cted agen
Prote AG.
♦ Never reuse old coolant.

♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
4.21.1 Checking frost protection, replenishing

coolant additive if necessary
♦ Refractometer - T10007 A-
Note
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
cardiagn.com
– Check concentration of coolant additive using refractometer -
T10007 A- (refer to operating instructions).
The scale -1- of the refractometer is calibrated for coolant additive
AG. Volkswagen AG
agen does
G12 Plus Plus. Volksw not
y gu
db ara
The scale -2- is only calibrated for coolant
or
ise additive G13. nte
eo
h
ut ra
– If frost protection is insufficient,
ss drain coolant and supplement
a c
coolant additive ⇒ page 85 .
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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♦ If the currently used coolant additive cannot be determined

h re
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precisely, use the scale -2- for coolant additive G13. spec
es, in part or in w
♦ Please observe disposal instructions!

t to the co
– Check coolant additive concentration after road test again.

rrectness of i
4.21.2 Checking coolant level, replenishing

l purpos
coolant if necessary
nform
ercia
– Check coolant level in expansion tank with engine cold.

m
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Delivery inspection: coolant level is at least at “MAX marking”.

♦ At delivery inspection, coolant level above “MAX marking” is
permissible as well.
♦ The excessive amount of coolant does not need to be extrac‐
ted as the coolant level in new vehicles will decrease after the
system has been bled.
♦ Inspection service or inspection: coolant level above “min.
marking”.
– If coolant is too low, add required amount according to mixture
ratio.
Note
If fluid loss is greater than can be expected through normal use,

determine source and rectify (repair measure). AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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4.21.3 Mixing ratio: ris nte
ho eo
aut ra
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nl
Caution
pt
du
an
itte
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ab
Only distilled water may be used for mixing coolant additives.
ility
ot p
The use of distilled water ensures optimum protection against
wit
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h re
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spec
es, in part or in w
t to the co
Frost protection to Coolant additive Distilled water
percentage
-25 °C approx. 40% approx. 60 %
rrectness of i
-36 C approx. 50 % approx. 50 %
l purpos
nf
ercia
o
4.22 Diesel fuel filter: renewing
rm
m
atio
m
Diesel fuel filter: renewing, version 1 ⇒ page 87

o
n in
or c
thi
e

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Cop py
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♦ Diesel extractor - VAS 5226-
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Angled screwdriver - VAS 6543-

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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pt
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ab
ility
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es, in part or in w
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4.22.1 Diesel fuel filter: Renewing, version 1
rrectness of i
Note
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After the diesel fuel filter has been changed, the fuel system must
be bled.
nf
ercia
or
cardiagn.com
m
m
atio
m
Remove engine cover panel ⇒ page 100 .

o
n in
or c
Removing:
thi
te
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Caution
f
en
ng
t.
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op py
♦ Do NOT pull fuel hoses off diesel fuel filter cover and do
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ht ht
rig
NOT lever at connection. Leaks could occur and the diesel py by
co Vo
fuel filter upper part can be damaged.
by lksw
cted agen
Prote AG.
♦ Ensure that no diesel fuel contacts other components in
the engine compartment. Clean immediately, if necessa‐
ry.
Note
Please observe disposal instructions!
Carry out the following procedure:

– Unscrew all bolts -arrows- from diesel fuel filter upper part and
remove diesel fuel filter upper part.
Note
If the diesel fuel filter upper part is stuck, loosen as follows:
The diesel fuel filter upper part can be raised at assembly groove
-arrow A- using angled screwdriver - VAS 6543- .
♦ The assembly groove can be of different size, depending on
the type of upper part.
– Insert appropriate side of angled screwdriver - VAS 6543- in
assembly groove -arrow A- and turn angled screwdriver - VAS
6543- .
Then the diesel fuel filter upper part is raised.
– Take filter -3- out of diesel fuel filter lower part.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
ss c
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un
pt
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove old seal -2- from diesel fuel filter upper part -1- by
levering seal out of respective groove -arrow-.
nform
mercia
a
com
Caution
ion in
r
te o
thi
Remove all diesel, dirt and water residues from diesel fuel filter
s
iva
do
lower part using diesel extractor - VAS 5226- .

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
Installing:
– Insert new filter into diesel fuel filter lower part.
Caution
Always moisten new seal -1- slightly with diesel fuel to avoid
malfunctions!
– Insert new seal -1- into upper part of diesel fuel filter
-arrows-.
– Place diesel fuel filter upper npart with
AG. V seal
olkswagenproperly
AG do onto diesel
wage
fuel filter lower part,Vpress
olks on firmly and evenly euntil
s no the diesel
t gu
y
fuel filter uppersepart
d b is correctly seated. ara
n ri tee
utho or
a ac
Caution
ss
ce
e
nl
pt
du
an
Do NOT tighten bolts for upper part, before it is correctly seated
itte
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onto lower part.
erm
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ility
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spec
– Screw all bolts into diesel fuel filter lower part and tighten hand-
es, in part or in w
tight.
t to the co
– Then tighten bolts to 5 Nm according to sequence shown in
illustration -arrows-.
rrectness of i
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Caution
cardiagn.com
This procedure prevents the seal from being damaged.
nform
mercia
at
om
ion
Bleeding fuel system:
c
in t
or
his
te
• Vehicle must have fuel.

a
do
priv
cum
for
en
g
ODIS Service
n
t.
yi Co
Cop py
– Connect the vehicle diagnostic tester .
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.

– Select “Engine electronics”.
– Select “Guided Functions”.
– Select “Activate fuel pump”.
– Follow instructions in “Guided functions” mode.
– After the fuel system has been bled, start engine.

– Allow 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.

Removing:
Note
♦ Ensure that no diesel fuel contacts coolant hoses.

♦ If necessary, clean hoses immediately.
♦ After the diesel fuel filter has been changed, the fuel system
must be bled.

– Unscrew bolts in the sequence shown.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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erm
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– Remove diesel fuel filter element -4- from lower part of fuel
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Caution
The seals -2- and -3- and diesel fuel filter element -4- must be
renewed.
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malfunctions!
– Insert new diesel fuel filter element in diesel wfuel

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– After the fuel system has been bled, start engine.

engine off again.
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♦ Safety goggles
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♦ Ensure that no diesel fuel contacts other components in
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the engine compartment. Clean immediately, if necessa‐

ry.
Note
Before opening the system, place a cloth around the filter hous‐
ing.
– Unscrew bolts -arrows- in sequence shown -1- to -5-.

– Collect any escaping fuel.
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– Lay fuel filter upper part -1- aside with fuel lines still attached.
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– Insert filter element -2- centrally into fuel filter housing -1-.
Further installation is performed in reverse sequence.
Specified torque Nm
Bolts for filter housing 5
Caution
The high-pressure pump has very close tolerances and must

not be allowed to run without fuel. To prevent this and to enable
the engine to start quickly after parts have been renewed, it is
important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump have been removed or re‐
newed, the fuel system must be filled and bled before the
engine is started for the first time.
Bleeding fuel system:

• Vehicle must have fuel.
ODIS Service
– Select “Control unit list”.
– Follow instructions in “Guided functions”
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4.23 Air filter: Clean housing and renew filter

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Removing and installing air filter element, 1.6 l FSI engines

⇒ page 96 .
Removing and installing air filter element, 1.6 l indirect inj. en‐
gines; 2.0 l FSI engines and 1.4 l TSI engines ⇒ page 97 .
Removing and installing air filter element, 2.0 l TFSI engines
⇒ page 98 .
Removing and installing air filter element, 6-cylinder FSI engines
⇒ page 99 .
Removing and installing air filter element for vehicles with diesel
engine or 1.4 l TSI, EcoFuel and MultiFuel, 1.8 l and 2.0 l TSI
engines ⇒ page 100 .
4.23.1 Removing and installing air filter ele‐

ment, 1.4 l TSI engines
Applicable for engine code CZDA only
Removing
– Pull air hose -2- off upper part of air filter -1-.
– Release hose clips -3- and -4-.
cardiagn.com
– Pull air filter housing -1- upwards off ball studs.
– Pull air hoses/ducts off air filter housing -1-.
– Remove air filter element -1- and set down inverted.
– Unscrew bolts -1- on underside of air filter housing.

– Carefully release retaining tabs -arrows- on upper part of air
filter housing one after the other (risk of breaking). gen AG
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– Fit air hoses/ducts to air filter housing -1-.
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Specified torque Nm
Securing bolts 1.5

ment, 1.6 l FSI engines
Removing
– Remove engine cover panel ⇒ page 100 .
– Unscrew bolts -arrows-.
– Remove lower part of air filter -1- and air filter element -2-.
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– Remove the 4 screws -arrows- and remove cover.
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– Unscrew bolts -arrows- from engine cover panel lower side.
– Remove lower part of air filter, and remove air filter element
-2- from upper part of air filter -1-.
Note
♦ Self-tapping bolts are the standard means of fastening the up‐

per part of air filter to the lower part of air filter and to the intake
connection. If these bolts are loosened or tightened with a
cordless screwdriver, it is possible that the thread in the upper
part of air filter will be damaged.
♦ For this reason it is only permitted to use a power screwdriver,
if the following prerequisites are fulfilled:
♦ The speed of cordless screwdriver must not exceed 200 rpm.
♦ A torque setting must be adjustable.
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– Fit engine cover panel ⇒ page 100 .

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– Pull off connector -2- and loosen clip -1- using spring-type clip
pliers - VAS 6499- .
– Unscrew bolts -arrows- and remove air filter housing upper
part.
– Renew air filter element -2-.
Note
– Tighten screws of air filter housing upper part -1- to 1.6 ±

0.2 Nm.
– Refit clamp, and push on connector until it engages.

ment for vehicles with a diesel engine,
1.4 l TSI EcoFuel and MultiFuel, 1.8 l TSI
and 2.0 l TSI engines
– Unscrew bolts -arrows-.
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– Clean upper part of air filter.
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– Insert new air filter element and install air filter upper part.
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4.24 Engine cover panel -top-: Removing and

installing
Caution
♦ Do not strike the engine cover with the fist or a tool when
installing or engaging in securing points as otherwise it
could be damaged.
Removing and installing engine cover panel, 1.4 l TSI engines

⇒ page 101
Removing and installing engine cover panel, 1.4 l TSI EcoFuel
⇒ page 101

Removing and installing engine cover panel, 1.6 l FSI petrol direct
injection engines ⇒ page 102
Removing and installing engine cover panel, 2.0 l FSI petrol direct
injection engines ⇒ page 103
Removing and installing engine cover panel, 2.0 l TFSI petrol di‐
rect injection engines ⇒ page 103
Removing and installing engine cover panel, 1.8 l TSI and 2.0 l
TSI petrol direct injection engines ⇒ page 104
Removing and installing engine cover panel, diesel engines
⇒ page 104 agen
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– Attach coolant hoses -2- on engine cover panel and fit engine
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cover panel onto camshaft housing.
– Tighten securing bolts -1- to 8 Nm.
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4.24.2 Removing and installing engine cover
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panel, 1.4 l TSI EcoFuel

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– If fitted, pull off hose from connection -arrow A-.
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– Push engine cover panel -1- with lug -arrow A- at securing

point -2- into bracket -arrow B-.

– Then fit engine cover panel at the other securing points

-arrows B- and press on, until they noticeably engage.
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4.24.3 1.6 l FSI petrol direct injection engines
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Removing:
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– Pull out oil dipstick -1-.
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– Loosen clip -A- and pull off hose.

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remove upwards.
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The engine cover panel for engine codes BLR and BLY has been
AG.
discontinued during model year 2006. The cover has been dis‐
continued for subsequent engine codes from start of production.
Removing:
– Unclip engine cover panel at securing points -arrows- and re‐
move upwards.
Installing:
Install in reverse order of removal.
4.24.5 2.0 l TFSI petrol direct injection engines

♦ Pliers for spring-type clips - VAS 6499-

– Relieve clip -3- on air intake nozzle using spring-type clip pliers
- VAS 6499- , and push back.
– Pull connector -1- off air mass meter, and place connector to
side. agen
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4.24.6 Removing and installing engine cover

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– Disengage engine cover panel at the securing points
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Installing:
– Fit engine cover panel at securing points -arrows- and press
on until it engages.
4.24.7 Diesel engines
Note
♦ There are different versions of engine cover panels:

♦ One-piece engine cover panel ⇒ page 104
♦ Two-piece engine cover panel ⇒ page 106
One-piece engine cover panel:

♦ Version 1 ⇒ page 105

AG. Volkswagen AG d
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– Disengage engine cover panel at securing points -arrow- and

raise.
Installing:
Caution
Before installing engine cover panel, check the correct position

of the 4 securing elements (ball sockets); reset to original po‐
sitions if necessary. Otherwise the engine cover panel will be
damaged.
– Push ball sockets of engine cover panel to correct installation

position, if necessary.
– Fit engine cover panel onto securing points and press on at
edges to engage.
Version 3
Removing:

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Maintenance - Edition
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damaged.
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– Push ball sockets of engine cover panel to correct installation

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Removing:
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not pull off engine cover panel abruptly
or only on one side.
Installing:
– To prevent damage, do not strike engine cover panel with the
fist or a tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into rubber grommets first on the left
side and then on the right side.
Two-piece engine cover panel:

Removing:
Note
The engine cover panel consists of two individual parts.
♦ 1. The outer part -A-, here shaded in illustration

♦ 2. The centre part -B-, here not shaded in illustration
– Disengage engine cover panel carefully at individual securing
points and raise as follows.
♦ -1-, -3-, -2-, -4-.
– Remove outer part -1-.

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– Disengage centre
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on, so that cover engages.
AG.

4.25 Removing and installing engine com‐

partment cover -bottom- (noise insula‐
tion)
Procedure
The procedure of removing the engine cover panel -bottom-
(noise insulation) can be found in Workshop Manual under:
»General body repairs, exterior« ⇒ General body repairs, AG. Vexte‐
olkswagen AG
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4.26 Engine and components in engine com‐
h re
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spec
partment (from above and below): Visu‐
t to the co
al check for leaks and damage
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Perform visual check as follows:
rrectne
– Check engine and components in engine compartment for
leaks and damage.
ss o
– Lines, hoses and connections
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♦ Fuel system
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♦ Cooling and heating system

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Check for leaks, abrasion, porosity and brittleness, and proper Prote
cted AG.
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securing in retainers.
Note
♦ Arrange for defects to be rectified as repair measures.

♦ If fluid loss is greater than can be expected through normal
use, determine source and rectify (repair measure).
4.27 Engine oil level: Checking

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, wipe with a clean cloth and push dipstick in
again to limit stop.
– Pull dipstick out again and read oil level.

Version 1
Note
♦ The oil level must always be in the upper third of area -B- for
the delivery inspection. This way, you will achieve the greatest
possible customer satisfaction.
♦ The oil-change quantity in the service table was determined
experimentally and is sufficient for the technical functionality
of the engine in all operating conditions. During all other serv‐
ice events, the oil level must be checked and corrected as
necessary if the customer requests this. This enables an ad‐
ditional topping-up to the specified oil quantity to the upper limit
of the dip stick. Due to tolerances, the oil temperature and the
drip time, various quantities may be required for topping up.
A - Do not top up oil.

B - Oil can be replenished up to the max. mark -A-.
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C - Oil must be replenished. The oil level
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♦ Oil level must always be in area -A- for the delivery inspection.
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isfaction.
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l purpos
experimentally and is sufficient for the technical functionality

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nform
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A - Do not top up oil.

B - Oil can be replenished up to area -A-.
C - Oil must be replenished. The oil level must then be at least in
the upper third of the measuring area -B-.
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4.28 Engine oil: draining or extracting, renew‐
ility
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h re
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spec
Draining or extracting engine oil ⇒ page 110
es, in part or in w
t to the co
Renewing oil filter: 1.4 l TSI engines ⇒ page 111
Renewing oil filter, 1.6 l indirect inj. engines ⇒ page 116
rrectness of i
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Renewing oil filter, 1.6 l FSI engines ⇒ page 116
l purpos
Renewing oil filter, 2.0 l FSI and TFSI engines ⇒ page 117
Renewing oil filter, 6-cylinder FSI engines ⇒ page 121
nform
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Renewing oil filter, diesel engines ⇒ page 122

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Renewing oil filter, 1.8 l TSI and 2.0 l TSI engines ⇒ page 125
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♦ Oil spill cloth

Draining or extracting engine oil

Note
♦ For engines with standing oil filter, the oil filter must be re‐
newed before changing the engine oil. When removing the
filter element a valve is opened, the oil in the filter housing
automatically flows into crankcase. en AG. V
olkswagen AG
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♦ 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.
4.28.2 Renewing oil filter, 1.4 l TSI engines


Maintenance - Edition 11.2016 lkswage es n
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♦ Hazet oil filter strap - 2171-1-

Version 1
Removing
Note
♦ Prevent engine oil from dripping onto vehicle parts.

