Volkswagen - New Beetle - Wiring Diagram - 2007 - 2008

Page 3788
Engine Oil: Description and Operation
Engine Oil
Oil Capacities and Specifications
For engine oil capacities and specifications refer to the Owner's Manual.
Oil Dipstick Marks
1 Max. mark
2 Min. mark
a Area above hatched area up to the Max. mark: Do not add engine oil.
b Oil level at hatched area: Can be replenished with engine oil
c Range from the Min. mark to the hatched area: fill with a Max. 0.5 liters of engine oil.
Page 7323
Part 1
Page 2404
Part 1
Page 2621
- Insert ignition key into lock cylinder and turn it to "Drive ".
- Unlock the lever with a steel wire (approximately dia. 1,2 mm) and install the lock cylinder into the
steering lock housing.
‹› When inserting lock cylinder, make sure connection for Anti-Theft Immobilizer Reading Coil (D2)
is inside the guide in the steering lock housing.
- Pull the steel wire out of the lock cylinder and then check to make sure the lock cylinder fits
securely in the steering lock housing.
- Connect the connector - arrow - from the Anti-Theft Immobilizer Reading Coil (D2) to the lock
cylinder.
Page 1859
Number in frame indicates track where the wire/circuit is continued. For example, the reference in
this diagram is to track 164, which is on another diagram. In the other diagram showing track 164,
the number in the frame for the same wire/circuit will change to the number 2, as that is the track
number for where the wire/circuit came from on this diagram.
3 - Relay Panel - Indicated by grey area.
4 - Diagram of threaded pin on relay panel White circle shows a detachable connection.
5 - Fuse designation Use legend at bottom of page to identify the fuse code.
6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram.
7 - Wire connection designation in wiring harness Location of wire connections are indicated in the
legend.
8 - Terminal designation Designation which appears on actual component and/or terminal number
of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8.
9 - Ground connection
10 - Component designation Use legend at bottom of page to identify the component.
11 - Component symbols
12 - Wire cross-section size (in mm sq.) and wire colors
13 - Component symbol with open drawing side Indicated component is continued on another
wiring diagram.
14 - Internal connections (thin lines) These connections are not wires. Internal connections are
current carrying and are listed to allow tracing of current flow inside components and wiring
harness.
15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter

Switch/terminal 50b.
16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel.
17 - Reference of internal connection continuation Letters indicate where connection continues on

the previous and/or next diagram.
18 - Relay location number Indicates the physical location of the relay (by position number) on the
relay panel. (For an actual relay panel image/view, see the component location for the relay in
question.)
19 - Legend
The legend contains the explanations for all of the designation codes used within the diagram. In all
wiring diagrams the same component designation (code) is used for a particular component. For
example, always "A" for the battery.
20 - Power/Ground Distribution Circuit Identification Following are the most common

numbered/lettered circuits:
Terminal (circuit) 1
Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer)
Switch Battery Positive Voltage (B+) from ignition/starter switch

Battery Positive voltage (B+), hot at all times

Page 5361
Oxygen Sensor: Locations Component Location Overview
Component Location Overview

17 Heated Oxygen Sensor (HO2S) in Front of the Catalytic Converter (G39), 55 Nm
‹› Component location: In the exhaust manifold.
19 Oxygen Sensor (O2S) in Center Three Way Catalytic Converter (TWC), Bank 1 (G465), 55 Nm
‹› Only for engine code BPR.
‹› Component location: In center catalytic converter.
21 Oxygen Sensor (02S) behind Three Way Catalytic Converter (TWC) (G130), 55 Nm
‹› Component location: In rear catalytic converter.

Page 3401
Fuse Block: Service and Repair
Left Instrument Panel Fuse Holder
Fuse Panel and Relay Carrier
CAUTION! When disconnecting and connecting the Battery ( A), the procedure must be followed
as described in the Repair Information. Refer to => [ Battery A, Disconnecting and Connecting ]
See: Starting and Charging/Battery/Service and Repair/Procedures/Battery A, Disconnecting and
Connecting.
Connecting.
CAUTION! ‹› When removing and installing components in visible area (switches, covers, trim,
etc.), cover by taping the areas at which a prying
tool ( (VAS 3409), screwdriver) will be positioned using commercially available adhesive tape.
Removing
- Disconnect the Battery (A). Refer to => [ Battery A, Disconnecting and Connecting ] See: Starting
and Charging/Battery/Service and Repair/Procedures/Battery A, Disconnecting and Connecting.
- Carefully pry out the side covers from the instrument panel.
- Remove the instrument panel trim panel on the driver side.
- Remove the screws - 1 - and remove the fuse panel - 2 -.
Installing
Install in reverse order of removal, noting the following:
- Tighten the screw to 3 Nm.
Current fuse assignments.
Relay Panel and 13-Pin Relay Carrier
as described in the Repair Information. Refer to =>
Diagrams
Drive Belt: Diagrams
Ribbed belt routing
Ribbed belt routing
1. Power steering pump 2. Belt pulley - generator 3. Lower idler pulley 4. Ribbed belt for generator,
vane pump and coolant pump 5. Belt pulley - air conditioning compressor 6. Ribbed belt for A/C
compressor 7. Belt pulley - crankshaft 8. Tension roller for A/C compressor ribbed belt 9.
Tensioning roller for ribbed belt for generator, vane pump and coolant pump
10. Belt pulley - coolant pump

Page 3043
Fuel Filter: Locations Fuel Tank With Attachments and Fuel Filter, Assembly Overview
Fuel Tank With Attachments And Fuel Filter, Assembly Overview
1 - Cap
2 - Seal -
Replace if damaged
3 - Bolt
4 - Tank flap unit -
With rubber gasket
5-
10 Nm
6 - Vent line -
Ensure seated tightly
7 - Switch-over valve -
To remove valve unclip sideways out of support
- Checking
8 - O-ring -
Replace if damaged
9 - To EVAP canister
10 - From EVAP canister
11 - Wiring router -
In long member
12 - Vent line -
- Secure with spring-type clips
13 - 10 Nm
14 - Protective plate
15 - Fuel tank -
Support using Engine/transmission jack V.A.G 1383 A when removing
16 - Heat shield
Page 1050
Page 7041
Page 5069
Part 3
Circuit and Terminal Designations
Several wiring circuits in the vehicle's electrical system are identified with a number or letter
designation. These circuits are identified the same in all wiring diagrams and are most commonly
shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit
designations may also be used to identify switch connector terminals (switch circuits). Following
are the most common numbered/lettered circuits:
Page 5024
Removing
‹› To pull off spark plugs, place ignition coil puller (T40039) on uppermost thick rib - arrow - of
ignition coils with power output stages.
‹› If lower ribs are used, these can be damaged
- Remove engine cover.
Spark plugs are located under ignition coils with power output stages.
- Pull out all ignition coils with power output stages - 1 - upward using ignition coil puller (T40039).
‹› Lines or connectors of ignition coils may remain connected when pulling out ignition coils with
power output stages.
‹› Note installation position of ignition coils with power output stages!
- Set ignition coils with power output stages (with lines connected) carefully to the side.
CAUTION! Make sure wires are not kinked or damaged.