♦ Cover alternator with cloth before removing.

– Loosen oil filter -arrow- first, using a strap or oil filter tool -
3417- before removing oil filter completely.
– Wait a few minutes, so that engine oil can flow back from filter
into engine.
– Then remove oil filter.
Caution
Ensure that no engine oil drips onto poly V-belt or alternator.
Installing
Note
♦ Observe fitting instructions on oil filter.

– Clean oil filter sealing surface on valve timing housing.
cardiagn.com
– Lightly oil seal on new filter.
– Screw new oil filter -arrow- in by hand.

– Then tighten to 20 Nm.
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– Remove oil filter cover -1- with oil filter element -4- and valve
-5-.
Installing
– Renew O-ring -2- of oil filter cover and O-ring -3- of valve.
– Renew used oil filter element by new filter element -4-.
Note
– Tighten oil filter cover -arrow-

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– Remove “bottom” engine compartment cover (noise insula‐

tion) ⇒ page 108 .
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– Loosen oil filter element -arrow- using Hazet oil filter strap -
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Installing oil filter

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Oil filter 20
Draining engine oil on 1st oil change ⇒ page 115

Draining engine oil after 1st oil change ⇒ page 115

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does - Edition 11.2016
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Note
– Screw in oil drain plug -2- with new seal -1- hand-tight and then
tighten it firmly to specified torque.
Specified torque Nm
Oil drain plug 30
– Install engine compartment cover (noise insulation) “bottom”

⇒ page 108 .
– Replenish engine oil.
Engine oil capacity:
♦ ⇒ Maintenance tables
♦ Engine oil: capacities and specifications ⇒ page 126
WARNING
♦ Torque specifications must not be exceeded.

♦ Excessive torque can cause leaks in the area of the oil
drain plug or even damage.

4.28.3 Renewing oil filter, 1.6 l indirect inj. en‐

gines
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wit
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Note
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– Clean sealing surface on engine oil cooler.
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f in
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form
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– Tighten filter by hand.
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4.28.4 Renewing oil filter, 1.6l FSI engines

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♦ Torque wrench - V.A.G 1331- Cop py
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rig ht
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Note

♦ Prevent engine oil from dripping onto subframe.
Removing

– Loosen threaded cap -arrow- on hexagonal flats and remove.
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– Take oil filter -4- out of threaded cap -1-.
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– Clean sealing surfaces on threaded cap and oil filter housing.
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– Insert new filter element -4- into threaded cap.

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– Renew seal -2-.

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– Clean thread -3- and lightly moisten with oil.

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Prote AG.
– Tighten threaded cap -arrow- to 25 Nm.

Further assembly is basically a reverse of the dismantling se‐
quence.
4.28.5 Renewing oil filter, 2.0 l FSI and TFSI

engines

Maintenance - Edition 11.2016 . Volkswage AG n AG d
agen oes
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♦ Oil drain adapter - T40057- db
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♦ Long nose pliers

Drain oil filter housing
Caution
♦ Before removing the oil filter housing, it must be drained.
Note
♦ When the oil drain adapter - T40057- is screwed in, a valve is

opened in oil filter housing.
♦ When the oil drain adapter - T40057- is removed again, the
valve closes automatically.

– Remove dust cap -arrow- from oil filter housing.
– Insert oil drain adapter - T40057- into oil filter housing and hold
hose in oil drip tray.
– Drain engine oil.
– Unscrew oil drain adapter - T40057- again.
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– Remove oil filter element -2- from centre pipe of oil filter hous‐
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Removing oil seal

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The seal of oil filter housing -3- must be renewed every time
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groove at the “service tag” -A-.

en AG . Volkswagen AG
– Remove seal -1- from sealing groove of oil filter housingks-2- wagby does
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Installing oil seal s au ra
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– Oil seal -3-.
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– Place seal into sealing groove of oil filter housing, so that the
service tag -A- faces upwards.
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– Push seal into sealing groove and check by touching with fin‐
ger, if the seal in sealing groove contacts evenly -arrows-.

Installing oil filter element

– Press new oil filter element -2- on centre pipe of oil filter hous‐
ing -4- until limit stop.
Installing oil filter housing
– Screw on oil filter housing -4- with new seal -3- and new oil
filter element -2- by hand until it nearly reaches the stop of oil
filter bracket -1-.
AG. Volkswagen AG d
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– Tighten oil filter housing -2- to 25 Nm.
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– Insert dust cap -arrow- into oil filter housing hand-tight.

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4.28.6 Renewing oil filter, 6-cylinder FSI en‐

gines

♦ Socket AF 36 mm - T10125-
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– Open oil drain plug -6- to empty oil filter housing.
– Release threaded cap with combination spanner, 36 mm -
rrectne
T10125- -4-.
– Remove oil filter insert -2-.
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Note
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– Renew O-rings -1,3,5- and lightly oil them before installing.

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– Now insert new oil filter insert.

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– Tighten oil threaded cap -4- to 25 Nm.
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– The oil drain plug -6- is tightened to 10 Nm. cop Vo
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4.28.7 Renewing oil filter, diesel engines

♦ Version 1: ⇒ page 123

Version 1:
Removing
Note

Release sealing cap -arrow- with suitable tool.
Note
Before draining or extracting, release sealing cap so that the en‐

gine oil can flow out of filter housing.

Installing
– Renew filter element.
cardiagn.com
– Renew O-rings.
– Install threaded cap -arrow- and tighten to 25 Nm.

quence.
Version 2:
Removing
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Prote AG.

– Loosen filler cap -2- e.g. using an appropriate combination

spanner or socket.
Note
Before draining or extracting release sealing cap, so that the en‐

gine oil can flow out of filter housing.
Installing
– Renew filter element -3-.
– Renew O-rings -2 and 4-.
cardiagn.com
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– Install threaded cap and tighten to 25 Nm.

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quence. Ensure that the solenoid change-over valve -1- audibly
engages.
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♦ Oil spill cloth

– Remove “bottom” engine compartment cover (noise insula‐
tion) ⇒ page 108 .
– Disconnect connector -1- from return-flow pump.
– Unclip alternator cable -2- from clip -3- and swing it in
-direction of arrow-.
cardiagn.com
– Unscrew oil drain plug -1- from screw cap -3- and drain engine
oil.
Removing oil filter wage
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– Remove screw cape-3- d using 32 mm hexagon socket insert
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Renewing oil filterauelement
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– Insert O-ring -2- in groove of oil drain plug for screw cap -1-.
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Screw in oil drain plug and tighten it to specified torque.

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– Screw on screw cap -3- and tighten it to specified torque using

es, in part or in w
32 mm hexagon socket insert .

t to the co
– Clip in alternator cables and connect connector to return-flow

pump.
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– Clean all lines contaminated with engine oil using oil spill cloth .
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Specified torque Nm
nform
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Screw cap for oil filter 25

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Oil drain plug in screw cap 5

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4.28.8 Renewing oil filter, 1.8 l TSI and 2.0 l TSI

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cardiagn.com
Removing
– Loosen oil filter cartridge -arrow- using oil filter tool - 3417- .
– Loosen filter by a few turns. Wait a few seconds to allow the
oil between filter and housing to flow back into sump. Now agen
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– Oil rubber seal lightly on new filter. This ensures best possible
es, in part or in w
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t to the co
– Tighten filter to 22 Nm using torque wrench - V.A.G 1331- .

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4.28.9 Replenishing engine oil

l purpos
Engine oil: capacities and specifications ⇒ page 126

nf
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Oil level: checking ⇒ page 108

orm
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4.29 Engine oil: capacities and specifications

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4.29.1 Passat CC/CC

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Passat CC/CC t. Cop py
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Petrol engines Oil quantity with filter VW engine oil standards
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Engine code Capacity / output With flexible service With fixed service Prote
cted AG.
agen
BLV 3.6 l 206kW 5.5 504 00 502 00 / 501 01

Passat CC/CC
Engine code Capacity / output (I) With flexible service With fixed service
BWS 3.6 l 220kW 5.5 504 00 502 00 / 501 01
BZB 1.8 l 118kW 4.7 504 00 502 00
CAWB 2.0 l 147kW 4.7 504 00 502 00
CBFA 2.0 l 147kW 4.7 504 00 502 00
CCTA 2.0 l 147kW 4.7 504 00 502 00
CCZA 2.0 l 147kW 4.7 504 00 502 00
CCZB 2.0 l 147kW 4.7 504 00 502 00
CDAA 1.8 l 118kW 4.7 504 00 502 00
CDAB 1.8 l 112kW 4.7 504 00 502 00
CGYA 1.8 l 112kW 4.7 504 00 502 00
CKMA 1.4 l 118kW 3.6 --- 502 00
CNNA 3.6 l 206kW 5.5 --- 502 00
CTHD 1.4 l 118kW 3.6 504 00 502 00
cardiagn.com
CZDA 1.4 l 110kW 4.0 504 00 502 00
Passat CC/CC
Diesel engines Oil quantity with filter VW engine oil standards
CBAA 2.0 l 100kW 4.0 507 00 507 00
CBAB 2.0 l 103kW 4.0 507 00 507 00
2.0 l 103kW n AG. Volkswag4.0
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507 00 505 01
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CBAC 2.0 edl 105kW
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CBBB au 2.0 l 125kW
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CFFA 2.0 l 100kW 4.3 507 00 507 00
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CFFB 2.0 l 103kW 4.3 507 00 507 00

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CFGB 2.0 l 125kW 4.3 507 00 507 00

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CFGC 2.0 l 130kW 4.3 507 00 507 00

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CUVC 2.0 l 110kW 4.6 507 00 507 00

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CUWA 2.0 l 135kW 4.6 507 00 507 00

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1) Without diesel particulate filter

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4.29.2 Passat 3C
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Passat 3C
nform
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Engine code Capacity / output With flexible service With fixed service
on in
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AXX 2.0 l 147kW 4.6 504 00 502 00 / 501 01

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AXZ 3.2 l 184kW 5.5 504 00 502 00 / 501 01

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BLF 1.6 l 85kW 3.6 504 00 502 00 / 501 01

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BLR 2.0 l 110kW 4.6 504 00 502 00 / 501 01
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BLV 3.6 l 206kW 5.5 504 00 502 00 / 501 01
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BLX 2.0 l 110kW 4.6 504 00 502 00 / 501 01
agen
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BLY 2.0 l 110kW 4.6 504 00 502 00 / 501 01

Passat 3C
BPY 2.0 l 147kW 4.6 504 00 502 00 / 501 01
BSE 1.6 l 75kW 4.5 504 00 502 00 / 501 01
BSF 1.6 l 75kW 4.5 504 00 502 00 / 501 01
BVX 2.0 l 110kW 4.6 504 00 / 503 00 502 00 / 501 01
BVY 2.0 l 110kW 4.6 504 00 / 503 00 502 00 / 501 01
BVZ 2.0 l 110kW 4.6 504 00 / 503 00 502 00 / 501 01
BWA 2.0 l 147kW 4.6 504 00 502 00 / 501 01
BWS 3.6 l 220kW 5.5 504 00 502 00 / 501 01
BZB 1.8 l 118kW 4.7 504 00 502 00
CAXA 1.4 l 90kW 3.6 504 00 502 00
CAWB 2.0 l 147kW 4.7 504 00 502 00
CCTA 2.0 l 147kW 4.7 504 00 502 00
CCTB 2.0 l 125kW 4.7 504 00 502 00
cardiagn.com
CCZA 2.0 l 147kW 4.7 504 00 502 00
CDAA 1.8 l 118kW 4.7 504 00 502 00
CDAB 1.8 l 112kW 4.7 504 00 502 00
CDGA 1.4 l 118kW 3.6 --- 502 00
CGYA 1.8 l 112kW 4.7
AG. Volkswagen
504 00 502 00
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BKC 1.9 l 77kW 3.8 507 00 505 01

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BKP 2.0 l 103kW 4.0 507 00 505 01

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BLS 1.9 l 77kW 4.3 507 00 507 00

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BMA 2.0 l 100kW 4.0 507 00 505 01

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BMP 2.0 l 103kW 4.0 507 00 505 01

BMR 2.0 l 125kW 4.0 507 00 505 01
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BUZ 2.0 l 120kW 4.0 507 00 505 01

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BVE 2.0 l 90kW 4.0 507 00 505 01

BWV 2.0 l 88kW 4.0 507 00 / 506 01 505 01
nform
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BXE 1.9 l 77kW 3.8 507 00 / 506 01 505 01

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CAYC 1.6 l 77kW 4.3 507 00 507 00

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CBAA 2.0 l 100kW 4.0 507 00 507 00

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CBAC 2.0 l 105kW 4.0 507 00 507 00
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CBDC 2.0 l 81kW 4.3 507 00 507 00
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1) Without diesel particulate filter

4.30 Tyre repair set: Check bottle for damage

and if used; check and enter use-by date
of tyre sealant
Note
♦ The tyre repair set is located in the spare wheel well.

♦ The tyre repair set also contains a filler bottle with tyre sealant.
4.30.1 Checking expiry date

AG. Volkswagen A
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– Check the expiry
by
Vol date.
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The expirythodate is printed on a sticker on the tyre sealantteecontainer
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or
-arrow-.s au ac
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– Enter the expiry date in maintenance table.

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– Renew tyre sealant if the expiry date has been reached. (The
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♦ If the tyre sealant has been used, the container must be re‐
newed.
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4.31 Performing road test (driving behaviour,

nform
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noises, air conditioner etc.)

m
Which of the following can be checked depends on vehicle equip‐

com
tion in
ment and local conditions (urban/country).

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Check the following during a road test:

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– Engine: output, misfiring, idling speed, acceleration

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– Clutch: pulling away, pedal pressure, odours
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– Gear selection: ease of operation, stick position
p by
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– Automatic gearbox: Selector lever position, shift lock/ignition
Prote AG.
key removal lock, shift behaviour, dash panel insert display.
– Foot brake and handbrake: function, free travel and effective‐
ness, pulling to one side, juddering, squeal
– ABS function: pulsing must be felt at the brake pedal during
ABS-regulated braking.
– Steering: function, steering free clearance, steering wheel
centred when vehicle is travelling straight ahead
– Tilting roof: function
– Radio/radio navigation system: Function, reception, GALA, in‐
terference noise
– Multi-function indicator (MFI): functions
– Air conditioning system: Check function At very low tempera‐
tures the air conditioner function must be checked in a work‐
shop.
– Vehicle: pulling to one side when travelling straight-ahead
(level road)

– Imbalance: wheels, drive shafts, propshaft

– Wheel bearings: noises
– Engine: hot starting behaviour
4.32 Wheel securing bolts: tighten to speci‐

fied torque
♦ Pulling off wheel hub trim: ⇒ page 130
♦ Pulling off wheel bolt caps: ⇒ page 130
♦ Loosening/tightening anti-theft wheel bolts ⇒ page 131
♦ Tightening wheel bolts ⇒ page 132
Pulling off wheel hub trim:
Caution
On vehicles with light alloy wheels do not lever wheel hub trim
off with screwdriver, only use the special tool for this purpose
(puller hook in vehicle tool kit).
cardiagn.com
wage es n
The puller hook -1- to remove the cover caps is located yV
with
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vehicle tool kit. ir se
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– Hook puller hook into one drilling of wheel hub
s au trim and pull off
t or
ac
in -direction of arrow-. s
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– On vehicles with full wheel trim install full wheel trim so that
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the tyre filler valve is guided through the cut-out provided
-arrow-.
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Pulling caps off wheel bolts:

nform
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Caution
m
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On vehicles with light alloy wheels do not lever wheel bolt caps
r
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off with screwdriver, only use the special tool for this purpose
s
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(puller hook in vehicle tool kit).

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Cop py
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Note cop Vo
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Prote AG.
Before loosening or tightening the wheel bolts, remove the cover
caps.
The puller hook to remove 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

is required, located in vehicle tool kit.
♦ To loosen the anti-theft wheel bolts (lockable wheel bolts) do
not use an impact screwdriver.
♦ If the adapter to loosen or tighten the anti-theft wheel bolts is
not available in the vehicle, use the appropriate adapter set for
tamper-proof wheel bolts.

♦ Adapter set for tamper-proof wheel bolts - T10101-
cardiagn.com
♦ Adapter set for tamper-proof wheel bolts - T10313-
AG. Volkswagen AG d
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131
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Prote
cted AG. 4. Descriptions of work:
agen
– Slide adapter -2- into anti-theft wheel bolt -1- onto stop.
– Slide the wheel bolt wrench onto adapter -2- onto stop.
Tighten wheel bolts:
– Tighten the wheel bolts diagonally and alternately to the fol‐
lowing torque setting.
Specified torque: 120 Nm
WARNING
Never use an impact screwdriver to tighten the wheel bolts!

AG. Volkswagen AG d
agen oes
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Place puller hooks and adapter with vehicle tool kit after complet‐
ce
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un
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ing work.
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cardiagn.com
4.33 Reading radio code using vehicle diag‐
ot
wit
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nostic tester
hole
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es, in part or in w
Authorization prerequisites for vehicle diagnostic tester
t to the co
• The vehicle diagnostic tester is connected via the Central
Partner Network (CPN) with the central database (Carport,
rrectness of i
Fazit).
• Available access for the user of the system “GeKo” (secrecy
l purpos
and component protection)
nform
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Note
m
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♦ The radio codes are also called security codes, they can be
r
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read in the central database and can be displayed on display

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of vehicle diagnostic tester .

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♦ For radio activation the codes must be entered via radio but‐
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tons, as previously ⇒ page 132 . Cop py
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– Select “Radio”.
– Select “Read radio code”.
4.34 Radio/navigation system: entering PIN

of anti-theft coding and storing local ra‐
dio stations to station buttons
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from

vehicle. The anti-theft codes are also called radio codes or se‐
curity codes. Security code means that each unit with an anti-theft
coding is programmed with its own code number. This security
code is not active when leaving the factory. The security code is
found on the unit card, if fitted. If the unit card is not fitted, the
security code can be read using vehicle diagnostic tester of a
central database ⇒ page 132 .
Note
If an incorrect code number is entered when releasing the elec‐

tronic lock, the whole procedure can be repeated once. If an
incorrect code number is entered again, the unit is locked for
about one hour. That means, it cannot be used. After one hour,
during which 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
Vehicle electrics → Communication ⇒ Rep. gr. 91 → e.g. radio
system "RCD 500" → Electronic anti-theft coding → Deactivating
electronic anti-theft coding.
cardiagn.com
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4.35 Tyre pressureuthloss
or
is
indicator: performing tee
or
basic settingss a ac
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♦ During normal vehicle operation, Tyre Pressure Monitoring wit

is n
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System (TPMS) with autolocation (direct measurement) func‐
ole,
spec
tion is automatically calibrated to the driver-defined tyre pres‐
sures.
t to the co
♦ Therefore, basic setting of the Tyre Pressure Monitoring Sys‐

tem (TPMS) is no longer necessary.
rrectne
Applicable only for tyre pressure indicator with PR number 7K6

s
(indirect measurement)
s o
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To model year ►2011: ⇒ page 134

inform
mer
From model year 2012►: ⇒ page 134

atio
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♦ The basic setting of Tyre Pressure Loss Indicator - K220- must

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only be performed “after” the tyre pressure has been corrected
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♦ If no pressure loss and tyre damage are found after a tyre
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pressure warning, the incorrect warning can be rectified by a
agen
Prote AG.
basic setting.
The tyre pressure monitoring warning lamp - K220- compares the

speed and the rolling circumference of individual wheels via the
ABS speed sensors. When the rolling circumference of one wheel
is changed this is displayed by the tyre pressure monitoring. The
rolling circumference of tyre can change if:
♦ The tyre pressure is too low.

♦ The tyre has structural damage.

♦ The vehicle is loaded more heavily on one side.
Volkswagen AG
♦ The wheels on one axle are loaded more heavily (e.g. swa
gewhen
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♦ Snow chains are fitted. ris
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♦ The temporary spare wheel is fitted.ss
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♦ One wheel per axle has been changed.
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To model year ►2011:
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The tyre pressure monitoring warning lamp - K220- has a yellow
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warning lamp in the dash panel insert -arrow-.
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spec
♦ “FLASHING LIGHT” means that the “INITIAL BASIC SET‐
es, in part or in w
TING” has not been performed.
t to the co
♦ A “PERMANENT LIGHTING-UP” in conjunction with a warn‐
ing tone, means “WARNING”, pressure loss has been recog‐
rrectness of i
nised, check inflation pressures and perform system basic
setting.
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Perform “INITIAL” basic setting
cardiagn.com
nform
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– Simultaneously press and hold buttons ESP and SET -A- in

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centre console for longer than 2 seconds.
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If ESP is not fitted, press TCS button.
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The start of basic setting will be confirmed by an acoustic signal. C py
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When switching on ignition again, no warning is indicated.
p by
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Perform basic setting
Prote AG.
– Press button SET -A- in centre console for more than 2 sec‐
onds.
The tyre pressure monitor warning lamp - K220- in dash panel

insert -arrow- lights up, as long as the button is pressed.
The start of basic setting will be confirmed by an acoustic signal.
When switching on ignition again, no warning is indicated.
From model year 2012►:

Use corresponding buttons on multifunction steering wheel to

perform basic setting:
Button -5- is used to confirm menu options.
Press arrow buttons -1- -2- and -4- to change the menu.
AG. Volkswagen
– Press respective arrow buttons -2-lksw
and
agen -4- of multi-function
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steering wheel repeatedly, until
db
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– Press arrow buttons -1- thountil submenu “Tyre pressure” is dis‐ or
played. s au ac
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– Press OK button -5-.
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– Press OK button -5- to confirm tyre pressure.
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– Press OK button -5- again to confirm the confirmation prompt
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Tyre pressure monitor display warning lamp lights up briefly in
es, in part or in w
t to the co
dash panel insert -arrow- to confirm that basic setting has been
completed successfully.
cardiagn.com
Use corresponding buttons on windscreen wiper lever to perform
rrectness of i
basic setting:
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Button -1- is used to confirm menu options.
nform
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ion
c
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Rocker lever -2- is used to change the menu.

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– Switch on ignition. Cop py
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– Push button -2- until the main menu is displayed. Then, use p by
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the button to scroll to the “Settings” menu.
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Prote AG.
– Press button -1-.
– Press rocker lever -2- repeatedly until “Tyre pressure” sub-
menu appears.
– Press button -1-.
– Press button -1- to save the tyre pressure values.
– Confirm resulting security question again with button -1-.
Tyre pressure monitor display warning lamp lights up briefly in

dash panel insert -arrow- to confirm that basic setting has been
completed successfully.

Maintenance - Edition 11.2016 olksw AG. V agen AG
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4.36 Dust and pollen filter: clean housing and
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renewing filter element
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Procedure
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⇒ Heating and air conditioning system; Rep. gr. 80 ; Heater unit;
itte
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Removing and installing dust and pollen filter
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ab
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4.37 Headlight adjustment: Checking halo‐
wit
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gen headlights and fog lights, adjust if
hole
spec
necessary, Passat/Passat Estate 2006► es, in part or in w
t to the co
Test and adjustment prerequisites ⇒ page 136
Checking headlight adjustment (using test screen without 15°
rrectness of i
setting line) ⇒ page 137
l purpos
Adjusting halogen headlights ⇒ page 138 .

Adjusting fog lights and other auxiliary lights. ⇒ page 139
nform
ercia
4.37.1 Test and adjustment conditions

m
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tion in
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• Tyre pressure OK
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thi
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• Lenses must not be damaged or dirty.
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• Reflectors and bulbs OK.
en
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t.
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op py
• The vehicle must be rolled forward and backward several me‐ t. C rig
gh ht
tres or front and rear springs must be bounced fully several yri
p by
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times so that springs settle.
by c lksw
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Prote AG.
• Vehicle and headlight adjuster must be on a level surface.
• Vehicle and headlight adjuster must be aligned.
• Inclination must be set.
• Refer to the ⇒ operating instructions for headlight adjustment
units .
Note
For vehicles for North America the side adjustment of headlight

is not permitted and has therefore an adjustment screw secured
against turning.
Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐
centage given is based on a projection distance of 10 metres.
Example: Converting a dip setting of e.g. 1.0 % is equivalent to
10 cm.
The inclination of headlights of vehicles in the North American
market is to be set to 0.7 %.
The inclination for fog lights is 2.0%.
Note
For certain export markets, halogen headlights with manually

regulated headlight range control are not offered.
– Check headlight height adjustment by setting the maximum

level and monitoring the headlights' light.

– If fitted, then set the headlight range control thumb wheel to

position “0”.
Loading: with one person or 75 kg on the driver seat and the ve‐
hicle otherwise unloaded (unladen weight).
The unladen weight is the weight of vehicle ready for operation
with fuel tank at least 90% full including weight of all equipment
normally carried (e.g. spare wheel, tools, jack, fire extinguisher
etc.).
If the fuel tank is not at least 90% full, then load as follows:
– Read fuel level in fuel tank on fuel gauge. Determine additional
weight from following table and place weight in luggage com‐
partment.
Fuel gauge table
Fuel level of Petrol and diesel engines: addition‐ Natural gas engine, additional
fuel gauge al weight agen AG. Volkswagen AG do weight
in kg Volksw es nin kg
ot g
y ua
db ran
To 1/4 40
ris
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To 1/2 ss
au 30 25 ac
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To 3/4 15 10
e
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an
Full 0 0
itte
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ility
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Example:
hole
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If the fuel tank is half full, an additional weight of 30 kg or 20 kg
es, in part or in w
t to the co
must be placed in the luggage compartment.
rrectness of i
Note
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♦ For this purpose, a container filled with water or gravel can be

used, for example (a 5-litre fuel canister filled with water
weighs approx. 5 kg). nform
ercia
♦ Write the weight in kg on the container and secure it against

m
at
om
being opened again in order to prevent misuse.

on
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in t
or
♦ In order to avoid soiling vehicle, place a mat or covering of

his
ate
some kind in the luggage compartment.

do
priv
cum
for
en
ng
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4.37.2 Checking headlight adjustment (using
yi Co
Cop py
t. rig
test screen without 15° setting line)
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Prote AG.
♦ Headlight adjustment unit - VAS 5046 A-

♦ Headlight adjustment unit - VAS 621 001-
Headlights:
Check the following:

– Whether, with the dipped beam switched on, the horizontal

bright/dark boundary contacts the dividing line -1- of the test
area and
– Whether the breaking point -2- between the horizontal part of
the bright/dark boundary 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 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 dipped beams, the centre point of
the main beam must lie on the centre mark -3-.
Test figure for fog light

– Check whether the upper light-dark border touches the setting
line and runs horizontally over the entire width of the test
cardiagn.com
screen. G. Volkswage
nA n AG d
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Other additional lights: y Volks not
gu
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ise of other systems
Additionally retrofittedthlights must be checked ntee
or
and set according to auvalid guidelines.
or
ac
ss
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nl
pt
du
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itte
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erm
ab
ility
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4.37.3 Adjusting halogen headlights

h re
hole
spec
es, in part or in w
t to the co
Note
♦ Please check that both headlights move evenly when man‐

rrectness of i
ually operated headlight range control is functioning.

l purpos
♦ If the vehicle is equipped with separate dipped and main

beam, adjust main beam additionally. When adjusting main
nform
ercia
beam ensure that the adjustment unit is set to 0%.

m
at
om
Adjusting right headlight:

on
c
in t
or
The adjustment bolts for the left headlight are a mirror image.
his
ate
do
priv
♦ Lateral adjuster screw for dipped beam (lead-sealed for the

cum
for
NAR market) -3-

en
ng
t.
yi Co
op
♦ Height adjustment screw of bright/dark boundary for dipped
C py
ht. rig
beam -2-
rig ht
py by
co Vo
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cted
♦ Lateral adjustment screw of bright/dark boundary for main
agen
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beam -1-
– Always turn the height adjustment screws of bright-dark boun‐
dary first.
– Then check lateral adjustment; correct if necessary.

4.37.4 Adjusting fog lights and other auxiliary

wage
lights by
Volks es n
ot g
ua d ran
se
Fog lights, Passat/Passat Estate 2006 ►,thin
or front bumper, right:
i tee
or
⇒ page 139 ss
au ac
ce
e
Other additional lights ⇒ page 139
nl
pt
du
an
itte
y li
Fog lights, Passat/Passat Estate 2006 ►, in front bumper, right:
erm
ab
ility
ot p
Location of adjustment screw on left-hand fog light is a mirror im‐
wit
age. , is n
h re
hole
– To adjust the headlight range turn adjustment screw
spec
-arrow A-.
es, in part or in w
t to the co
There is no provision for lateral adjustment.
Other additional lights
rrectness of i
Additionally retrofitted lights of other systems must be checked
l purpos
and set according to valid guidelines.
nform
mercia
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at
om
ion
c
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or
his
ate
do
riv
4.38 Headlight adjustment: Checking halo‐

p
cum
for
en
g
gen headlights, Passat CC and CC

n
t.
yi Co
op py
2010► t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Additional 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.

Checking headlight adjustment (ECE) ⇒ page 140
Checking headlight adjustment (SAE) ⇒ page 140
Adjusting halogen headlights ⇒ page 142

• Lenses must not be damaged or dirty.
• Reflectors and bulbs OK.
• The vehicle must be rolled forward and backward several me‐
tres or front and rear springs must be bounced fully several


AG. Volkswagen AG d
• Inclination must be set. ksw
agen oes
not
ol
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• Refer to the ⇒ operatingiseinstructions for headlight adjustment aran
d b
units . ut
ho
r tee
or
a ac
ss
4.38.2 Checking headlight adjustment (ECE)
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
For certain export markets, halogen headlights with manually
l purpos
nform
ercia
cardiagn.com
m
at
om
i
on
c
in t
position 0 .
or
his
ate
do
riv
The inclination on the headlight adjustment unit is set according

p
cum
to the fuel level in the fuel tank.
for
en
ng
t.
yi
Inclination setting for ECE-compliant headlights
Co
Cop py
t. rig
gh ht
yri
Fill level of Inclination
p by
o Vo
by c
fuel gauge
lksw
cted agen
Prote AG.
0 to 1/2 1.2 %
1/2 to 1 1.0 %
Inclination for halogen headlights on the ECE CNG-Passat

Inclination
1.0 %

area and
– Whether the breaking point -2- between the horizontal part of
the bright/dark boundary 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
After correct adjustment of dipped beams, the centre point of the

main beam must lie on the centre mark -3-.
4.38.3 Checking headlight adjustment (SAE)



Note agen
AG. Volkswagen AG d
oes
olksw not
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by
♦ The VOL/VOR marking is visible on the outside the headlight.
d ara
ise nte
or eo
h
ut
♦ The lateral
s a adjustment mechanism is sealed on SAE-compli‐ ra
c
ant headlights. s
ce
e
nl
pt
du
♦ For certain export markets, halogen headlights with manually
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
position 0 .
rrectness of i
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Inclination for SAE VOL halogen headlights
l purpos
nform
ercia
fuel gauge
m
0 to 1/2 0.9 % at
om
ion
c
1/2 to 1 0.7 %
in t
or
his
ate
do
priv
cum
for
en
VOL: Visual Optical Aim Left -1-

ng
t.
yi Co
op py
– Check whether the left horizontal light-dark border touches the t. C rig
gh ht
separating line -1- in the test area of the headlight adjustment pyri by
Vo
o
by c
unit.
lksw
cted agen
Prote AG.
Inclination for SAE VOR halogen headlights

fuel gauge
0 to 1/2 0.2 %
1/2 to 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.
4.38.4 Adjusting halogen headlights
Note

a separate charge.
♦ If the vehicle is equipped with separate dipped and main
cardiagn.com
beam, adjust main beam additionally. When adjusting main
beam ensure that the adjustment unit is set to 0%.
Adjusting right headlight: AG. Volkswagen AG d

agen oes
olksw not
V gu
The adjustment bolts for the left headlight are a mirror image. ed by ara
nte
ris
ho eo
♦ Lateral adjuster screw for dipped beam (lead-sealed afor ut the ra
c
NAR market) -3- s s
ce
le
un
pt
♦ Height adjustment screw of bright/dark boundary for dipped
an
d
itte
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beam -2-
erm
ab
ility
ot p
♦ Lateral adjustment screw of bright/dark boundary for main
wit
beam -1-
is n
h re
ole,
– Always turn the height adjustment screws of bright-dark boun‐
spec
dary first.
t to the co
– Then check lateral adjustment; correct if necessary.
rrectne
4.39 Headlight adjustment: Checking gas
discharge headlights without DLA, ad‐ ss o
just if necessary, Passat/Passat Estate
cial p
f inform
2006►
mer
atio
m

o
n
c
i
or
n thi
Checking headlight adjustment (using test screen without 15°

te
sd
a
setting line) ⇒ page 144

iv
o
pr
cum
r
fo
Gas discharge headlights without “Dynamic Light Assist” dynamic

en
ng
t.
yi
main beam regulation: adjusting ⇒ page 145
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
AG.
• Headlight lenses must not be damaged or dirty.