Page 4660
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Diagnostic Procedures
Engine Coolant Temperature Sensor 1, Checking
CAUTION! ‹› Cooling system is under pressure.
‹› Danger of scalding when opening!
‹› The ECT (G62) Sensor 1 and ECT Gauge sensor are combined into a single unit. The unit is
mounted in the thermostat housing and has a 4 wire
connector.
‹› Use only gold-plated terminals when servicing terminals in the electrical harness connector of
Engine Coolant Temperature (ECT) Sensor (G62 ).
Special tools, testers and auxiliary items required
‹› Multimeter.
‹› jumper wire.
‹› Wiring diagram.
Test requirements
‹› The Motronic Engine Control Module (ECM) ( J220 ) fuses OK.
‹› Battery voltage at least 12.5 volts.
‹› All electrical consumers such as, lights and rear window defroster, switched off.
‹› Vehicles with automatic transmission, shift selector lever into position " P" or "N".
‹› A/C switched off.
‹› Ground connections between engine/transmission/chassis OK.
‹› Ignition switched OFF.
‹› Engine COLD.
Test procedure
- Perform a preliminary check to verify the customers complaint. Refer to => [ Preliminary Check ]
See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and
Procedures/Preliminary Check
Start diagnosis
- Connect the scan tool.
- Switch the ignition ON.
- Using the scan tool, check the coolant temperature:
If the specified value was Not obtained:
- Continue test according to the following table:

Page 6256
Fuel Pressure Sensor/Switch: Diagnostic Aids
Explanation Of Troubleshooting Procedures
Starting with the reported problem, troubleshooting procedures show step-by-step what is checked
and how it is checked in order to find the problem in the quickest and most reliable way. If several
causes (of a problem) are possible in one system, a test procedure is used for diagnosis.
Page 3870
WHAT ARE TRACKS?
Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams.
They are only identified by numbers at the bottom of the diagram.
The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is
identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track
15-28, and so on).
HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS?
Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where
they are coming from/going to at either end.
Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the
previous/next diagram in the series.
However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and
when they enter/leave a diagram they could be skipping
Page 483
Page 977
numerous diagrams in the series before picking up again on the destination diagram. When these
wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will
be shown within a continuation reference frame/box.
HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS?
Track 1-14
Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram
named Track 1-14.
This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To
continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram
named Track 169-182.
But before going to the diagram named Track 169-182, again make note of the current track that
you are leaving, which is Track 8.
Track 169-182
After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram.
Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8
(the track you are coming from).
When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro
and can continue to trace it until it terminates at either a component or at yet another continuation
reference box.
NOTE: It is equally important that you always know the track that you are coming from as well as
the one you are going to.
Symbols Used In Wiring Diagrams

Page 2336
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4768
- Check the wiring for an open, high resistance or short to Ground and replace any open fuse.
- Check the electrical harness connector for damage, corrosion, loose or broken terminals.
- If necessary, repair the faulty wiring connection.
If the specified value was obtained:
Checking Ground activation
If the manufacturers test box is being used, perform the following step.
- Install the test box.
If the manufacturers test box is not being used, perform the following step.
- Remove the Motronic Engine Control Module (ECM) ( J220). Refer to the Repair Information.
- Using a multimeter, check the Heated Oxygen Sensor (HO2S) (G465) electrical harness
connector terminal to the Motronic Engine Control Module (ECM) (J220) electrical harness
connector T121 for an open circuit.
Specified value: 1.5 ohms max.
- Check the wiring for an open or high resistance.
If no malfunction is detected in the wiring and the voltage supply was OK:
- Replace the Motronic Engine Control Module (ECM) (J220). Refer to the Repair Information.
- Install the right side vehicle O2S connector cover.
Final procedures
After the repair work, the following work steps must be performed in the following sequence:
1. Check the DTC memory. Refer to => [ Diagnostic Mode 03 - Read DTC Memory ] See:
Computers and Control Systems/Testing and
Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09.
2. If necessary, erase the DTC memory. Refer to => [ Diagnostic Mode 04 - Erase DTC Memory ]
See: Computers and Control Systems/Testing and

3. If the DTC memory was erased, generate readiness code. Refer to => [ Readiness Code ] See:
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Readiness Code.

Page 5701
Transmission Position Switch/Sensor: Diagnostic Aids
Page 4849
Part 1
Page 7243
- Remove forward mount for selector mechanism (2 nuts) - arrows -.
- Disconnect intake hose - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.
- Disconnect hose for Secondary Air Injection (AIR) pump - 3 - from air filter housing.
- Remove bolts - 4 -, - 5 - and - 6 -.
- Remove air filter completely.
- Pry off selector lever cable - 1 - from lever/selector shaft - 3 - e.g. using a 10 mm open-end
wrench - 2 -.
Page 1354
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2154
Part 2
Page 3784
Wu-Ze
Worldwide List of Engine Oils

Diagram Information and Instructions
Window Shade Switch: Diagram Information and Instructions
How to Find Wiring Diagrams
NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories.
These Three OE Categories Are::
1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common
Systems)
Standard Equipment
This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail
Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc..
Standard equipment is found on all vehicles regardless of which engine or optional equipment is
installed.
The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or
via a component name on the Master Diagram Index at the vehicle level diagrams.
Engine Specific
This category includes components and systems circuits such as Starting and Charging Systems,
Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific
engine.
The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a
component name on the Master Diagram Index at the vehicle level diagrams.
System Specific and Optional Equipment
This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated
Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and
components.
Master Diagram Index
See: Diagrams/Electrical Diagrams/Master Diagram Index
How to Read Track Diagrams

Page 7843
WHAT ARE TRACKS?
15-28, and so on).
Page 5411
WHAT ARE TRACKS?
15-28, and so on).
Page 4898
Air Flow Meter/Sensor: Locations Component Location Overview

9 Mass Air Flow (MAF) Sensor (G70)/Intake Air Temperature (IAT) Sensor (G42)
Page 2863
Part 3
Page 4631
- Start the engine and let it run at idle.
- Using a multimeter, check the Mass Air Flow (MAF) Sensor (G70) electrical harness connector
terminal 2 to Ground.
Specified value: Battery voltage.
- Switch the ignition OFF.
If specified value was not obtained:
- Check the Mass Air Flow (MAF) Sensor (G70) electrical harness connector terminal 2 to the Fuel
Pump Relay (J17) socket 23/87 for an open circuit or short to Ground. NOTE: Fuse S-243 is also
part of this circuit and may be open if circuit is shorted. See Wiring Diagram for circuit details.
If no malfunction is detected in the wiring and the voltage supply is OK:
Checking electrical circuit
If the manufacturers test box is being used. Perform the following step.
If the manufacturers test box is not being used. Perform the following step.
terminals to the Motronic Engine Control Module (ECM) (J220) electrical harness connector T121
terminals for resistance.
If the specification was not obtained:
- Check the wiring for a short circuit to each other, Battery (+) or Ground.
- Replace Mass Air Flow (MAF) Sensor (G70).