• Reflectors and lights OK
• The initialisation of the headlight range control must have been
completed. 1)


tres or front and rear springs must be AG. Volkswfully
genbounced
agen AG
several
does
swa
times so that springs settle.by Volk not
gu
a d ran
se
• Vehicle and headlightthadjuster
or
i
must be on a level surface. tee
or
au ac
• Vehicle and headlight
ss adjustment unit must be aligned.
ce
le
un
pt
an
d
itte
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rm
ab
• Event memory must be cleared.
pe
ility
ot
• If the headlight adjustment unit has an adjustment mode, se‐
wit
, is n
h re
lect it.
hole
spec
es, in part or in w
units .
t to the co
1) During the initialisation, the step motors for the headlight range
control are reset to dipped beam position. The initialisation of the
rrectness of i
headlight range control is performed during vehicle start or after
an "on" signal is applied to terminal 15.
l purpos
nform
ercia
Note
m
cardiagn.com
a
com
ti
For vehicles for North America the side adjustment of headlight
on in
is not permitted and has therefore an adjustment screw secured
r
te o
thi
against turning.
s
iva
do
r
rp
cum
fo
Inclination information in “%” is stamped into trim above headlight.
en
ng
t.
yi
Headlights must be adjusted according to this information. Per‐
Co
Cop py
centage given is based on a projection distance of 10 metres.
t. rig
gh ht
yri
Example: Converting a dip setting of e.g. 1.0 % is equivalent to
p by
co Vo
by lksw
10 cm. Prote
cted AG.
agen
The inclination of headlights of vehicles in the North American

market is to be set to 0.7 %.
Loading: with one person or 75 kg on the driver seat and the ve‐
hicle otherwise unloaded (unladen weight).
The unladen weight is the weight of vehicle ready for operation
with fuel tank at least 90% full including weight of all equipment
normally carried (e.g. spare wheel, tools, jack, fire extinguisher
etc.).
If the fuel tank is not at least 90% full, then load as follows:
– Read fuel level in fuel tank on fuel gauge. Determine additional
weight from following table and place weight in luggage com‐
partment.
Fuel gauge table
Fuel level of Petrol and diesel engines: addition‐ Natural gas engine, additional
fuel gauge al weight weight
in kg in kg
To 1/4 40 35
To 1/2 30 25
To 3/4 15 10
Full 0 0
Example:
When the fuel tank is half full, an additional weight of 25 kg must
be placed in the luggage compartment.

CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC AG. 2009
Volksw➤
age,nPassat
AG do
Vari ...
Maintenance - Edition 11.2016 agen es n
olksw ot
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nl
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♦ For this purpose, a container filled with water or gravel can be
an
itte
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used, for example (a 5-litre fuel canister filled with water
erm
ab
weighs approx. 5 kg).
ility
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♦ Write the weight in kg on the container and secure it against
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being opened again in order to prevent misuse.
hole
spec
es, in part or in w
♦ In order to avoid soiling vehicle, place a mat or covering of
t to the co
some kind in the luggage compartment.
4.39.2 Checking headlight adjustment (using
rrectness of i
test screen without 15° setting line)
l purpos
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
cardiagn.com
o
r
♦ Vehicle diagnostic tester

rp
cu
o
m
f
en
ng
Light pattern for dimmed beam, version 1:

t.
yi Co
Cop py
ht. rig
Check the following: opy
rig by
Vo
ht
c lksw
by
cted agen
Prote
AG.
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

Light pattern for dimmed beam, version 2:

– 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 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.

4.39.3 Gas discharge headlights without “Dy‐

namic Light Assist” dynamic main beam
regulation: adjusting
Passat/Passat Estate 2006 ► ⇒ page 145
Passat/Passat Estate 2006 ►
Performing basic setting of headlight range control
ODIS Service
– Select “Headlight range control”.
– Select “Basic settings”.
cardiagn.com
– Follow instructions in “Guided
agen
AG. Vfunctions” mode.
olkswagen AG
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Adjusting right
au gas discharge headlight: ra
c
ss
ce
le
un
pt
an
d
itte
y li
♦ Lateral adjustment screw for bright/dark boundary (lead-

rm
ab
sealed for the NAR market) -3-

pe
ility
ot
wit
♦ Height adjustment screw of bright/dark boundary -2-

, is n
h re
hole
♦ Adjustment bolt for cornering light -1- (is preset at the factory,
spec
need not be adjusted)

es, in part or in w
t to the co
Note
rrectness of i
If the adjustment screw for cornering light was adjusted by mis‐

l purpos
take, set the inclination on the adjustment unit to 1.1 % to correct

the light settings.
nform
ercia
– First turn height adjustment bolt of bright/dark boundary -2-.

m
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com
tion in
– Then check lateral adjustment, if necessary correct with ad‐

r
te o
thi
justment screw -3-.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.40 Headlight adjustment: Checking gas

discharge headlights without DLA, Pas‐
sat CC and CC 2010►
Note

AG. Volkswagen AG d
♦ Instead, a different inclination setting on the headlight adjust‐ lkswagen oes
not
ment unit is used. Vo
db
y gu
ara
rise nte
ut
ho eo
ra
in the vehicle-specific maintenance list as of modelsyear
sa 2014. c
ce
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nl
pt
du
an
headlights are used. itte
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erm
ab
ility
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a separate charge.
wit
, is n
h re
hole
spec
es, in part or in w
cardiagn.com
t to the co
Checking headlight adjustment (SAE) ⇒ page 147
rrectness of i
Gas discharge headlights without “Dynamic Light Assist” dynamic
l purpos
nform
ercia
m
at
om
i
on
c
in t
or
his
ate
do
priv
c
um
for
completed. 1)
en
ng
t.
yi Co
op py
• The vehicle must be rolled forward and backward several me‐ t. C rig
gh ht
tres or front and rear springs must be bounced fully several pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
• Vehicle and headlight adjustment unit must be aligned.
lect it.
units .



Inclination setting for ECE-compliant gas discharge headlights,
LED headlights and DLA headlights
fuel gauge
0 to 1/2 1.0 %
1/2 to 1 1.0 %
Test pattern with dipped headlights

izontal light-dark border must be aligned with the dividing line
-1- of the test area.
cardiagn.com
Note

. Volkswagen AG
gen AG does
swa
Light pattern for dimmed beam, y V version 2:
olk not
gu
d b ara
e
Check the following: tho ris nte
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ss c
ce
le
un
pt
an
d
itte
test area
y li
erm
ab
ility
ot p
wit
is n
h re

ole,
spec
t to the co
Note
To simplify the determination of the breaking point -2-, cover and

rrectne
uncover left (from driver perspective) half of the headlight a few

times. Then check dipped beam again.
ss o
cial p
f inform

mer
atio
m

o
n
c
i
or
n thi

te
sd
iva
o
pr

cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
♦ Vehicle diagnostic tester rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
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h
ut ra
ss a c
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e
nl
♦ The lateral adjustment mechanism is sealed on SAE-compli‐
pt
du
an
ant headlights.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Inclination setting for SAE-compliant VOL gas discharge head‐
es, in part or in w
lights, LED headlights and DLA headlights
t to the co
fuel gauge
rrectness of i
0 to 1/2 0.7 %
l purpos
1/2 to 1 0.7 %
nform
mercia
at
VOL: Visual Optical Aim Left -1-
om
ion
cardiagn.com
c
in t
r
– Check whether the left horizontal light-dark border touches the

o
his
e
separating line -1- in the test area of the headlight adjustment

at
do
riv
unit.
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Inclination setting for SAE-compliant VOR gas discharge head‐

fuel gauge
0 to 1/2 0.0 %
1/2 to 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.

4.40.4 Gas discharge headlights without “Dy‐

namic Light Assist” dynamic main beam
regulation: adjusting
Note
wage
As of model year 2014 the headlight adjustment yV
ois subject to a
lks es n
ot g
separate charge. ir se
d b ua
ran
o tee
th or
au ac
Passat CC 2009 ►, CC 2010 ► ⇒ page ss 149
ce
e
nl
pt
CC 2012 ► ⇒ page 149
du
an
itte
y li
Passat CC 2009 ►, CC 2010 ►
erm
ab
ility
ot p
Performing basic setting of headlight range control
wit
, is n
h re
ODIS Service
hole
spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
l purpos

nform
ercia

m
at
om
ion
c
in t
r

o
his
ate
do
priv
cum
for
en
ng
t.
Adjusting right gas discharge headlight:
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Lateral adjustment screw for bright/dark boundary (lead- Prote
cted AG.
agen
sealed for the NAR market) -3-
♦ Height adjustment screw of bright/dark boundary -2-
♦ Adjustment bolt for cornering light -1- (is preset at the factory,
need not be adjusted)
Note
If the adjustment screw for cornering light was adjusted by mis‐

take, set the inclination on the adjustment unit to 1.1 % to correct
the light settings.
– First turn height adjustment bolt of bright/dark boundary -2-.

– Then check lateral adjustment, if necessary correct with ad‐
justment screw -3-.
CC 2012 ►

Overview of gas discharge headlights without “Dynamic Light As‐

sist” dynamic main beam regulation:
1- Bulb for left parking light - M1- or bulb for right parking light
- M3- based on LED technology
2- Bulb for front left turn signal - M5- or bulb for front right left
turn signal - M7-
3- Bulb for left cornering light - L148- or bulb for right cornering
light - L149-
4- LEDs for daytime driving light and dimmed for parking light
5- Left gas discharge lamp - L13- or right gas discharge lamp
- L14-
6- Side marker: either as screen; or US version of side marking
light SML based on LED technology and orange
Carrying out basic setting of headlight range control:
ODIS Service
wage
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es n
– Switch on ignition. y Volks ot g
ua
d b ran
– Carry out identification
oris
e
of vehicle. tee
th or
u
– Enter taskss data or select “Without task”.
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le

un
pt
an
d

itte
y li
rm
ab

pe
ility
ot
wit

, is n
h re
hole

spec
es, in part or in w
t to the co
Adjusting left headlight:

rrectness of i
1- Height adjustment
l purpos
2- Lateral adjustment
– Turn height adjustment screw -1- until setting is correct.
nform
mercia
a
com
ti
Note
on in
r
te o
thi
In some markets, the adjustment bolt for lateral adjustment is

s
iva
do
-2- encapsulated. Lateral adjustment is not permissible here.

r
rp
cum
fo
en
ng
t.
yi Co
– Turn lateral adjustment screw -2- until setting is correct. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
Note
cted agen
Prote AG.
♦ Adjustment of the right headlight is carried out in the same

sequence.
♦ The adjustment screws for the right headlight are a mirror im‐
age.

4.41 Headlight
agen
AGadjustment:
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Checking headlight adjustment (SAE) ⇒ page 153 thi
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Gas discharge headlights with “Dynamic Light Assist” dynamic

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• Vehicle and headlight adjustment unit must be aligned.
lect it.
units .



Inclination setting for ECE-compliant gas discharge headlights,
LED headlights and DLA headlights
fuel gauge
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 settings can only be reset using vehicle diagnostic
cardiagn.com
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 the headlights to ensure that they
do not dazzle other road users.
♦ In vehicles with DLA the dipped headlight setting can be
checked as an alternative. ⇒ page 152
♦ DLA: “Dynamic Light Assist”, dynamic
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The setup pattern only applies to the left headlight. The setup
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Inclination setting for SAE-compliant VOL gas discharge head‐
fuel gauge
0 to 1/2 0.7 %
1/2 to 1 0.7 %
Note

automatically.
♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation.


– Whether the horizontal light-dark border touches the separat‐
ing line -1- in the test area when the main beam is on.
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Inclination setting for SAE-compliant VOR gas discharge head‐

fuel gauge
0 to 1/2 0.0 %
1/2 to 1 0.0 %

Note

automatically.
♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation.

– Whether the horizontal light-dark border touches the separat‐
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ing line -1- in the test area when the main beam is on.
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4.41.4 Gas discharge headlights with “Dynamic

Light Assist” dynamic main beam regu‐
lation: adjusting
Note
As of model year 2014 the headlight adjustment is subject to a

separate charge.
Identification:
There is no external difference between headlights with “Dynamic
Light Assist” and headlights without DLA The production control
number 8G3 or 8IP means that the vehicle is equipped with DLA.
Overview of gas discharge headlights and “Dynamic Light Assist”
dynamic main beam regulation
1- Bulb for left parking light - M1- or bulb for right parking light
- M3- based on LED technology
2- Bulb for front left turn signal - M5- or bulb for front right left
cardiagn.com
turn signal - M7-
3- Bulb for left cornering light - L148- or bulb for right cornering
light - L149-
4- LEDs for daytime driving light and dimmed for parking light
5- Left gas discharge lamp - L13- or right gas discharge lamp
- L14-
6- Side marker: either as screen; or US version of side marking agen
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Carrying out basic setting of headlight range control: rise nte
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Adjusting left headlight:

1- Height adjustment
2- Lateral adjustment
– Turn height adjustment screw -1- until setting is correct.
Note
In some markets, the adjustment bolt for lateral adjustment is

-2- encapsulated. Lateral adjustment is not permissible here.
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– Check headlight setting.
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4.42 Headlight adjustment: Checking fog
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lights, Passat CC and CC 2010►
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Note

ment unit is used.
a separate charge.
Test and adjustment conditions ⇒ page 157

Check headlight adjustment ⇒ page 158 .
Adjusting fog lights and other additional lights ⇒ page 158 .


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4.42.2 Checking headlight adjustment
nform
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Inclination setting for fog lights C py
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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 lights of other systems must be checked
and set according to valid guidelines.
4.42.3 Adjusting fog lights and other auxiliary

lights
Note
As of model year 2014 the headlight adjustment is subject to a

separate charge.
Fog lights, Passat CC 2009 ►, CC 2010 ►, in front bumper, right:

⇒ page 159
Fog lights CC 2012 ► in front bumper, right: ⇒ page 159
Other additional lights ⇒ page 159

Fog lights, Passat CC 2009 ►, CC 2010 ►, in front bumper, right:

age.
– To adjust the headlight range turn adjustment screw
-arrow A-.
Fog lights CC 2012 ► in front bumper, right:
age.
– Turn adjustment screw -arrow- to adjust beam range.