- Erase the DTC memory. Refer to => [ Diagnostic Mode 04 - Erase DTC Memory ] See:
Computers and Control Systems/Testing and Inspection/Scan Tool Testing and
Procedures/Diagnostic Modes 01 - 09
- Perform a road test to verify repair.
If the DTC does not return:
Generate readiness code. Refer to => [ Readiness Code ] See: Computers and Control
Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Readiness
Code.
If the DTC does return, no malfunction was detected in the wiring and the voltage supply was OK:
Page 2856
Wiring Diagram Layout
1 - Track Numbers
Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the
diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams.
2 - Reference of wire/circuit continuation to another diagram

Page 1732
Part 3
Headlamp Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4265
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6366
^ Can the complaint be reproduced?
Workshop procedure
1. Read out the data memory of all engine control modules, and note the environmental conditions
on the DTC log.
a. If there are other entries in addition to combustion misfires, address the other entries before
addressing the cylinder misfires.
b. If DTC P0301 P0312 (Cyl.1 Misfire Detected - Cyl.12 Misfire Detected) is accompanied by
P1250 (Fuel level too low), it is likely the faults
occurred due to a low fuel level and not a malfunction of the coils.
c. Review all applicable TBs related to cylinder misfires and ECM software improvements before
diagnosing the misfire condition. For example, if
data shows that a DTC was set during cold start, search ElsaWeb for TBs related to cold start
misfires.
2. Try to duplicate customer complaint based on the environmental conditions at the time the DTC
was set. The freeze data gives important indicators
for the traceability of the complaint, in particular if it occurs sporadically or at cold start.
3. Review the vehicle repair history for previous misfire or maintenance service that could be
related to the current complaint.
4. Observe the requirements of Guided Fault Finding. Perform Guided Fault Finding in full
according to the proposed sequence (test plan). Do not skip
any steps.
5. Complete Guided Fault Finding correctly and set the readiness code.
Tip: This is important to ensure that no subsequent faults occur due to the misfire.
6. In the case of single cylinder misfires:
a. Before replacing components, determine whether the complaint migrates to the other cylinders
after exchanging the coils. If necessary, perform a
test drive to ascertain this.
b. If the misfire migrates to the cylinder the coil was moved to, replace only the affected coil.
7. Verify repair under the same environmental conditions (e.g.: engine speed, engine load value,
vehicle speed, coolant temperature, intake air
temperature, ambient air pressure, voltage at terminal 30, etc.) as noted on the DTC log.
Warranty
This Technical Bulletin is informational only and not applicable to any Volkswagen warranty.
Required Parts and Tools
None
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or
removal. Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 345
Part 1
Page 6400
WHAT ARE TRACKS?
15-28, and so on).
Page 7451
‹› Wear up to half the thickness of diaphragm spring - arrow - is permitted.
Check Spring and Rivet Connections
- Check spring connections - arrows A - for damage and rivet connections- arrows B - for secure
seating.
‹› Replace clutch plates and pressure plates with damaged or loose rivets.
‹› Pressure plate and clutch plate must only be replaced together.
‹› Allocate clutch plate and pressure plate via engine code.
‹› If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine
facing the transmission in order to reduce the smell
of burnt clutches.
‹› Clean input shaft splines and (in case of used clutch plate) clean hub splines, remove corrosion
and apply only a very thin coating of lubricant for
clutch plate splines (G 000 100) on splines. Then move clutch plate on input shaft back and forth
until hub on shaft moves easily. Always remove excessive applied grease.
‹› Pressure plates are protected against corrosion and greased. Only the contact surface may be
cleaned, otherwise service life of clutch is
significantly reduced.
‹› Contact surface of pressure plate and clutch plate lining must make complete contact on
flywheel. Only then insert mounting bolts.
- Reposition flywheel retainer (3067) when installing.

Page 961
WHAT ARE TRACKS?
15-28, and so on).
Page 623
Ground (GND)
Starter control; switched B+ from ignition/starter switch
Switched headlight B+ from light switch
Switched parking light, taillight. illumination B+ from light switch
Terminal (circuit) S (SU)
Key in ignition circuit; switched B+ from ignition/starter switch
Terminal (circuit) X
Load reduction circuit; switched B+ from load reduction relay
Wire and Fuse Color Code Identification
Wire Color Code Identification
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Wire Size Conversion
Wire Size Conversion Chart
Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional
area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in
American Wire Gauge (AWG) sizes.
Locations
Headlamp Alignment Control Module: Locations
Electrical and Electronic Component Locations

4 Headlight range control module (J431)
‹› Component location: In left wheel housing

Page 7267
- Guide selector lever cable - 2 - into selector mechanism housing and press onto selector lever - 3
- using a screwdriver - 4 -.
- Install new securing plate - 1 - for selector lever cable to shift mechanism housing.
Installation position:
Angled end of securing plate faces toward end of selector lever cable.
- Lower vehicle
- Pull up pull-rod and move selector lever from "P" to " S" with pull rod pulled up.
‹› Selector mechanism and selector lever cable must have freedom of movement during this, if
necessary, replace selector lever cable or service shift
mechanism.
- Pull up pull-rod and place selector lever in "P" with pull rod pulled up.
- Install cover with seal glued on hand-tight on to selector mechanism housing.
‹› While doing this, make sure seal makes correct contact.
- First tighten nuts - arrows A -.
- Then tighten two bolts - arrows B -.
- Insert protective sleeve of selector lever cable into cover.
- Move selector lever/shift rod - 3 - at transmission in "P" position. Catch must engage in parking
lock gear, both front wheels are locked (cannot be turned together in one direction).
Page 6916
Control Module: Service and Repair 09G Transmission
Transmission Control Module
Removing
- Switch ignition off.
- Remove defroster duct.
‹› Harness connector of control module may only be disconnected or connected 30 seconds after
ignition is switched off.
- Release harness connector - arrow 1 - and remove it from Transmission Control Module (TCM) -
arrow 2 -.
‹› Separating the connector automatically resets the adaptation values of the transmission. The
control module must relearn the values once the
transmission is operational again. The quality of the gear changes may deteriorate during the
"learning" process.
- Remove nuts - arrow 3 -.
- Remove control module.
Installing
Installation is in reverse order of removal.
- When installing, insert multi-pin harness connector on to pins of Transmission Control Module
(TCM) (J217) - arrow 1 - and then engage multi-pin harness connector - arrow 2 -.
Page 3334
Secondary Air Injection (AIR) Pump Relay J299

Page 6273
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 70
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7244
- Press locking devices on selector lever cable support bracket together - arrows - and pull out
selector lever cable from support bracket/transmission.
- Unclip selector lever cable - 1 - from clip - arrow - on transmission.
- Raise vehicle.
- Loosen double clamp - A - and slide toward rear.

Page 5607
Page 285
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5872
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5549
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6020
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1831
WHAT ARE TRACKS?
15-28, and so on).
Wiper Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6842
Part 2
Page 3750
Page 4596
Part 2
Page 4235
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1180
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6035
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4340
Part 1
Page 6466
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 145
Global Positioning System Module: Service and Repair
Telematics Control Module (J499)
‹› If the Telematics control module was replaced, the OnStar system must be re-configured. Refer
to => [ Telematics Control Module , Configuring ]
See: Testing and Inspection.
‹› Do not swap out any Telematics control module between different vehicles! Each Telematics
control module has a special identification and an
electronic serial number that matches the VIN. Using this data, the vehicle is identified by the
OnStar Call Center and assigned to the respective customer account.
‹› To diagnose, use the "Guided Fault Finding" function of the Vehicle Testing, Measurement, And
Information System ( VAS 5051B). Before
removing the Telematics control module, while diagnosing with the Vehicle Diagnostic, Testing And
Information System (VAS 5051B) in the "replacing the J499 - Telematics control module" function,
the option will be offered to read out the coding and then reprogram it in the new Telematics control
module after it has been replaced.
The Telematics control module is installed behind the left side trim.
Removing
- Disconnect the battery.
- Remove the right side trim panel.
- Remove speaker mount - 1 -.
- Disconnect harness connector - 2 - at the speaker.
- Remove protective housing - 1 - under the speaker.