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Other additional lights

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4.43 Window wash/wipe system and head‐ ss
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Checking anti-freeze protection of fluid, topping up fluid
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⇒ page 159
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Window wash/wipe system: check spray jet settings and adjust
hole
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Headlight washer system: check spray jet settings ⇒ page 163
Wiper blades: check park position. ⇒ page 163 rrectness of i
Rear window wiper blade: check park position. ⇒ page 163

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4.43.1 Checking anti-freeze protection of fluid,

topping up fluid if necessary
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♦ Refractometer - T10007 A-
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Note
In countries and regions where no frost occurs due to the local

climatic conditions, the anti-freeze protection does not need to be
checked.
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
– Check concentration of anti-freeze additive using refractome‐
ter - T10007 A- .
The scale -4- of the refractometer is applicable for the anti-freeze
protection of the window wash/wipe system.
Mixing ratio:
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spec
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Use genuine washer fluid ⇒ ETKA throughout all year to fill win‐
dow wash/wipe system.
rrectne
Depending on season, a winter product with anti-freeze protection

or a summer product with increased cleaning capabilities should
be used.
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Note
♦ Genuine washer fluid ⇒ ETKA prevents the spray jets, washer

fluid reservoirs and connecting hoses from freezing.
♦ In vehicles with fan jets, the reservoir must be filled with Gen‐
uine washer fluid, as this fluid has a low viscosity at tempera‐
tures below freezing. Otherwise the swa
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4.43.2 Window wash/wipe system: checking
cardiagn.com
spray jet settings and adjusting if nec‐
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essary
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♦ Adjusting tool - T40187-
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♦ Adjusting tool - T10564-
Note
If the spray field is uneven due to soiling in the spray jet, remove
spray jet, and rinse with water opposite to direction of spray. Sub‐
sequent blowing through with compressed air against the spray‐
ing direction is permitted. Never use solid objects to clean the
washer jets!

Windscreen spray jet settings Passat:

The spray jets are preset. However, small differences in height
may be corrected.
– If both spray fields are not at same height, adjust spray direc‐
tion upwards or downwards as follows:
1 - Cowl panel in front of windscreen
2 - Adjusting tool
3 - Fan jet
4 - Bonnet
cardiagn.com
– Adjust the spray jet -3- by turning the adjuster -2- using a
screwdriver.
♦ “Clockwise” lower.
♦ “Anti-clockwise” higher.
Windscreen spray jet settings CC:
– Adjust jets according to this pattern. Values for spray jets are
given in “mm” and serve as a means of orientation.
– Dimensions can be mirrored and therefore apply to driver and
front passenger side. agen AG. Volkswagen AG do
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Rear window spray
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– Adjust spray jet using adjusting tool - T10564- or adjusting tool

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- T40187- so that the water jet sprays onto the upper third of
rear window.
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4.43.3 Headlight washer system: Checking

spray jet settings
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Checking washer spray jet settings
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– Operate windscreen washer system.
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The headlights are washed if the windscreen wiper lever is hold
in “Wipe position” for at least 1.5 seconds.
The washer jet must spray to centre of headlights, see -B- and
rrectne
-C-.
If spray pattern deviates from specifications, carry out repair
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4.43.4 Wiper blades: Check park position
atio
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Procedure for CC:
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⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system;

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Adjusting windscreen wiper arms
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Adjusting wiper blade park position
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Note
♦ Adjusting the wiper blades is a repair measure.

♦ The repair measure is carried out subject to a separate charge.
4.43.5 Rear window wiper blade: Checking

park position
Procedure for Passat:
⇒ Electrical system; Rep. gr. 92 ; Rear window wiper system;
Adjusting rear window wiper park position
Note
♦ Adjusting the wiper blades is a repair measure.

♦ The repair measure is carried out subject to a separate charge.
4.44 Wiper blade protection: removing
Note
There are 3 different versions of wiper blade protection:

Version 1: blade protector with 2 securing clips

♦ Identification, blade protector with two securing clips
-arrows 1 + 2-.
Removing wiper blade protection, version 1 ⇒ page 164
Version 2: blade protector to slide on

♦ Identification, the blade protector -arrow- is slid on the wiper
blade.
Removing wiper blade protection, version 2 ⇒ page 165
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Version 3: transport wiper blade auth or
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deflector, it must be replaced by the standard wiper blade.
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Changing wiper blade protection, version 3 -transport wiper
ab
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blade- ⇒ page 166
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4.44.1 Removing wiper blade protection, ver‐

sion 1
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– Switch ignition on and off briefly with bonnet closed.

m
at
om
io
– When engine is switched off move wiper lever down to touch-

n
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ate
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The wiper blades move to the service position.

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– Lift the wiper arm away from windscreen.

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Caution p by
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When doing this, do not touch the wiper blade to prevent dam‐
age.

– Remove upper securing clip upwards and lower

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– Pull blade protector off wiper blade from bottom to top, as
shown in illustration.
rrectness of i
– Carefully place wiper arm back onto windscreen.
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– Switch ignition on and briefly operate the wiper lever to move

the wipers back to park position. Switch ignition off again.
nform
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4.44.2 Removing wiper blade protection, ver‐
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Caution
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– Pull blade protector off wiper blade upwards, as shown in il‐

lustration.

4.44.3 Changing wiper blade protection, ver‐

sion 3 -transport wiper blade-
– Depending on version, turn wiper blade with lip upwards, and

pull it off. Or release wiper blade at joint -3- by pushing locking
device -1- into mounting -2-, and pull out wiper blade. agen AG. Volkswagen AG do
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4.45 Service interval display: Recode
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Recoding from flexible to fixed intervals

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– Select “Change flexible/fixed intervals”.
AG.
– Carry out adaptation according to the information of “Guided functions”.
Changing values for maximum distance to be driven (km) until

next oil change service (fixed) during delivery inspection
ODIS Service

AG. Volkswagen AG d
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– Select “Oil change service (fixed)”.
spec
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– Reset “-1- Oil change service (fixed)”.
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The current values for maximum distance to be driven (km) until next oil change service are shown in the
l purpos
display of the vehicle diagnostic tester .

– Select “No”.
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– Select value for maximum distance to be driven until next oil change service, according to specifications
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4.46 Service interval display: Reset
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Additional information for service interval display ⇒ page 11
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Resetting SID using vehicle diagnostic tester . ⇒ page 168
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Resetting SID without vehicle diagnostic tester . ⇒ page 168
The service interval display must be reset (adapted) during
♦ Delivery inspection
♦ Every inspection service (only vehicles ►2004), oil change
service and interval service
♦ each oil change (flexible/fixed)
is carried out!
Until now, only service events linked to oil changes could be dis‐
played in the service interval display. Service stickers have been
used for all other service events.
Model year Service interval display for oil Service interval display for inspec‐
change service / interval service tion service (channel 2)
(channel 1)
►2013 Yes No
From model year 2014, a second service channel is provided so

that both service events, even those not linked to an oil change,
can be conveniently displayed.
Model year Service interval display for oil Service interval display for inspec‐
change service (flexible/fixed) tion (channel 2)
(channel 1)
2014► Yes Yes

Note
It is also possible to reset the service interval display (SID) man‐

ually. However, bear in mind that, on vehicles coded to flexible
interval, the SID needs to be coded to fixed intervals. This also
modifies the adaptation channel for oil quality.
4.46.1 Resetting service interval display using vehicle diagnostic tester

ODIS Service
– Select the respective service which is to be reset.
cardiagn.com
4.46.2 Resetting service interval display with‐

out vehicle diagnostic tester
Up to ►2013 ⇒ page 168 AG. Volkswagen AG d
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With rocker switch on windscreen wiper lever or using buttons in

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the multifunction steering wheel

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– Select menu “Settings” using rocker switch on windscreen

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– Select menu “Settings” using buttons in the multifunction

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steering wheel.
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– Mark menu option “Reset” in sub-menu “Service” and reset

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service interval display by pressing OK button -1- on wind‐

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screen wiper lever or on multifunction steering wheel -5-.

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With function buttons on dash panel insert
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– With ignition switched off, press button -3- and hold.
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– Release button -3- and press clock setting button -1- briefly.
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The service interval display is now in the resetting mode.
es, in part or in w
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After a short time the display switches back to the original display.
Applies as of 2014►
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Resetting oil change service interval display:
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– With ignition switched off, press and hold button -3-.
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– Switch on ignition. m
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– Reset oil change service information by pressing OK button

-5- on multifunction steering wheel or OK button -1- on wind‐
screen wiper lever.
Resetting inspection service interval display:
– Switch on hazard warning lights.

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– With ignition switched off, press and hold button -3-. aut or
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– Release button -3-.
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– Reset inspection service interval display by pressing OK but‐
ton -5- on multifunction steering wheel or OK button -1- on
windscreen wiper lever.

4.47 Sunroof: Checking function, cleaning

and greasing guide rails
– Check function of sunroof.
– Clean guide rails -arrows- and grease with special grease G
060 751 A2.
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4.48 Sliding sunroof drains: Checking for

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blockage, cleaning if necessary

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♦ Cleaning and insertion aid - VAS 6620- h re

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– Open sliding sunroof.

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– Check sliding sunroof drain holes -arrows- for dirt and clean if
necessary.
– Pour 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 water at all flows out of the wheel housings, perform
the following procedure:
– Removing plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 64 ; Flush bonded windows; Assembly over‐
view - plenum chamber cover
Note AG. Volkswagen AG d

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– Remove cover -1- by loosening fasteners -A and B-.
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– To press out dirt, guide cleaning and fitting tool - VAS 6620-
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onto drain valves by pushing and pulling it slowly.
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the plenum chamber.
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– To check, pour tap water
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4.49 Track rod ends: check clearance, firm

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seating and boots

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– With vehicle raised (wheels hanging free), check clearance by

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moving track rods and wheels. Clearance: zero clearance
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– Check attachment. yri
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– Check that boots -arrow- are not damaged and are seated
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correctly.

4.50 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 agen
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– Wipe off excess universal oil with a cloth.
h re
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spec
– Then, lubricate door arrester rollers with lubricating paste - G

000 150- at positions marked with an -arrow-.
t to the co
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4.51 Transportation mode: switching off

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♦ The transportation mode is responsible for assuring the start‐
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ing capability of vehicle.
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♦ Battery discharging is reduced by the transportation mode,

because electrical consumers are switched off.
♦ All vehicle functions which are not necessarily used during
vehicle transportation and require no-load voltage or battery
capacity are switched off with the activated transportation
mode, with regard to the service life of battery.
♦ These are especially all functions in the vehicle which can re‐
duce the battery capacity when being misused.
♦ Examples are radios, electronically operated flaps and attach‐
ments and anti-theft alarm systems which can produce faults
during transportation.
Procedure
Note
If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnostic tester
ODIS Service
– Connect vehicle diagnostic tester ⇒ page 32 .

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– Select “Identify control unit”.
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– Select “Switch transportation mode off/on”.
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4.52 Transport locks: Remove blocking
nf
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pieces from springs on front axle
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Blocking pieces are fitted to front axle springs of vehicles with

o
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sports running gear. These vehicles are identified by a warning

or
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tag on the mirror -arrow-.

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transporter or railway wagon.
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WARNING
The blocking pieces must be removed without reservation be‐

fore delivering the vehicle. A “Warning” notice, attached to the
interior mirror, specifically reminds of this.
Note
♦ There is no requirement to remove the wheels.

♦ Ensure that the surface of the springs is not damaged.
– Relieve weight on springs by raising vehicle with a hoist.
– Push blocking piece -arrow- off coil spring.

4.53 Underbody: visual check for damage to

underbody sealant, underbody panels,
routing of lines, plugs
During visual check, also check floor pan, wheel housings and
sills.
Always ensure that all lines are secured in their mountings, all
plugs are available and that there is no visible damage on the
underbody.
Note
Faults found must always be rectified (repair measure). This in‐

hibits corrosion and rusting through.
4.54 Clock: Set to correct time

Setting clock via dash panel insert: Passat 2006►
– Press the left button -1- to set the hours. Press the button only
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briefly to advance the time one hour. gen AG
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– Press the right button -2- to set the minutes. Press the
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Setting clock via dash panel insert: Passat 2009►
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– Press button -1- to activate hours display.
– Now press button -2- to set correct hour.
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– Repeat same process to set minutes.
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Setting clock using buttons on multi-function steering wheel: Pas‐

sat 2006►
– Press button -1- until menu “Settings” appears.
– Then select menu option “Time” with buttons -2- and -4-.
– Confirm the selection with button -3-.
– When “Hours” is marked, the marked menu option is found
between the two horizontal lines, confirm with button. V-3- and
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– The menu can be closed withs button -1-.
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– Press button -5- to activate multi-function display.
spec
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– Press button -2- repeatedly until “Settings” menu is displayed,
t to the co
and confirm with button -5-.
– Now select “Time” option.
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– Use button -1- to select “Hours” and confirm with button -5-.
s
– “Hours” can now be set with buttons -2- and -4- and then con‐
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firmed with button -5-.
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– Also repeat this with the “Minutes”.
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– Button -3- returns you to the “Main menu”.

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Setting clock using buttons on windscreen wiper lever

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– Press button -2- to select the menu “Time” and confirm using
button -1-.
– Now mark menu item “Hours” by pressing button -1-, set cor‐
rect hour using button -2- and confirm with button -1-.
– For the menu option “Minutes” it is the same procedure.
– The menu “Settings” can be closed via the menu option “back”.
– Now select “MFI” for actual display and confirm this using but‐
ton -1-.
Note
Note that summer and winter time must be set on each ignition
key. The season setting can be found in the clock menu in the
multi-function display.

4.55 Camshaft drive toothed belt: renewing

(diesel engines)
TDI common rail engines:
– ⇒ 4-cylinder injection engine (1.6 l and 2.0 l, 4V, direct injec‐
tion engine, turbocharger); Rep. gr. 15 ; Toothed belt drive;
Removing and installing toothed belt .
4.56 Toothed belt and toothed belt tensioning

roller: renewing (TDI unit injector)
Note
Generally it is not necessary to renew the toothed belt before the

actual change interval is reached. Especially cracks on the belt
side are not relevant for service life and cannot be covered by
goodwill or warranty processing.
– Removing and installing toothed belt, »power unit« ⇒ Power

unit; Rep. gr. 15 ; Cylinder head, valve gear/Removing and
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4.57 Camshaft drive toothed belt: renewing au
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Generally it is not necessary to renew the toothed belt before the

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actual change interval is reached. Especially cracks on the belt

spec
side are not relevant for service life and cannot be covered by
es, in part or in w
goodwill or warranty processing.

t to the co
– Removing and installing toothed belt, »power unit« ⇒ Power

rrectness of i
unit; Rep. gr. 15 ; Cylinder head, valve gear/Removing and

installing toothed belt » Cylinder head, valve gear/Removing
l purpos
and installing toothed belt«.
4.58 Camshaft drive toothed belt: checking

nform
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(1.6 l, 4-cyl. petrol engines)

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4.58.1 Checking condition of toothed belt

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– Remove toothed belt cover »4-cylinder injection engine« ⇒ 4-

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cylinder injection engine; Rep. gr. 15 ; Removing and installing
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cylinder head »Removing and installing cylinder head«.
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– Turn crankshaft at least one full turn and check toothed belt
condition on following points:
♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
♦ -C- Fraying of cord strands
♦ -D- Cracks (in teeth base)
♦ Layer separation (toothed belt body, tensile cords)
♦ Surface cracks (synthetic coating)
Note
If faults are found, always renew toothed belt. This can avoid
breakdowns and malfunctions. The replacement of a toothed belt
is a repair measure.
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4.59 Camshaft drive toothed belt: Checking
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♦ Engines without prescribed toothed belt change interval can

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be found in service tables ⇒ page 11 .

spec
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4.59.1 Checking condition of toothed belt

Procedure
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– Move clear hoses at retainer -3-.

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– Unscrew bolt -2-.

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– Release clips -arrows-, and detach upper toothed belt guard

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– Turn crankshaft by the bolt of the crankshaft toothed belt in the

direction of the engine and check the entire toothed belt for the
following:
♦ Cracks, cross-sectional breaks, cracks (coating) -arrow-
♦ Side contact
♦ Cracks (in teeth base) -arrow-
Note
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Assemble in reverse order of dismantling.
Specified torque Nm
Bolt for toothed belt guard 8
4.60 Coolant pump toothed belt: Checking

Procedure
– Release hose clips -1 and 2-, and remove air intake pipe.
– Move clear air intake hoses at air intake pipe. n AG. Volkswagen AG do
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– Disconnect electrical connector -1-.