Downshift Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4250
WHAT ARE TRACKS?
15-28, and so on).
Page 5441
For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table,
may require an ECM replacement to achieve the new software level.
Warranty Information only.
No Special Parts required.
No Special Tools required.
removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 1945
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2889
Check the wiring harness connector, terminal ends and harness routing for transmission input RPM
-G182- / clutch temperature sender -G509-.
If wiring harness connector, terminal ends and harness routing for transmission input RPM -G182- /
clutch temperature sender -G509- are OK:
- Replace sensor -G182-.
Warranty
No Special Parts required.Always see ETKA for the latest part(s) information.

Page 5647
Oxygen Sensor: Testing and Inspection Oxygen Sensor In Center Catalytic Converter, Checking
Heater
Oxygen Sensor in Center Catalytic Converter, Checking Heater
‹› When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S) (G465), use
only gold-plated terminals.
‹› Multimeter.
‹›
Test requirements
‹› The Heated Oxygen Sensor (HO2S) (G465) fuse 15 in Fuse box B is OK.
Test procedure
See: Testing and Inspection/Scan Tool Testing and Procedures/Preliminary Check
Start diagnosis
- Remove the black plastic cover (right side) underneath the vehicle to access the O2S connector.-
arrows -.
- Disconnect the Heated Oxygen Sensor (HO2S) (G465 ) electrical harness connector.
- Using a multimeter, check the Heated Oxygen Sensor (HO2S) (G465) terminals 1 and 2 for
correct resistance.
Specified value: 2.5 to 14.0 ohms (at approx. 20 °C)
- Replace the Heated Oxygen Sensor (HO2S) (G465 ).
Checking voltage supply
- Start the engine.
connector terminal 1 to engine ground for voltage.
- Turn the ignition switch OFF

Page 3622
Part 2
Page 7248
8 Selector mechanism
9 Bolt, 23 Nm
10 Bolt, 13 Nm
‹› For selector lever cable adjustment
11 Lever
‹› For selector shaft
12 Pivot
‹› For selector lever cable to transmission
13 Bolt, 23 Nm
‹› For mounting bracket
‹› 2x
14 Nut, 8 ± 0.8 Nm
‹› For bracket => [ (Item 15) Bracket ] to transmission
15 Bracket
‹› With clip for selector lever cable
Selector Mechanism Cover Assembly Overview
Selector Mechanism Cover Assembly Overview
1 - Cover
‹› With symbol insert

Page 814
Relay and Fuse Arrangements on Relay Panel (Fuses)
Page 6658
Transmission Position Switch/Sensor: Adjustments
Multi-Function Transmission Range Switch, Adjusting
- Place selector lever in position "N".
- Do not bend selector lever cable.
Requirements:
‹› Selector lever cable has been removed from lever/selector shaft.
‹› Selector shaft in "N" position

‹› Mounting bolts of Multi-Function Transmission Range (TR) Switch ( F125) have been loosened
‹› Lever/selector shaft has been removed
Work procedure:
- Attach adjustment fixture to selector shaft - 2 - and rotate multi-function switch - 1 - far enough
until adjustment fixture engages on to tab on connector at multi-function switch.
- Fasten adjustment fixture onto selector shaft - 2 - using bolt - 3 -.
- Tighten bolts - arrows - to 6 Nm.
- Remove adjustment fixture.
- Rest of installation is in reverse order of removal => [ Multi-Function Transmission Range Switch ]
See: Service and Repair.
Page 1653
Part 1
Page 5912
WHAT ARE TRACKS?
15-28, and so on).
Page 3008
Suspension version installed in vehicle is indicated by the corresponding PR. No. for the front axle
on the vehicle data sticker.
Example of a vehicle data sticker
In this example the vehicle has basic suspension G16 - arrow - installed.
The PR. No. can also be e.g. G18, G80 etc.
Vehicle data plate is located in spare tire well and in service book.
PR. numbers are decisive for the allocation of specified values to the vehicle.
Wheel Alignment, Preparing to Measure
‹› Brake pedal depressor (V.A.G 1869/2)
The present lateral run-out of the rims must be balanced (compensated). Otherwise, measurement
will result in incorrect readings.
If compensation for wheel run-out is not performed, it will not be possible to obtain a correct toe-in
adjustment!
For this purpose, observe notes of alignment equipment manufacturer.

- Perform wheel run-out compensation.
- Insert brake pedal depressor (V.A.G 1869/2 ).
- Operate brake pedal using brake pedal depressor.
Vehicle Transverse Inclination Neutral Position
Always applies!
When one measured value is not within tolerance, vehicle transverse inclination must be checked
before the adjustment.
When measured values lie outside tolerance range of specified values, the cause for this may be
an off-center vehicle.
Right-hand drive vehicles or e.g. vehicles with automatic transmission may be slightly off-center.
This is due to the installation position of the assemblies and the corresponding weight transfer and
is normal.
- Then, always check dimension - a - at left and right side from rear.
Page 1786
Oil Pressure Sender: Diagnostic Aids
Page 2232
Page 7010
Pressure Regulating Solenoid: Diagnostic Aids
Page 2801
Ground (GND)
How to Use Track Diagrams

Page 6402
Part 1
Page 5542
- Check the value indicated on the scan tool display.
If the value jumps to approx. 140.0° C:
- Replace the Engine Coolant Temperature (ECT) Sensor (G62 ).
If indication remains at approx. -40.0° C:
Checking wiring
- Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor (G62 ) electrical
harness connector terminals to the Motronic Engine Control Module (ECM) (J220) electrical
harness connector for an open circuit or a short to voltage, refer to the chart below.
Specified circuit values: 1.5 ohms Max. resistance and 0 volts when disconnected from ECM.
- Check the wiring for an open or short circuit to Battery (+).
If no malfunction is detected in the signal circuit:
- Using a multimeter, check terminal 3 of the ECT sensor to engine ground.
Specified value: 1.5 ohms Max
- Check the wiring for an open circuit or high resistance.
If no malfunction is detected in the ground circuit:

Testing if display approx. 140.0 C
- Disconnect the Engine Coolant Temperature (ECT) Sensor (G62 ) electrical harness connector.
- Turn the ignition switch ON.
If indication jumps to approx. -40.0° C:

Page 5928
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4141
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 793
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5808
Final procedures
After repair work, the following work steps must be performed in the following sequence:

Page 3067
Spark Plug: Tools and Equipment
Spark Plug Pliers
AST tool# H 1849
Used for the R and R of spark plug connectors and specifically for those with anti-heat terminals.
These Pliers are applicable to Mercedes models 190 E and 300 E, and VW/Audi.
- Spark Plug Pliers
- Applicable to Mercedes, VW and Audi
- Steel Construction and Easy-Grip Handle
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943

Page 4697
Electronic Throttle Actuator Position Sensor: Testing and Inspection
Throttle Position Sensor/Accelerator Pedal Position Sensor 2, Checking
‹› Multimeter.
‹› Wiring diagram
Test requirement
‹› The Motronic Engine Control Module (ECM) ( J220) fuses OK.
‹› Use only gold-plated terminals when servicing the electrical harness connector terminals in
Throttle Position (TP) Sensor (G79 )/Accelerator
Pedal Position Sensor 2 (G185).
Test procedure
Start diagnosis
- Remove the drivers side storage compartment. Refer to the Repair Information.
- Disconnect the Throttle Position (TP) Sensor ( G79)/Accelerator Pedal Position Sensor 2 (G185 )
6 pin electrical harness connector - 2 -.
Page 766
In all cases, the fault codes stored P0301 (Cyl 1), P0302 (Cyl 2), P0303 (Cyl 3), P0304 (Cyl 4) &
P0305 (Cyl 5) correspond to the correct cylinder.
Normal measuring value block channel assignments for misfire count: (cylinders are in numerical
order)
Tip:
As of VAS 5051/VAS 5052 Brand CD V08.67.00, GFF has been corrected. Self Diagnosis will still
read as outlined above.
Page 5554
Part 2
Page 7319
legend.
wiring diagram.
harness.


question.)
19 - Legend



Locations
Transmission Mode Indicator - A/T: Locations
Transmission Range (TR) Display Y6 for vehicles as of model year 2006, 09G, 6 Speed A/T
Component location: In instrument cluster in lower area of display - arrow -

Page 4752
Manifold Pressure/Vacuum Sensor: Diagnostic Aids
Page 3596
- Check the wiring connection for damage, corrosion, loose or broken terminals.
Checking wiring
- Using a multimeter, Check the Camshaft Adjustment Valve 1 (N205) electrical harness connector
terminal 2 to the Motronic Engine Control Module (ECM) electrical harness connector T121 for an
open circuit.
Specified value: 1.5 ohms Max.
- Check the wiring connection for an open circuit, high resistance, short circuit to Battery (+) or
Ground.
If no malfunction is found in the wiring and voltage supply was OK:
- Install the engine cover with air filter. Refer to the Repair Information.
Final procedures
Powertrain Management/Computers and Control
Systems/Testing and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09.
See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 -

09.

Code.
Page 1223
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Nuts .........................................................................................................................
....................................................................... 25 Nm
Replace nuts
Page 6148
Ground (GND)

Specifications
Timing Cover: Specifications
Timing Chain Compartment Cover Bolts
.................................................................................................................................. 10 Nm in
diagonal sequence
Sealing Flange to Cylinder Block Bolts

.................................................................................................................... 10 Nm uniformly in
diagonal sequence
Page 5380
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4817
Part 2
Page 2066
1 - Track Numbers

Page 3627
Variable Valve Timing Actuator: Testing and Inspection
Camshaft Adjustment Valve, Checking
‹› Multimeter.
Test requirements
‹› The Camshaft Adjustment Valve 1 (N205) fuse OK.
‹› Motronic Engine Control Module (ECM) Power Supply Relay (J271) OK, checking.
Test procedure
See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool
Testing and Procedures/Preliminary Check
Start diagnosis
- Remove the engine cover. Refer to the Repair Information.
- Disconnect Camshaft Adjustment Valve 1 (N205) electrical harness connector.
- Using a multimeter, check the Camshaft Adjustment Valve 1 (N205) terminals for resistance.
- Replace the Camshaft Adjustment Valve 1 (N205 ) Refer to the Repair Information.
Checking voltage
terminal 1 for voltage.

- Check the wiring connection for an open circuit, high resistance or short to ground. Refer to the
wiring diagram.
Page 7108
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5084
Body Control Module: Service and Repair
Control Modules
=> [ Tire Pressure Monitoring Control Module ]
=> [ Comfort System Central Control Module ]
Tire Pressure Monitoring Control Module
‹› Additional information:
Vehicles owner's manual

DTC recognition and display
The Tire Pressure Monitoring Control Module (J502 ) is equipped with OBD.
Use Guided Fault Finding.
The Tire Pressure Monitoring Control Module (J502 ) is located behind the glove compartment on
the left side. It is mounted to tunnel on the front passenger side.
CAUTION! ‹› Turn off the ignition and all electrical components.
‹› Remove the key.
Removing
The Tire Pressure Monitoring Control Module (J502 ) - 3 - is attached to the tunnel by two screws -
1 -. The spring nuts - 2 - are installed on the Tire Pressure Monitoring Control Module (J502) - 3 -.
The screws - 1 - are accessible above the center air vent and the Tire Pressure Monitoring Control
Module ( J502) - 3 - is above the glove compartment.
- Remove the center air vent.
- Remove the switch mount.

Page 7266
- Then remove two bolts - arrows B -.
- Carefully slide cover with protective sleeve forward over selector lever cable.
‹› Do not damage protective sleeve when doing this.
‹› Before the next work step, selector lever - 3 - must stand in the Tiptronic gate - arrow A -.
- Using a screwdriver, pry off selector lever cable - 2 - from selector lever - 3 - - arrow B -.
- Remove securing plate - 1 - for selector lever cable at selector mechanism downward.
- Carefully pull selector lever cable out of selector mechanism housing.
Installing
- Installation is in reverse order of removal. Note the following:
‹› Check protective sleeve for damage, protective sleeve can only be replaced together with
selector lever cable.
‹› Check protective sleeve for correct seating and do not install protective sleeve twisted.
‹› Do not grease cable eyelet and ball socket.
‹› Do not bend or kink selector lever cable.
‹› Selector lever - 3 - stands in Tiptronic gate - arrow A -.

Page 1536
Part 2
Page 2276
WHAT ARE TRACKS?
15-28, and so on).
Page 618
WHAT ARE TRACKS?
15-28, and so on).
Page 5100
Ground (GND)

A/T - Won't Shift Out of PARK/DTC's U0101/28773/01315
Control Module: All Technical Service Bulletins A/T - Won't Shift Out of PARK/DTC's
U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition
Transmission, Will Not Shift Out of Park
Customer may state that the transmission will not shift out of Park.
Symptom may be accompanied by No Communication from Transmission Control Module (TCM)

DTCs from table below.
Technical Background
Fuse S7, S15 and/or S231 may be open, missing or not properly seated.
Poor or corroded power and/ or ground connections.
Production Solution
No production change required.
Service
Testing Power Supply and Grounds

Page 2491
Throttle Position (TP) Sensor G88

Page 5580
See: Testing and Inspection/Scan Tool Testing
and Procedures/Diagnostic Modes 01 - 09.
Testing and Inspection/Monitors, Trips, Drive
Cycles and Readiness Codes/Readiness Code.

Page 6263
Throttle Position Sensor: Locations Component Location Overview
Throttle Position (TP) sensor (G79)/accelerator pedal position sensor 2 (G185).
‹› Component location: In the accelerator pedal.