– Release catches -arrows- and remove air pipe.
– Press release tabs, and disconnect hose -1- for activated
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charcoal filter.
– Unscrew bolts -arrows-, and detach crankcase breather hose.
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♦ Risk of chemical damage to the coolant pump gasket caused
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♦ If one or both O-rings are damaged, renew crankcase breather

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♦ Moisten new O-rings with engine oil when installing.

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spec
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t to the co
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1 and 3-, and detach guard -2- for toothed belt
rrectness of i
for coolant pump.

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– Turn crankshaft by the bolt
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direction of the engine and check the entire toothed belt for the
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following:
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♦ Cracks, cross-sectional breaks, cracks (coating) -arrow-
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♦ Cracks (in teeth base) -arrow-
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Assemble in reverse order of dismantling.
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Specified torque yri
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Bolt for toothed belt guard 8
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Bolt for crankcase breather 9
4.61 Spark plugs: renewing

Renewing spark plugs, 1.4 l TSI engines ⇒ page 184
Renewing spark plugs, 1.6 l indirect inj. engine ⇒ page 190
Renewing spark plugs, 1.6 l FSI engine ⇒ page 194 .
Renewing spark plugs, 1.8 l TSI; 2.0 l FSI; 2.0 l TFSI; 2.0 l TSI
engines ⇒ page 191 .
Renewing spark plugs, 6-cylinder FSI engine ⇒ page 195 .
♦ Spark plug socket and extension - 3122 B-

♦ Puller - T40039-
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♦ Puller - T10112-
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♦ Puller - T10094 A-
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4. Descriptions of work:
♦ Assembly tool - T10118-
♦ Puller - T10095 A-
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Version 1
Removing:

– Disengage clamps of cable guide -arrows-.

– Remove hoses -1- and -2-.
Note
♦ When pulling out the ignition coils with output stages, the wires
or 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.
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– 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- .
Note
♦ Spark plug designation and specified torque: »Power unit« ⇒

Power unit; Rep. gr. 28 ; Test data, spark plugs »Test data,
spark plugs«.
– Seat puller - T10094 A- on ignition coil with output stage.

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– Secure clips of line guide -arrows-.

– Connect hoses -1- and -2-.
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– Install engine cover panel ⇒ page 100 .

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Note
To simplify removing and installing spark plugs, loosen some

components and place them to side.
– Pull off connector -2-.

– Pull off hose end -3-, (press together to release).
– Unscrew bolts -1-.
– Raise hose with bracket and charge pressure control solenoid
valve and place to side.

– Disengage clamps of cable guide -arrows-. agen

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– Seat puller - T10094 A- on ignition coil with output stage.
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– Unscrew spark plugs using spark plug socket and extension - Prote AG.
VAS 3122B- .
Installing:
Note


– Screw in new spark plugs using spark plug socket and exten‐
sion - VAS 3122B- .
Note
♦ Spark plug designation and torque setting: »Power unit« ⇒

Rep. gr. 28 »Repairing ignition system/test data«.
– 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 connector -2-.
– Connect hose end -3-.
Version 3
Applicable for engine code CZDA only
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– Disconnect electrical connector -2-.

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– Unscrew bolt -1-.

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– Push puller - T10530- as far as stop into hole in ignition coil

-1-.
– Tighten knurled nut -2- in -direction of arrow-.
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♦ Ensure that the cables are not kinked or damaged.
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– Screw in new spark plugs and tighten them to specified torque
using spark plug socket - 3122 B- ⇒ page 190 .
– Align and insert all ignition coils with output stage one after
another loosely into spark plug hole.
– Press ignition coils with output stage onto spark plugs evenly
by hand (do not use any tools).

– Tighten bolt -1- of ignition coil with output stage to specified

torque ⇒ page 190 .
– Connect electrical connector -2-.
Repeat step for all ignition coils with output stage.
– Fit air pipe.
– Fit hose clips -1- and -2-.
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– Pull off injector connectors of first and fourth cylinder.

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– Pull off spark plug connectors using puller - T10112- .

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3122 B- .
Note
♦ Spark plug designation and torque setting: »Power unit« ⇒

Rep. gr. 28 »Repairing ignition system/test data«.
Installing:
sion - 3122 B- .
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– Fit spark plug connectors using puller - T10112- .
– Fit connectors of injectors.
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4.61.3 Renewing spark plugs, 1.8 l TSI; 2.0 l

spec
FSI; 2.0 l TFSI; 2.0 l TSI engines

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The spark plugs are located below the ignition coils with output
stages -2-.
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Note installation position of ignition coils with output stages.
– Pull all ignition coils out of cylinder head approx. 30emm

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♦ Spark plug designation and specified torque, »Power unit« ⇒

spark plugs«.
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– Insert ignition coils with output stages into cylinder head.

– Align ignition coils with output stages in respective recesses
of cylinder head cover.
– Fit all connectors onto ignition coils -arrows-.
– Press ignition coils with output stages on spark plugs until stop
by hand. They must be felt to engage.
– Install engine cover panel.

4.61.4 Renewing spark plugs, 1.6l petrol direct

injection engines
Removing
– Place puller - T10094 A- on ignition coil with output stage
-arrow-.
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as illustrated.
– Release connection locking device carefully and pull off con‐
nector.
– Pull out ignition coil with output stage. AG. Volkswagen AG d
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– Place 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 -arrow- into cylinder head.
4.61.5 Renewing spark plugs, 6-cylinder FSI

engines
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– Press ignition coils with output stage onto spark plugs.

– Slide connectors onto ignition coils with output stage until they
can be heard to engage.
4.62 Compass module: Activating

To activate the compass module the rear window heating must
be learnt as follows:
• Activation must be performed when the engine is not running.

– Wait 10 seconds.
– Switch on rear window heating.
– Wait 10 seconds.
– Switch off rear window heating.
4.63 Static cornering light (cornering light)

and driving light assist: Check function
4.63.1 Checking static cornering light (corner‐

ing light)
The static cornering light is integrated in the headlights.
• Prerequisite: vehicle stationary, steering in straight-ahead po‐
sition
– Switch on ignition and dipped beam or driving light assist.
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– Turn steering wheel from straight-ahead position one turn Vol to
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The rain and light sensor -G397- is secured on the interior rear
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– Turn light switch -4- to position O -1- and switch off ignition.
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4.64 All-wheel drive coupling: Change oil
Note
♦ On vehicles with all-wheel drive coupling the drain plugs and

sealing plugs of both systems are often interchanged owing to
the integrated housing construction of all-wheel drive coupling
and final drive. Caution must be exercised during maintenance
and servicing as incorrect 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
Further information on arrangement of plugs ⇒ TPI 2017008

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♦ Temperature gauge - VAS 6519-
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♦ -VAS 6291 A-

♦ Adapter for oil filling - VAS 6291/1-
♦ Drip tray for workshop hoist - VAS 6208-
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– Screw in new oil drain plug with new seal and tighten it to
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Filling with oil

– Remove oil filler plug -1-.
– Separate angled piece -B- from adapter -A- and screw adapter
fully in oil filler hole.
– Reconnect angled piece and route hose above drive shaft to
prevent sagging.
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Oil capacity and oil specification ⇒ page 201
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– Screw oil container -A- onto charging device -VAS 6291 A-

with valve closed -arrow-.
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– Open valve -arrow- and hold oil container as shown in the il‐
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– Fill enough oil in system with charging device -VAS 6291 A-

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Specified torque Prote AG.
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 be ensured by running gear‐
box warm or allowing it to cool down.
Oil capacity and oil specification
Oil capacity, Passat 2006 ► ⇒ Propshaft and rear final drive; Rep. gr. 00 ; Identification code, assembly
4Motion allocation and capacities, Passat 2006 ►
Passat CC, CC ⇒ Propshaft and rear final drive; Rep. gr. 00 ; Identification code, assembly
2010 ► 2012 allocation and capacities, Passat CC, CC 2010 ►
CC 2013 ► ⇒ Rear propshaft and final drive; Rep. gr. 00 ; Technical data; Capacities
Oil specifica‐ ⇒ Electronic parts catalogue (ETKA)
tions
4.65 Front and rear final drive: checking oil

level
Procedure:»Power transmission; final drive« ⇒ Power transmis‐
sion; final drive; Rep. gr. 39 ; Checking gear oil level in rear final
drive »Checking gear oil level in rear final drive«
Procedure:»Power transmission« ⇒ Power transmission; Rep.
gr. 34 ; Checking oil level in front bevel box »Checking oil level
in front bevel box«

4.66 Auxiliary heater: Setting weekday in

menu of dash panel insert
As the weekday in the menu for the auxiliary heater is not part of
the time and date setting for the dash panel insert, it must be set
separately.
Setting weekday using buttons on multifunction steering wheel
– Press button -1- until the menu for auxiliary heater appears.
– Press button -4- until “Weekday” is shown and select using
button -3-.
– Now set weekday using buttons -4- and -2-, and confirm with
button -3-.
– Exit menu using button -1-.
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Setting weekday using buttons on windscreen wiper lever

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– Follow same path through menu as followed using buttons on
erm
ab
multifunction steering wheel.
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4.67 Multi-purpose additive for petrol fuel:
inform
mer
Add atio
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Note
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♦ Applies only to Chinese, Russian and Indian markets

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♦ Use only additives satisfying the standards VW 507 53 A or
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VW 507 53 B.
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♦ Observe the dosing instructions on the additive container.
cted agen
Prote AG.
♦ After adding the additive, always recommend that the custom‐

er fill up the tank completely in order for the additive to be the
most effective.
– Fill multi-purpose additive for petrol fuels into regular fuel tank
during each service.
China Russia India
– Use VW 507 53 B for all petrol – Use VW 507 53 B for all petrol – Use VW 507 53 B for all petrol
engines, including CNG and engines, including CNG and engines, including CNG and
MultiFuel (E85) engines. MultiFuel (E85) engines. MultiFuel (E85) engines.
– Use VW 507 53 A: for all petrol – Use VW 507 53 A: for all petrol
engines, excluding CNG and engines, excluding CNG and
MultiFuel (E85) engines. MultiFuel (E85) engines.

China Russia India

♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001
780-M3- 780-M3- 780-M3-
♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001
770-A2- 770-A2-
– Observe dosing instructions on – Observe dosing instructions on – Observe dosing instructions on

additive container. additive container. additive container.
4.68 Memory seat: Perform initialisation

All memories and settings will be cleared during the initialisation
process. The memory buttons can then be reprogrammed and
resynchronised with a remote control key.
– Open driver door.
– Move the backrest as far forward as it will go.
– When the backrest is fully moved forwards, release switch and
operate again until a gong signal sounds after a few seconds.
cardiagn.com
4.69 Checking diesel particulate filter
Note
When checking the diesel particulate filter the ash mass limit val‐
ue is read.
ODIS
agenService
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– Connect vehicle diagnostic tester ⇒ page ed by 32 .
V gu
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– Switch on ignition. ut
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– Deselect “Work with guided fault finding”.

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– Select “Identify control unit”.

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– Select “Check ash mass of diesel particulate filter”.

t to the co

rrectne
4.70 Automatic gearbox: Change ATF

ss o
cial p
f in
– Change ATF: »Power transmission« ⇒ Power transmission;

form
mer
Rep. gr. 37 ; Draining and filling ATF »Draining and filling

atio
ATF«
om
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Note
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In particularly hot climates, a transmission fluid change of the

t.
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gearbox must be performed. The transmission fluid wear in these C py
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climatic conditions is especially high. All affected countries are
gh ht
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listed in the table below.
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Prote AG.

Countries with hot climate

Afghanistan Egypt Algeria
Angola Equatorial Guinea Ethiopia
Australia Bahrain (AGCC) Benin (Dahomey)
Botswana Brunei Burkina Faso (Upper Volta)
Burundi Brazil Dem. Rep. Congo
Djibouti China Ivory Coast
Eritrea Dubai (AGCC) Gambia
Ghana Gabon Guinea-Bissau
India Guinea Iraq
Iran Indonesia / (Borneo) Japan
Yemen (AGCC) Israel Cameroon
Qatar (AGCC) Jordan Congo
Kuwait (AGCC) Kenya Lebanon
Liberia Lesotho Madagascar
Malawi Libya Mali
cardiagn.com
Morocco Malaysia Mauritius
Mexico Mauritania Namibia
Niger Mozambique Oman (AGCC)
Palestine Nigeria Rwanda
Zambia Puerto Rico Senegal
Sierra Leone Saudi Arabia (AGCC) Singapore
Somalia Zimbabwe Sudan
Swaziland South Africa Tanzania
Thailand Syria Chad
Tunisia Togo AG. Volkswagen AG d Uganda
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Central African Republichorise
United Arab Emirates / Abu Dhabi ntee
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ac
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4.71 Reducing agent (AdBlue®/DEF): Re‐

erm
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Note
es, in part or in w
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To prevent the descriptions from becoming unclear, the “NOx re‐

ducing agent AUS 32” (AdBlue®) is merely called reducing agent
rrectness of i
(AdBlue®/DEF) in the following texts.

l purpos
Caution
nf
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orm
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atio
Only the reducing agent (AdBlue®/DEF) can be used in Blue

om
n in
TDI vehicles. NEVER fill in additive which has been used in the
or c
thi
past. It can destroy the reducing agent.

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Note
♦ The following description applies to diesel vehicles with SCR

process (selective catalytic reduction).
♦ Additional information on the SCR process and reducing agent
(AdBlue ®) can be found in the glossary ⇒ page 225
General notes ⇒ page 205

Health/endangerment and cleaning ⇒ page 207
Disposal instructions ⇒ page 207
Work preparation for filling reducing agent tank ⇒ page 208
Filling reducing agent tank ⇒ page 208
Work after filling reducing agent tank ⇒ page 209
♦ Filling device for AdBlue - VAS 6960-
cardiagn.com
AG. Volkswagen AG d
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4.71.1 General information
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Characteristics
♦ The reducing agent (AdBlue®/DEF) is not a diesel additive and rrectne
must not be poured into the diesel fuel tank.
ss o
♦ The reducing agent (AdBlue®/DEF) is used for exhaust treat‐

cial p
f in
ment to reduce nitrogen oxides in the exhaust gas of diesel

form
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powered vehicles.
atio
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♦ The reducing agent (AdBlue®/DEF) reduces these nitrogen

o
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c
i
or
oxides to water and nitrogen.

thi
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♦ The reducing agent (AdBlue®/DEF) is a high-purity 32.5%

i
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urea solution and is used in systems with exhaust treatment

en
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(SCR catalytic converters) ⇒ page 225 for diesel engines.
yi Co
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♦ The reducing agent (AdBlue®/DEF) is legally required for op‐
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erating vehicles with SCR.
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Prote AG.
♦ AdBlue® is a registered trademark of the Verband der Auto‐
mobilindustrie e. V. (VDA) in the USA, Germany, the European
Union and other countries.
Application
♦ Do not mix additives with reducing agent (AdBlue®/DEF).
♦ Do not dilute the reducing agent (AdBlue®/DEF) with water.
♦ Do not use fluid which has already been used.

♦ Use only reducing agent (AdBlue®/DEF) in the intended, orig‐

inal containers. Also note the expiry date information.
♦ Additionally note the reducing agent manufacturer's usage
and storage instructions.
Technical data
♦ “NOx reducing agent AUS 32” is the designation 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 reducing agent tank has a capacity of approx. 16 litres.
♦ The part numbers for available sizes of containers is available
in ⇒ ETKA .
Insufficient reducing agent
lkswagen AG
If the level of reducing agent is low, one of the following messages agen
AG. Vo does
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appears on the dash panel insert: yV
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♦ From a remaining distance of 2400 km, a gong sounds and tho
r eo
“Top up AdBlue (DEF)!” is displayed“ Remaining distance s au ra
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2400 km”. s
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♦ From a remaining distance of 1000 km, a warning buzzer
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sounds and “Top up AdBlue (DEF)!” is displayed“ No engine
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starting in 1000 km”
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♦ From a remaining distance of 0 km, a warning buzzer sounds
h re
three times and “Top up AdBlue (DEF)!” is displayed“ Engine
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start no longer possible is shown.”
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Note
rrectness of i
In order to be able to restart the engine, the tank for reducing
l purpos
agent must be replenished with a minimum of 5.7 litres of reducing

agent (AdBlue®/DEF).
nform
ercia
System malfunction or incorrect filling

m
at
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ion
c
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or
Caution
his
ate
do
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The vehicle is damaged by filling with reducing agent (AdBl‐

um
for
en
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In case of system malfunction or incorrect filling, one of the fol‐
o Vo
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lowing messages appears on the dash panel insert: Prote AG.
♦ From a remaining distance of 1050 km, “Check AdBlue

(DEF)!” is displayed“ Remaining distance 1050 km”.
♦ From a remaining distance of 1000 km, a warning buzzer
sounds and “Check AdBlue (DEF)!” is displayed“ No engine
start possible in 1000 km”.
♦ From a remaining distance of 0 km, a warning buzzer sounds
three times and “Check AdBlue (DEF)!” is displayed“ Engine
start no longer possible”.

WARNING
♦ As soon as “Check AdBlue!” appears:“ No engine start

possible! ” is displayed and the engine is switched off; the
engine cannot be started again.
– Fault recovery ⇒ Guided fault finding
4.71.2 Health risk and cleaning
WARNING
♦ AdBlue®/DEF is corrosive and an irritant that can cause

injury on contact with the skin, eyes and respiratory or‐
gans.
♦ In the event of AdBlue®/DEF coming into AG. Vo agen AG lksw
ksw contact with the
agen does
not
eyes and skin, wash off immediately V with plenty of water
ol
by gu
ara
for at least 15 minutes and seek
orise medical assistance.
d
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ut
♦ In the event of skin contact
a with this fluid, immediately ra
cardiagn.com
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wash off with plenty of water.
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♦ In the event of AdBlue®/DEF ingestion, rinse out the

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mouth immediately with plenty of water for at least 15 mi‐
ab
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nutes. Do not induce vomiting unless instructed to do so
ot p
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by a doctor. Seek medical assistance without delay.
is n
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spec
t to the co
Caution
Never allow reducing agent (AdBlue®/DEF) to come into con‐
rrectne
tact with trim or body parts.
If this happens, wash off the reducing agent (AdBlue®/DEF) ss o
cial p
f
with clear water and wipe area with a lint-free cotton cloth.
inform
mer
If the reducing agent (AdBlue®/DEF) has already crystallised,

atio
use warm water and a sponge.

om
n
c
i
or
Residual reducing agent that is not removed crystallises after

thi
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a while and can damage the surfaces affected.

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4.71.3 Disposal instructions Cop py
t. rig
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pyri by
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Caution
cted agen
Prote AG.
Information reference for storage and disposal ⇒ InfoNet, Op‐

eration, Strategy and deadlines, Environment, Handbook
Service Environmental Protection ! Ask your importer about
country-specific information on storage and disposal.
The refill container must be disposed of in accordance with
environmental regulations.

4.71.4 Work preparation for filling reducing

agent tank
Note
Ensure that vehicle stays on an even ground.
The filler opening for the reducing agent tank is located under the
floor covering in the luggage compartment. olks
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– Raise floor covering -1- and push it back orrishook
ed it in. nte
tho eo
– Remove spare wheel -2-, if available, sby
s a unscrewing wing nut
u ra
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-3-.
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– Remove foam part, if fitted.
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t to the co
rrectne
– Remove tank filler neck sealing plug -1-.
ss o
cial p
f inform
mer
atio
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c
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4.71.5 Filling reducing agent tank
cted agen
Prote AG.
Procedure
Note
♦ Refer to the ⇒ Operating manual for the filling device for AdBl‐
ue - VAS 6960- .
♦ Use only demineralised water for cleaning any components of
the AdBlue®/DEF system. Do not use tap water for this.

– Open tank cap in luggage compartment -1-.

– Clean reducing agent tank 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.
4.71.6 Work after filling reducing agent tank

– Screw in tank cap -1- of tank filler neck until it engages.
cardiagn.com
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– Carefully insert sealing plug -1-.

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es, in part or in w
t to the co
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nform
mercia
at
om
ion
c
in t
or
– Install spare wheel -2- (if available), tightening wing nut -3-
his
ate
hand-tight.
do
priv
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for
– Insert foam part (if fitted) beneath floor covering.

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ng
t.
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– Fold floor covering -1- down and pull forwards.
C py
ht. rig
rig ht
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Prote AG.

4.72 Reducing agent (AdBlue®/DEF): Chang‐

ing
Procedure
⇒ Power unit; Rep. gr. 26 ; SCR system (selective catalytic re‐
duction); Draining reducing agent tank
4.73 Transport locks: Removing fastening

rings
Tie-down rings are used to secure transported vehicles, e.g. on
transporters or during shipping.
The tie-down rings are screwed into the towing eye brackets.
• Fastening rings must be removed from the vehicle and scrap‐
ped prior to vehicle delivery.
• Add-on parts removed to install the tie-down rings must be
installed again.
– Ascertain which eyes are installed on the vehicle to determine
which eyes have to be scrapped.
cardiagn.com
Caution
Do not place fastening rings in the vehicle tool kit under any AG. Volkswagen AG d
circumstances. olksw
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Externally, towing eyes and fastening rings are distinguished
s a by
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the fact that fastening rings -1- have no surface protection
s and
ce
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are designed as welded parts.

nl
pt
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itte
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The long version of the fastening ring -1- has the part number 3C0
erm
ab
802 994 A.
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The short version of the fastening ring -2- has the part number
h re
3C0 802 994.
hole
spec
In contrast, towing eyes -3- have surface protection and are
es, in part or in w
t to the co
forged parts, i.e. no weld seams are visible.
The towing eye forms part of the vehicle tool kit in the luggage
compartment and must not be scrapped.
rrectness of i
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Note nform
ercia
Vehicles which are factory-fitted with a towing attachment have

m
no mounting bracket for the screw-in towing eye.

at
om
ion
c
in t
or
♦ The front bumper vent grille and the relevant bolt are located
his
ate
do
in the luggage compartment.

priv
cum
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♦ The rear cap is fitted with a retaining strap. It is masked with

en
ng
t.
yi
tape to protect it against damage.
Co
Cop py
t. rig
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AG. Volkswagen AG d
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CC 2010 ➤ , CC by
V2012 ➤ , Passat 2006 ➤ , Passat
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d ara
orise Maintenance
nte - Edition 11.2016
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Tie-down ring in front right bumper: ss
ce
le
un
pt
– Unscrew tie-down ring to right -arrow-.
an
d
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ab
pe
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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Insert vent grille -1- by first inserting guide lugs into openings on
bumper -arrows-.
nform
mercia
a
com
t
Caution
ion in
r
te o
thi
When installing the cover, make sure that your vehicle's paint
s
iva
do
is not damaged.
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
– Tighten screw -arrow A- to 1.5 Nm.
Fastening ring in rear right bumper:
Note
Note that the cover cap is fitted with a retaining strap, and that
movement range is therefore limited.
– Unscrew tie-down ring to right -arrow-.

– Remove cover cap bond, if fitted.

– Carefully re-insert cover cap; to do this, right side must be in‐

serted first -arrow- and left side must then be pressed in.
4.74 Natural gas system: visual check of nat‐

ural gas tank for corrosion and leakage
♦ Gas leak detector - VAS 6227-
cardiagn.com
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♦ Mirror ss
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♦ Battery lamp - VAS 6901-
an
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es, in part or in w
t to the co
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nform
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♦ Leak detector spray

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ate
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Prote AG.

WARNING
For reasons of safety, service and maintenance of the natural

gas system may only be meticulously carried out by specially
trained personnel.
Natural gas is highly flammable and, in combination with air,
creates a combustible mixture.
There must be no open flame or source of ignition near the
natural gas system.
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.
Prerequisites for testing

wage es n
♦ All parts of the natural gas system to Vobe
lks checked must be ot g
by ua
reached easily. ed ran
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♦ The exhaust gas warning lampsa
u in the dash panel insert must ac
not light up and there musts be no entries concerning natural
ce
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gas in the event memory of the engine control unit.
pt
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♦ Working environment free of draught
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Note
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es, in part or in w
♦ Every draught of air above 1.8 km/h (slight gust of wind) will
t to the co
result in falsification of the measuring result. Therefore, it is
essential to work in a draught-free environment.
♦ When working on the natural gas system always ensure for
tidiness and cleanliness! rrectness of i
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Visual check
nf
ercia
– Remove underbody cover. ⇒ General body repairs, exterior;

rm
m
Rep. gr. 50 ; Natural gas tank covers

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– Check the natural gas system for damage, corrosion and se‐
or
thi
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curity.
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– With the aid of a mirror, carry out visual check of complete

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natural gas tank.

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– For German market only: make sure gap between natural gas t. C rig
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fuel tank and fuel tank shut-off valve is sufficiently waxed yri
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⇒ page 216 .
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cted agen
Prote AG.

– Check whether the natural gas tank cover in the luggage com‐
partment -arrow- is damage-free.
Applicable procedure for assessment of steel and CFRP fuel
tanks: ⇒ Gas engines - general information; Rep. gr. 20 ; Fuel
tanks; Damage assessment catalogue - fuel tanks
Leakage test
– Start engine to set pressures in gas system to operating state.
For the leakage test, the engine can be switched off.
Caution
♦ Pressurised natural gas may escape from natural gas

tanks.
♦ Natural gas is highly flammable and, in combination with
air, creates a combustible mixture.
♦ Close fuel tank shut-off valves manually. ⇒ Fuel supply
system – natural gas engines; Rep. gr. 20 ; Fuel tanks;
Closing fuel tank shut-off valves N361/N362 manually
cardiagn.com
– Using gas leak detector for natural gas vehicles - VAS 6227- ,
check only indicated test locations -arrows- for leaks. It is ab‐
solutely necessary to check all threaded connections of the
gas system. AG. Volkswagen A
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♦ The gas leak detector can only determine whether there is gas
ce
le
in the ambient air.

un
pt
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♦ Any other result than a green LED for »OK« is not permitted
rm
ab
on the gas leak detector. As soon as a yellow or red LED lights

pe
ility
ot
up, a leak detector spray must be used to prove conclusively

wit
, is n
whether the gas is actually escaping from the vehicle system.

h re
hole
When a leak detector spray is used, no bubbles may escape

spec
from the sprayed area within a test period of 3 minutes. Should

es, in part or in w
t to the co
leaks occur, these must be repaired, after which the gas sys‐
tem must be retested.
rrectness of i
Test locations
l purpos
nform
mercia
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com
tion in
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te o
thi
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by
cted agen
Prote AG.

♦ Test area of filler connection in wheel housing (measure total

concentration, if »not OK« remove wheel housing liner and
cardiagn.com
repeat test more carefully)
♦ 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-
AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
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pt
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itte
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ility
ot
wit
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spec
es, in part or in w
t to the co
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rrectness of i
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a
com
tion in
r
te o
thi
s
iva
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r
rp
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t.
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op
♦ Tank shut-off valve for natural gas tank 3 with respective high- C py
t. rig
pressure line coupling point with all connections, threaded
gh ht
yri by
connections and bleed valves -arrows- cop Vo
by lksw
cted agen
Prote AG.
♦ Check electromechanical high-pressure regulator for gas
mode with all connections and threaded connections
-arrows-. Check then whether rubber stopper of pressure relief
valve -1- is fitted as well as condition of low-pressure hose
-2-.
♦ Gas rail with gas injection valve -1- and gas rail sensor -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. 50 ; Natural gas tank covers
4.75 Natural gas system: check wax layer be‐

tween natural gas fuel tank and fuel tank
shut-off valve
Note
For the German market only.


♦ Wax ⇒ ETKA
– Make sure gap between natural gas fuel tank and -1- and fuel
tank shut-off valve -2- is sufficiently waxed.
– If necessary, spray wax over entire circumference -arrows-.
4.76 Checking condition of natural gas filler

neck, cleaning if necessary and check‐
ing seal
cardiagn.com
– 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 cor‐
rosion. Clean natural gas filler neck ONLY from outside.
– If the filler neck is dirty, clean off dirt using compressed air.
The filler neck will not be damaged as a result.
– If corrosion is found on the surface of the natural gas filler neck,
remove it using a lint-free cloth. agen
AG. Volkswagen AG d
oe w s no
olks t gu
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ed nte
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an
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4.77 Natural gas tank: renewing

itte
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ab
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WARNING
is n
h re
ole,
spec
Service and maintenance on the high pressure part of natural

gas system must only be performed by specially trained per‐

t to the co
sonnel.
Natural gas is highly flammable and, in combination with air,
rrectne
creates a combustible mixture.

There must be no open flame or source of ignition near the
ss
natural gas system.

o
cial p
f inform
Inhaling natural gas can lead to light-headedness and lung

mer
damage. High concentrations may lead to suffocation due to

atio
m
lack of oxygen.
o
n
c
i
or
Natural gas is NOT odourless because a gas having a strong

thi
te
sd
a
odour is added.
iv
o
pr
cum
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ng
t.
yi Co
Procedure: “Power unit” ⇒ Power unit; Rep. gr. 20 ; Removing Cop py
t. rig
and installing fuel supply system parts (natural gas) “Removing gh ht
yri by
and installing fuel supply system parts (natural gas)”. cop Vo
by lksw
cted agen
Prote AG.

4.78 Activation of environment monitoring

system (Front Assist): Check
Before vehicle is delivered to customer, the environment moni‐
toring system should be checked to ensure it is active. When
ignition is switched on, active status can be recognised by green
warning lamp in dash panel insert. Environment monitoring sys‐
tem is fitted depending on equipment. Maintenance point is dis‐
played in maintenance list depending on PR number.
If system is not active, proceed as follows.
– Select menu “Assist Systems” in dash panel insert menu.
– There, mark “Front Assist” entry, and set tick and confirm with
“OK”.
AG. Volkswagen AG d
agen oes
System is now active. Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
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ss c
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nl
pt
du
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ab
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es, in part or in w
t to the co
rrectness of i
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ion
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.

5 Exhaust emissions test

This chapter provides information on the following subjects:
Exhaust emissions test for petrol engines ⇒ page 219
Exhaust emissions test for diesel engines ⇒ page 221
Note
♦ Please observe the country specific legal regulations.