Page 183
legend.
wiring diagram.
harness.


question.)
19 - Legend



Locations
Ignition Control Module: Locations

8 Ignition Coil with Power Output Stage (N70, N127, N291, N292, N323)
Page 4047
Removing

Page 7128
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7794
- Tighten nuts - arrow 3 - to 10 Nm.
- Connect diagnostic operation system ( VAS 5051 ) and advance program until
"function/component selection " is displayed => [ VAS 5051, Connecting and Selecting Functions ]
See: Automatic Transmission/Transaxle/Testing and Inspection/Scan Tool Testing and
Procedures.
- Then press "Powertrain (Repair Group 01; 10 to 26; 28 to 39) ".
- Then press "6 Spd. Automatic Transmission 09G".
- Press "01 - On Board Diagnostic".
- Press "Functions".
- Press "Basic setting".

Locations
Parking Brake Warning Light Switch F9

Page 1201
Part 3
Page 3920
- Remove the (VAS 5161).
The rest of the installation follows the reverse of the removal procedures. When doing this note the
following:
‹› Remove the (T40069) from the cylinder block and install the locking bolt.
‹› Fill with coolant. Refer to => [ Draining and Filling ] See: Cooling System/Service and
Repair/Procedures/Draining and Filling.
Page 606
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2408
Page 3194
Observe operating instructions for (VAS 5234)!
- Unscrew brake fluid reservoir cap.
- Extract as much brake fluid as possible using suction hose from (VAS 5234) - 1 - or using a
suction bottle with built-in strainer.
‹› After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in
the reservoir must align with the lower edge of
the strainer).
CAUTION! Do not reuse used / extracted brake fluid!

Page 3576
Part 3
Page 5119
Part 1
Page 7449
of burnt clutches.
- Place pressure plate onto alignment pins.
- Hand-tighten all bolts evenly by hand until bolt head makes contact on pressure plate.
- Tighten bolts in a diagonal sequence and in small stages to avoid damage to centering holes of
pressure plate and centering pins of dual-mass flywheel.
- Install transmission => [ Transmission, Installing ] See: Manual Transmission/Transaxle/Service

and Repair/Removal and Replacement/Transmission, Installing.
Page 5841
Part 1
Page 6608
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7360
Module (TCM) J217 electrical harness connector T52 terminals for resistance.
Transmission Output Speed Transmission Control Module (TCM)
(RPM) Sensor G195 electrical J217 electrical connector T52
harness connector terminal terminals or test box sockets
5 38
6 50
Specified value: 1.5 Ohms Max.
- Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).
If no malfunction was found in the wiring and the resistance was not OK:
- Replace the Transmission Output Speed (RPM) Sensor G195.
- Erase the DTC memory.
If the DTC does not return: Repair complete, Generate readiness code. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive
Cycles and Readiness Codes
- End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and resistance was OK:
- Replace the Transmission Control Module (TCM) J217.
- Assembly is performed in the reverse of the removal.
Final procedures
1. Check the DTC memory. 2. If necessary, erase DTC memory of the Transmission Control
Module (TCM) J217. 3. Generate readiness code.
End diagnosis.
Page 445
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1875
- Bridge contacts - 1 - and - 2 - with engine running. If A/C Clutch (N25) switches on, refrigerant
system may be empty => [ A/C Refrigerant System, Testing with Pressure Gauges ] See: Heating
and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/A/C
Refrigerant System, Testing With Pressure Gauges.
Page 7092
‹› Do not screw in metal bolt too deep to prevent damage to bearing lying behind.
‹› Illustration shows the left seal, procedure is the same on the right seal.
- Pull seal out using puller (T10055) and adapter (T10055/2).
- Remove cloth and thoroughly clean transmission and opening for drive axle.
CAUTION! No metal particles may enter the transmission or the axle shaft opening. Clean the area
of metal particles using a vacuum cleaner if necessary.
If only the metal ring of the seal could be removed when pulling out:
- Carefully pry out rest of seal using a screwdriver - A -.
B Assembly lever
Installing right flange shaft sealing ring
Installation is in reverse order of removal. Note the following:
- Coat outer circumference and sealing lips of seal with ATF.
Open side of the sealing ring faces the transmission.
- Carefully guide sealing ring with inner sealing lip - A - over transmission stub shaft - B -. Sealing
lip must not roll back.
Page 2242
legend.
wiring diagram.
harness.


question.)
19 - Legend



Component Locations Overview
Engine Control Module: Locations Component Locations Overview

5 Motronic Engine Control Module (ECM) (J220)
Page 4405
Ground (GND)

Page 6036
Part 1
Page 5954
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7049
Control Module: Description and Operation
Function
The Transmission Control Module (TCM) J217 receives information from the components that
affect the shifts and forwards this information to the pressure regulator valves of the valve body,
which control the slide valves in the valve body.
Page 4789
Tire Pressure Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5742
Part 3
Page 4138
Part 1
Page 3584
1 - Track Numbers

Page 3373
Part 3
Instruments - Fuel Gauge May Not Read Full
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Fuel Gauge May
Not Read Full
20 07 05
Apr. 2, 2007
2010432, Supersedes Technical Bulletin Group 20 number 07-04 dated March 29, 2007 due to
removal of Jetta (A5) from Metadata.
Vehicle Information
Condition
Fuel Gauge Sender, Incorrect Reading
Instrument Cluster Fuel Gauge may not read full.
Instrument Cluster software does not recognize tolerances in fuel sender signal which prevents the
fuel gauge from reading full.
Production Solution
Not applicable.
Service
Tools required:
^ VAS 5051 or 5052 diagnostic tool.
Procedure
^ Connect VAS 5051/5052.
^ Turn Ignition switch ON.
^ Select Guided Functions" on screen.
^ Select Brand.
^ Select appropriate vehicle model year and engine code.

^ Select continue.
^ Select J285-Instrument Cluster.
^ Select Fuel Gauge-Adapting.
^ Select continue.
^ Select fuel gauge adaption from programming list and select continue.
^ Select Option 2.
^ Continue with program.

Page 4725
Part 3
Page 7954
Shift Interlock Solenoid: Service and Repair
Shift Lock Solenoid
Removing
- First determine whether a coded radio is installed. In this case, determine anti-theft coding.
- Move selector lever in position "R".
- Switch ignition off and disconnect battery Ground (GND) cable.
- Remove selector mechanism cover and circuit board => [ Selector Mechanism Cover and Circuit
Board ] See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Removal and
Replacement/Selector Mechanism Cover and Circuit Board.
- Disconnect connector - arrow - from Shift Lock Solenoid (N110).
- Raise vehicle.

Page 6315
Specified value: 1.0 to 5.0 ohms (at 20° C)
- Replace the Throttle Valve Control Module ( J338 ). Refer to the Repair Information.
- Check the voltage supply of the Throttle Valve Control Module (J338) from the Motronic Engine
Control Module (ECM) (J220) as instructed below.
Checking voltage supply and wiring
- Using a multimeter, check the Throttle Valve Control Module (J338) electrical harness connector,
terminals 2 to 6 for voltage from the ECM.
Specified value: at least 4.5 V
Checking wiring

Page 2826
Downshift Switch: Diagnostic Aids
Service and Repair
Camshaft: Service and Repair
Camshafts
‹› Torque wrench (5-50 Nm) (VAG 1331)
‹› Hand drill with plastic brush attachment
‹› Protective eyewear
‹› Sealant (D 154 103 A1)
Removing
‹› Sealing surfaces on the bottom of the guide frame and top of the cylinder head must not be
reworked.
‹› Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide
frame, chain sprockets of camshafts must be removed.
‹› If the guide frame was loosened, the sealing plugs must be replaced.
- Secure the camshafts and remove the sprocket and actuator from the camshafts. Refer to => [
Valve Timing, Adjusting ] See: Cylinder Head Assembly/Adjustments.
- Remove the (T40070).

- Remove the guide frame bolts evenly from the outside toward the inside and remove the guide
frame.
- Carefully remove the camshaft and place it on a clean surface.
Installing
CAUTION! To prevent injuries from shavings, wear protective goggles and protective clothing.
- Remove the remainder of sealant from the guide frame (out of the grooves as well) and from the
cylinder head using a rotating plastic brush.
CAUTION! Make sure that no sealant residue enters the engine.
- Clean the sealing surfaces, they must be free of oil and grease.
- Oil the journal surfaces of the camshafts.
- Place the guide frame on a soft surface.

Temperature Switch (Warning Indicator): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5174
Electronic Throttle Actuator: Service and Repair
Accelerator Pedal Module Assembly Overview

1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
4 Throttle Position (TP) Sensor (G79)
‹› Not adjustable.
‹› The TP sensor transmits the driver control to the Engine Control Module (ECM).
‹› Remove the footwell cover to remove the sensor.
5 Bracket
‹› For the footwell cover.
‹› Clipped to the TP sensor.

Capacity Specifications
Fluid - M/T: Capacity Specifications
0A4, 5 Speed M/T FWD
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 1.8 liters
02J, 5 Speed M/T FWD
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 2.0 liters
02M, 5 & 6 Speed M/T FWD
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 2.3 liters
Power Door Lock Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3749
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3828
Oil Filter: Removal and Replacement
Oil Filter Bracket Assembly Overview

1 Bolt, 25 Nm
2 Oil Filter Bracket
‹› Removing:
- Drain the coolant. Refer to => [ Draining and Filling ] See: Cooling System/Service and
- Remove the intake manifold. Refer to => [ Intake Manifold ] See: Intake Manifold/Service and
Repair/Intake Manifold.
- Remove the connection for the thermostat.
- Disconnect the coolant hose from the thermostat housing.
- Drain the oil filter housing, refer to => [ Oil Filter Housing, Draining ] See: Oil Filter
Housing/Service and Repair, and remove.
- Remove the oil filter bracket, the vent hose - item 6 - remains connected.
3 Gasket
‹› Replace
4 Oil Pressure Switch (F1), 20 Nm

Locations
Fuel Level Sensor: Locations
Engine Code BPS (Plastic Fuel Tank)

Fuel Tank and Attachments Assembly Overview
25 Fuel Delivery Unit
‹› Fuel level sensor removal and installation, refer to => [ Fuel Level Sensor ] See: Fuel Delivery
and Air Induction/Fuel Tank/Service and
Repair/Removal and Replacement.

Page 2901
Transmission Speed Sensor: Service and Repair Transmission Output Speed Sensor
Transmission Output Speed Sensor
Removing
- Remove valve body => [ Valve Body ] See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/Valve Body.
- Remove bolt - 2 - of Transmission Output Speed (RPM) Sensor (G195).
- Remove sensor from housing.
Installing
- Press sensor into transmission up to stop.
- Tighten bolt - 2 - of Transmission Output Speed (RPM) Sensor (G195) => [ (Item 17) Bolt, 7 Nm ]
See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and
Repair/Valve Body Assembly Overview.
- Install valve body => [ Valve Body ] See: Transmission and Drivetrain/Automatic
Locations
Shift Solenoid: Locations
Solenoid Valve Identification

1 Wiring harness with 14-pin connector - arrow - for solenoid valves
2 Solenoid Valve 1 (N88)
7 Automatic Transmission Pressure Regulating Valve 4 (N218)

Page 1136
Headlamp Washer Motor Relay: Diagnostic Aids
Page 3086
1 - Tensioner roller
2 - Pulley - Generator
3 - Pulley - A/C compressor
4 - Ribbed Belt - Tensioner roller, generator, a/c compressor, power steering pump and
crankshaft/vibration damper
5 - Pulley - Power steering pump
6 - Pulley - Crankshaft/vibration damper belt
Accessory Drive Assembly Overview
1 Bolt
2 Power Steering Pump Pulley
3 Bolt
4 Power Steering Pump

Page 743
removal.
Page 2594
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 2212
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5688
Tiptronic Switch (F189) is integrated into circuit board, which is located in shift mechanism cover.
It consists of hall sensors, which are activated by a magnet - arrow - on transverse slide of cover
strip - 2 -.
If there are malfunctions, it must first be checked whether the magnet - arrow - on transverse slide
of cover strip - 2 - is secured correctly, replace cover strips if necessary. Selector mechanism cover
with integrated circuit board must only be replaced after checking the wires.
Page 465
Page 7947
Page 175
Page 158
Part 3
Page 3729
- Loosen the bolts - 1 + 2 -.
3 Clamp
4 Generator
- Insert clamping lever, secure with pin - arrow - and tip generator down (use e.g. torque wrench as
drive for 3297).
- Press generator as far as clamp stop at least three times using clamping lever to ensure optimum
ease of movement.
- Tighten first the lower, then the upper generator bolt to 25 Nm.
Page 290
Part 2
Page 1851
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5943
Fuel Pressure: Testing and Inspection Fuel Pump Pressure, Checking
Fuel Pump Pressure, Checking
‹› Multimeter.
‹› Fuel line adapter set (V.A.G. 1318/17A). These tools may be substituted with an equivalent
aftermarket tool and are also available for rental or
purchase through Volkswagen.
‹› In line Fuel pressure gauge with shutoff. (high pressure).
Test conditions
‹› Battery voltage 12.5 V
‹› Function and voltage supply for the Fuel Pump is OK.
‹› Fuel tank at least 1/4 filled.
Test procedure
CAUTION! Fuel system is under pressure! Before opening the system, place rags around the
connection area. Then release the pressure by carefully loosening the connection.
Start diagnosis
- Disconnect fuel supply line at the supply location and catch any fuel coming out with a shop towel.
Refer to the Repair Information for location.
‹› Pull circlip upward to unlock fuel line
- Install a fuel pressure gauge with appropriate adapters.
- Open shut off valve on fuel gauge.
- Switch ignition ON, pause 3 Sec. then OFF, repeatedly until fuel pressure stops increasing
pressure.
- Read fuel pressure on the gauge.
‹› Specified value: 3.5 to 6 bar
If specification is exceeded:
- Check return line between fuel filter and fuel pump for kinks or blockage.
If no malfunction in fuel return line is found:
- Pressure relief valve in fuel filter is malfunctioning.
- Replace the fuel filter. Refer to the Repair Information.

If specified value was Not obtained:
- Check fuel pressure at the fuel filter between fuel pump and fuel filter using appropriate adapters
Page 2955
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2335
1 - Track Numbers

Page 6923
Final Drive Fluid: Fluid Type Specifications
01M, 4 Speed A/T FWD
Planetary gearbox
Initial filling ...........................................................................................................................................