♦ The exhaust emissions test described below has been created
according to the legal regulations valid in Germany.
Exhaust emissions test intervals

Vehicles with regulated catalytic converter or vehicles with diesel
engine:
♦ 3 years after initial registration and then every 2 years.
♦ Vehicles for commercial passenger transport, e.g. taxis: every
cardiagn.com
12 months
Information for natural gas vehicles
Note
For Passat EcoFuel this is a bivalent drive. The EET can in this
case be carried out in the mode that the vehicle is currently in,
gas or petrol mode. For monovalent drive, however, the EET must
olksw gen
be carried out inlkgas en AG. V The aEET
wagmode.
Aprocedure
G do
es n is the same as
s
for petrol engines.
by Vo ot g
ua
ed ran
oris tee
th or
5.1ss au Exhaust emissions test for petrol en‐ ac
gines
ce
e
nl
pt
du
an
itte
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erm
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ility
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♦ Exhaust gas testing station L - VAS 7320 A-

wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
rrectness of i
♦ The OBD monitors all components and part systems influenc‐

ing the exhaust emissions quality.
l purpos
♦ It is possible to carry out an exhaust emissions test only when

all units of the emissions testing station are connected prop‐
nf
ercia
erly and joined to each other according to the operating in‐

rm
m
atio
structions.
om
n in
c
♦ All work to be performed is displayed by the emissions testing

or
thi
e
station .
t
sd
iva
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op py
• All test conditions and data required for exhaust emissions test
t. C rig
gh ht
are found on EET data sheet for the respective engine.
yri
p by
o Vo
by c lksw
cted
• For bar code reading the EET data sheet must be printed out.
agen
Prote AG.
• Automatic gearbox: Selector lever in position “P” or “N”.
5. Exhaust emissions test 219

• Manual gearbox: Gear lever in neutral

• Parking brake applied agen
AG. Volkswagen AG d
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– Perform exhaust emissions test according ed by to instructions on
V gu
ara
display. horis nte
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Vehicle data input ss c
ce
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nl
– Enter the following data:
pt
du
an
itte
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♦ Registration number
erm
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♦ Key numbers
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♦ Vehicle identification number
hole
spec
es, in part or in w
♦ Fuel type
t to the co
♦ Mileage
The following vehicle data can be found in the vehicle registration
rrectness of i
certificate part 1:
l purpos
♦ Registration number: “e.g. WOB-HH 1234”

♦ Emission key number “Field 14.1 (code for field 14)”
nform
ercia
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♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
m
at
om
io
♦ Vehicle identification number “field E”
n
c
in t
or
his
e
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
at
do
riv
field D.2)”
p
cum
for
en
g
Specified data input for EET

n
t.
yi Co
Cop py
There are different ways to enter the specified data:
t. rig
gh ht
pyri by
Vo
o
♦ 1. By manual input
by c lksw
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♦ 2. By bar code input from EET data sheet
♦ 3. Through ELSA web service
Note
♦ To use the ELSA web service, the exhaust gas testing station
L which is used for the exhaust emissions test must be inte‐
grated in the workshop network.
♦ The ELSA web service automatically transmits the data for the
specific vehicle via the network to 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 (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature
220 5. Exhaust emissions test

4- Increased idling speed

5- 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”.
9- Lambda probe value
Specified data input for EET as bar code:
– If specified data for EET are available as bar code, read bar
code of EET data sheet with bar code reader.
All data required are shown on display.
Visual check
– Perform visual check of all exhaust emissions relevant com‐
ponents.
– Check if exhaust system is fitted and complete
AG. Voland
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gen AG for
agen does
leaks and damage. olksw not
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V g by ua
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Procedure oris tee
th or
au
– Follow instructions on sexhaust
s gas testing station L . ac
ce
le
un
5.2 Exhaust emissions test for diesel en‐
pt
an
d
itte
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wit
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ole,
♦ Exhaust gas testing station L - VAS 7320 A-
spec
Note t to the co
rrectne
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
s
♦ The OBD monitors all components and part systems influenc‐

s o
cial p
ing the exhaust emissions quality.

inform
mer
♦ It is possible to carry out an exhaust emissions test only when

atio
all units of the emissions testing station are connected prop‐

om
erly and joined to each other according to the operating in‐

c
i
or
structions.
thi
te
sd
iva
♦ All work to be performed is displayed by the emissions testing

pr
cum
r
fo
station .
en
ng
t.
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Cop py
.
ht rig
rig ht
py by
co Vo
• All test conditions and data required for exhaust emissions test
by lksw
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are found on EET data sheet for the respective engine.
AG.
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
• Automatic gearbox: Selector lever in position “P” or “N”.
• Manual gearbox: Gear lever in neutral
• Parking brake applied
– Perform exhaust emissions test according to instructions on
display.
Vehicle data input
– Enter the following data:

♦ Registration number
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type
♦ Mileage
The following vehicle data can be found in the vehicle registration
certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234” lkswage es n
o ot g
yV ua
♦ Emission key No. “field 14.1 (code for field 14)” rised b ran
tee
tho
or
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code
au for field 2)” ac
ss
ce
e
♦ Vehicle identification number “field E”
nl
pt
du
an
itte
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
y li
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ab
field D.2)”
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Specified data input for EET
, is n
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hole
There are different ways to enter the specified data:
spec
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es, in part or in w
♦ 1. By manual input
t to the co
♦ 2. By bar code input from EET data sheet
rrectness of i
♦ 3. Through ELSA web service
l purpos
Note
nform
ercia
♦ If there is no ESP to deactivate the engine speed limiter, the

m
at
rev limit can be measured using the engine speed limited by
om
ion
the control unit. To do this, all the EET specifications must be
c
in t
or
entered manually.
his
ate
do
riv
♦ To use the ELSA web service, the exhaust gas testing station
p
cum
or
L which is used for the exhaust emissions test must be inte‐

f
en
ng
t.
yi
grated in the workshop network.
Co
Cop py
t. rig
gh
♦ The ELSA web service automatically transmits the data for the
ht
pyri by
specific vehicle via the network to the respective mask.
co Vo
by lksw
cted agen
Prote AG.
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.
♦ If the engine speed limiter cannot be deactivated, enter the
value 2500 ± 200 rpm in the box for rev limit and 2500 in the
box for engine speed for conditioning.

– 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- Speed for conditioning
2- Number of throttle bursts for conditioning
3- Engine oil temperature (min. value)
4- Select engine oil temperature measurement procedure
5- Idling speed
6- Governed speed agen
AG. Volkswagen AG d
oes
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V
7- Governed speed measuring period (1edsecond)
by gu
ara
ris nte
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8- Type plate value ⇒ page 223 auth eo
ra
ss c
9- Select probe type (No. of probe)
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an
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10 - Select measuring mode

itte
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11 - Measured period portion
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Note
spec
es, in part or in w
t to the co
♦ When performing the exhaust emissions test, the respective
engineer must always use the vehicle-specific exhaust emis‐
sions limit value indicated on the type plate.
rrectness of i
♦ If no value is indicated on the type plate, the opacity figure
l purpos
specified by the manufacturer and indicated in ELSA must be

used.
nform
ercia
♦ If no value is indicated on the type plate and no opacity figure

has been specified by the manufacturer, the statutory opacity
m
a
com
t
figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐
ion in
istration) must be used.
r
te o
thi
s
iva
♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐

do
r
rp
plies.
um
fo
en
ng
t.
yi Co
op
Specified data input for EET as bar code:
C py
ht. rig
rig ht
py by
– If specified data for EET are available as bar code, read bar
co Vo
by lksw
cted
code of EET data sheet with bar code reader.
agen
Prote AG.
If the opacity figure on the EET data sheet is different from the
value indicated on the type plate, enter the type plate value man‐
ually.
Visual check
– Perform visual check of all exhaust emissions relevant com‐
ponents.
– Check if exhaust system is fitted and complete and check for
leaks and damage.
Procedure
– Follow instructions on exhaust gas testing station L .
– If it is not possible to perform an inspection readiness test with
the vehicle diagnostic tester owing to non-erasable faults, per‐
form an emissions test as a substitute routine for diesels
without OBD
Inerasable faults may be encountered on the following vehicles:

Model Model/engine code Manufacturer Model (VIN) Production date

Passat 3C_/CBAC 0600 WVW_3CAE000025 25/05/2009 -
– 28/05/10
WVW_3C_AE56760
1
. Volkswagen AG
agen AG does
Passat 3C_/CBAC 0600 olksw WVW_3CAP000093 not 11/05/2009 -
yV gu
ed b - a13/08/2010
ran
is
thor WVW_3C_AP06467 tee
or
au 3 ac
ss
Passat 3C_/CBAC 0600 WVW_3C_BE70005 05/03/2010 -
ce
le
un
pt
1- 08/11/2010
an
d
itte
y li
WVW_3C_BE73509
rm
ab
03
pe
ility
ot
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, is n
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hole
spec
The following faults are listed for the SCR dosing system:
es, in part or in w
t to the co
P20F4 Reductant consumption too low
P2BA7 NOx exceedance - empty reagent tank
rrectness of i
P2BA9 NOx exceedance - insufficient reagent quality
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l purpos
P2BAD NOx exceedance - root cause unknown

P2BAB NOx exceedance - incorrect EGR flow
nform
ercia
P2BAC NOx exceedance - deactivation of EGR

m
a
com
tion in
P2BA8 NOx exceedance - interruption of reagent dosing activity
r
te o
thi
s
iva
do
r
rp
cum
fo
en
Evaluation
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note co Vo
by lksw
cted agen
Prote AG.
♦ If the exhaust emissions test was performed with an active rev
limiter, enter the following in the test log:
♦ “The governed speed test was performed with an automatic
engine speed limit of 2500 rpm. ”

6 Glossary
kswage es n
Term Explanation byV
ol ot g
ua
d ran
ir se
ABS (Anti-lock brake system): the ABS tho is a regulating system in the brake system that
tee prevents
or
locking when braking. This helpsau to maintain directional stability and steerability. ac
ss
All-wheel drive Term to be used in place of “Haldex” with immediate effect. Legal implications make this
ce
le
un
pt
coupling step necessary. The term may nevertheless appear in older documents but need not be
an
d
itte
y li
replaced.
erm
ab
ility
TCS Traction control system: prevents the wheels from slipping when the vehicle is driven off.
ot p
wit
is n
ATF Automatic transmission fluid: gear oil for automatic gearboxes
h re
ole,
EET Exhaust emissions test
spec
AUS 32 Abbreviation for “aqueous urea solution” with an urea concentration of 32.5%, see also
t to the co
(AdBlue®) ⇒ page 225
AdBlue® Is an invented name.
rrectne
This fluid is also called “NOx reducing agent AUS 32”, “AUS 32” or “Diesel Exhaust Fluid”
for the USA.
AdBlue® is a clear reducing agent which is used for exhaust treatment to reduce nitrogen
ss
oxides emissions and particulates.
o
cial p
f
AdBlue® is a registered trademark of the VDA (Verband der Automobilindustrie - German
inform
cardiagn.com
association of the automotive industry) in the USA, Germany, the European Union and
mer
other countries.
atio
m
The AdBlue urea solution is not mixed with diesel fuel, but is carried in a separate tank
o
n
c
i
or
n
in the vehicle.
thi
te
sd
a
ATF level Filling level of ATF in gearbox

iv
o
pr
cum
r
fo
BEV Battery Electric Vehicle: vehicle powered by electric energy
en
ng
t.
yi Co
CNG Compressed Natural Gas t. Cop py
rig
gh
CO Carbon monoxide: is produced when fuels containing carbon are not combusted com‐
ht
pyri by
Vo
pletely.
co lksw
by
cted agen
Prote AG.
Common rail Refers to a common high-pressure injection line “rail”, which supplies all cylinders of the
“CR” relevant cylinder bank with fuel
Diesel exhaust flu‐ Designation in the USA for the NOx reducing agent AUS 32, or (AdBlue®)
id
DIN Deutsches Institut für Normung e.V. (German Standards Authority)
DLA Dynamic Light Assist: a system with variable road illumination allows the vehicle to be
driven permanently with main beam without dazzling oncoming traffic.
DPF Diesel particulate filter
DS Direct shift
DSG Dual clutch gearbox
DWA Anti-theft alarm system
ECE Economic Commission for Europe
ETKA Electronic parts catalogue
Part no. Abbreviation for part number
EN European standard
EOBD European On-Board Diagnosis
ESP Electronic stabilisation programme (prevents potential vehicle skidding by targeted in‐
tervention in the brake and engine management systems).
FAME Fatty acid methyl ester
HEV Hybrid Electric Vehicle
MM Maintenance Manual
LongLife service The LongLife service enables extremely long inspection or oil change intervals, depend‐
ing on individual driving style and conditions under which the vehicle is used. For the
LongLife service a special engine oil is required.
LED Light emitting diode
LPG Liquefied Petroleum Gas
6. Glossary 225
Term Explanation
MIL (Malfunction indicator light); American designation for exhaust emissions warning lamp
K83
MPI Multi-point injection
NAR North American region
NSC National Sales Company
NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBlue®)
agent AUS 32 ⇒ page 225
NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBlue®)
agent AUS 32 ⇒ page 225
OBD (Onboard diagnosis); the OBD monitors all components influencing the exhaust emis‐
sions quality.
OBD-II American onboard diagnosis
PHEV Plug-in Hybrid Electric Vehicle: a vehicle with hybrid drive whose battery can also be
recharged externally using mains electricity.
PR No. Abbreviation for production control number. It identifies among other things optional
equipment, country-specific deviations
PM Particulate matter: soot particulate value for diesel engine emissions
cardiagn.com
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
wage
n AG. Volkdisplay
swagen Aand
G do are fitted with the following components:
es n
♦ Flexible
y Volks
service interval display oin
t gudash panel insert
b ara
ed
oris♦ Engine oil level sensor nte
e
th or
au ac
ss ♦ Brake lining wear indicator
ce
e
nl
pt
du
an
QG2 The LongLife service is not factory-activated. This means vehicles have a non-flexible
itte
y li
service interval display (service intervals based on time and distance) and are fitted with
erm
ab
the following components:

ility
ot p
♦ Non-flexible service interval display in dash panel insert

wit
, is n
h re

hole
spec
es, in part or in w
♦ Brake lining wear indicator

t to the co
QG3 The LongLife service is not factory-activated. This means vehicles have a non-flexible
service interval display (service intervals based on time and distance) and are fitted with
rrectness of i
the following components:

♦ Non-flexible service interval display in dash panel insert
l purpos
♦ Brake lining wear indicator

nform
ercia
® Registered trademark symbol

m
at
om
Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been performed
on
c
in t
by the electronic engine management.

or
his
ate
RON Research Octane Number Measurement for knock resistance of petrol

do
priv
cum
or
SPF Particulate filter

f
en
ng
t.
yi
TPMS, TPLI Tyre pressure monitoring
Co
Cop py
t. rig
SAE Society of Automotive Engineers: association which creates proposals/guidelines for im‐
gh ht
pyri by
plementing legal requirements (e.g. standards).
co Vo
by lksw
cted agen
Prote
SCR With the SCR process (selective catalytic reduction) the noxious nitrogen oxides emis‐
AG.
sions are reduced to a great extent and are converted to steam and nitrogen by the urea
solution.
A special urea solution (AdBlue®) is injected into the exhaust system upstream of a spe‐
cial catalytic converter.
SRE Intake manifold injection system (indirect injection system)
SULEV Super Ultra Low Emission Vehicle
226 6. Glossary
Term Explanation
TSI TSI turbocharger: charging only with turbocharger
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 German Association of the Automotive industry
VW Volkswagen
ESI Extended service interval
ZEV Zero Emission Vehicle
ASSY Assembly
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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itte
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ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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6. Glossary 227

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Service

Service Department. Technical Information

5. Exhaust emissions test

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Copyright © 2016 Volkswagen AG, Wolfsburg K0059021420

4.7 Status of battery: Read, send diagnosis protocol online . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.9 Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ab 72

4.10 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wit 76

4.14 Electric windows: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . . . 81

according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.17 Boots: visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.19 Poly V-belt: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.20 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.21 Cooling system: Checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 84

4.22 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.23 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.45 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

4.46 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

4.51 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.55 Camshaft drive toothed belt: renewing (diesel engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.57 Camshaft drive toothed belt: renewing (petrol engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.59 Camshaft drive toothed belt: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

4.60 Coolant pump toothed belt: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.61 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4.62 Compass module: Activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

4.67 Multi-purpose additive for petrol fuel: Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Passat CC ►2009 Petrol engines ⇒ page 5

Engine code AXX AXZ BLF BLR

No. of cylinders/valves per cylin‐ 4/4 6/4 4/4 4/4

Power kW at rpm 147/5700 184/6250 85/5800 110/6000

Torque Nm at rpm 280/2000 330/3200 155/4000 200/3500

Injection/ignition Motronic MED Motronic MED Motronic MED Motronic MED

Engines: ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Engines: ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Injection/ignition Motronic MED Motronic MED Motronic MED Motronic MED

9.5.10 9.1 9.1 17.5

FSI TFSI FSI TSI turbocharger

Camshaft drive Toothed belt Toothed belt Chain Chain

Engines: ⇒ Petrol engine Petrol engine Petrol engine

Engine code CAXA CAWB CCTA

No. of cylinders/valves per cylinder 4/4 4/4 4/4

Power kW at rpm 90/5000 147/5100 to 6000 147/5100 to 6000

Torque Nm at rpm 200/1500 to 4000 280/1700 to 5000 280/1700 to 5000

Bore Diameter, mm 76.5 82.5 82.5

Stroke mm 75.6 92.8 92.8

Engines: ⇒ Petrol engine Petrol engine Petrol engine

Displacement I 2.0 2.0 1.8

Engine code CCTB CCZA CDAA

Compression ratio 9.6 9.8 9.6

RON unleaded, at least 95 95 95

Camshaft drive Chain Chain Chain

Passat diesel engines

Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Power kW at rpm 88/4000 77/4000 77/4400 100/1750 to

Torque Nm at rpm 300/1750 250/1900 250/1500 to 2500 320/4200 t to the co

Compression ratio 18.5 18.5 16.5 16.5

Injection/ignition TDI TDI TDI TDI

Diesel particle filters No No Yes Yes

ticulate filter. Vehicles with factory-fitted diesel particulate filter

can be identified by production control number 7GG or 7MB on