....................................................... approx. 5.3 L Changing ...............................................................
........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
............................................................... VW ATF Part number ..........................................................
.............................................................................................................................................. G 052
162
Final drive
Initial filling ...........................................................................................................................................

..................................................... approx. 0.75 L Changing ...............................................................
........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
........................... SAE 75w-90 Synthetic Gear oil Part number ..........................................................
.............................................................................................................................................. G 052
145
02E, 6 Speed Direct Shift A/T FWD
Planetary gearbox and final drive
Initial filling ...........................................................................................................................................

.......................................................... 7.2 L (7.6 qts)
Replacement capacity in service

........................................................................................................................................................
approx. 5.2 L (5.5 qts)
Lubricant ..............................................................................................................................................
...................................................................... DSG oil
09G, 6 Speed A/T FWD
Initial filling ...........................................................................................................................................

........................................................... approx. 7.0 L
Changing .............................................................................................................................................
.............................................................. Filled for life
Lubricant ..............................................................................................................................................
......................................................... ATF G 055 025
Page 6021
Page 1266
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Description and Operation
Global Positioning System Switch: Description and Operation
Telematics Control Head - OnStar(R) Control Buttons, Description
The telematics control head is integrated to the interior rear view mirror. The control head contains
three separate buttons as well as a system telematics indicator lamp (LED).
The OnStar(R) ("OnH") button is used to contact the OnStar(R) call center to request various
convenience services. It is also used to initialize/activate the owner's subscription to OnStar(R)
services and/or update the customer's account in the event that the Telematics Control Module
requires replacement.
The Emergency button is used to contact the OnStar(R) call center to request emergency services
such as fire department, police etc.
The Communication ("DOT") button is used to end a call to the OnStar(R) call center, place or
answer personal calls or cancel a call if one of the other buttons is accidentally pressed.
NOTE: Use of certain OnStar(R) services requires a subscriber's Personal Identification Number
(s) (PIN).
For complete system operation details, See Volkswagen Telematics by OnStar(R) Owner's Manual
Page 5663
WHAT ARE TRACKS?
15-28, and so on).
Page 3621
Part 1
Page 7283
- Remove ATF cooler - 1 - from transmission - arrow A -.
Installing
Installation is performed in reverse order of removal. Note the following:
- Replace ATF cooler O-rings.
- When installing ATF cooler - 1 -, tabs - arrow B - must be inserted in recess of transmission
housing.
- Tighten bolt - arrow A - to 36 Nm.
- Check coolant level in cooling system.
- Check ATF level and top off if necessary => [ ATF Level ] See: Fluid - A/T/Testing and
Inspection/ATF Level.
Page 3462
WHAT ARE TRACKS?
15-28, and so on).
Page 7956
- Pull Shift Lock Solenoid (N110) out of pawl - arrow B -.
- Remove Shift Lock Solenoid (N110) downward.
Installing
- Engage Shift Lock Solenoid (N110) into pawl - arrow B -.
- Clip Shift Lock Solenoid (N110) into retainer- arrows A -.
- Tightly screw cover with bonded seal onto selector mechanism housing. While doing this, make
sure seal makes correct contact.

Page 3259
Gear Oil, Filling
Fill up gear oil in collect container to 1.7 liters.
- Remove backup light switch (F4) - arrow -.
- Connect hose (approximately 600 mm long, outside diameter 10 mm) to commercially available
funnel.
- Insert hose into mounting hole of backup light switch (second mechanic) and fill up gear oil.
- Install backup light switch (F4) - arrow - => [ (Item 2) ] See: Transmission and Drivetrain/Manual
Transmission/Transaxle/Shifter M/T/Service and Repair/Removal and Replacement/Shift
Mechanism Assembly Overview.
- Check switching function.
- Install battery tray and battery.
- Install complete air filter housing.
- Connect battery and note work steps after connecting battery.
- Install center section of noise insulation below engine/transmission.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4365
Water Pump: Tools and Equipment
Water Pump Wrench
AST tool# VAG 1590
Water Pump Wrench.
- Made in Germany
- Call AST for Pricing

Page 5291
1 - Track Numbers

Adjustments
Shifter M/T: Adjustments
Shift Mechanism, Adjusting
‹› Connecting pin (T10027)
‹› The following points are essential to ensure correct shift adjustment:
‹› Components of shift mechanism and linkage must be in proper working condition.
‹› Shift mechanism moves freely
‹› Transmission, clutch and clutch mechanism must be in proper working condition.
‹› Transmission in neutral
- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor (G70).
- Remove bolts - 3 - and - 4 -.
- Remove complete air filter.
- Pull locking mechanism on shift cable and on selector cable toward front to stop in direction of -
arrow 1 - and then lock toward left in direction of - arrow 2 -.
Secure shift rod as follows:

Page 2818
Ground (GND)

Locations

Page 6611
Part 3
Page 4030
3 Fuel Supply Line
‹› Black
‹› From the fuel tank.
‹› Press in the securing ring to disengage the line.
4 Fuel Return Line
‹› Blue
‹› To the fuel tank.
5 Fuel Pressure Regulator
‹› New version integrated in the fuel filter.
‹› 4 bar
‹› Checking, refer to => [ Fuel Pressure Regulator and Residual Pressure Checking, Engine Code
BPS ] See: Fuel Pressure/Testing and
Inspection/Fuel Pressure Regulator and Residual Pressure Checking, Engine Code BPS.
6 Gasket
‹› Replace
7 O-ring
‹› Replace
8 Fuel Supply Line
‹› Black
‹› To the engine.
9 Bolt, 3 Nm
10 Bracket
‹› For the fuel filter.
‹› Secured to the fuel tank.

Page 2683
Part 1
Page 4692
Part 2
Power Steering Pressure Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7104
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 207
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5722
Throttle Position Sensor: Testing and Inspection
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 2664
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6266
- Using a multimeter, check the Throttle Position (TP) Sensor (G79)/Accelerator Pedal Position
Sensor 2 (G185) electrical harness connector terminals to the Motronic Engine Control Module
(ECM) (J220) electrical connector T121 for an open circuit.
- Check the wiring for a short circuit to each other, Battery (+) or Ground or high resistance.
If no fault is detected in the wiring and the voltage supply was OK:
- Replace the Throttle Position (TP) Sensor (G79 )/Accelerator Pedal Position Sensor 2 (G185).
Refer to the Repair Information.
If no fault is detected in the wiring and the voltage supply was Not OK:
- Install the drivers side storage compartment.
Final procedures

Page 3608
- Install the camshafts correctly into the guide frame.
‹› Intake camshaft with sensor wheel - 2 - points toward the Camshaft Position (CMP) sensor (G40)
- 1 -.
‹› Camshafts must lie exactly in the axial bearings - 3 - in the guide frame.
‹› Seal ends - 4 and 5 - must point upward or downward, they must not point to the side under any
circumstances.
- With the camshafts installed in the guide frame, hold the camshafts firmly in place and turn over
and install the guide frame.
- Rotate the camshafts until the threaded holes - arrows - point upward.
- Check whether the camshafts still lie exactly in the axial bearings of the guide frame.
- Install the (T40070) as shown to the camshafts and tighten the bolts to 20 Nm.
Page 899
Seat Occupant Classification Module - Air Bag: Diagnostic Aids
Page 7728
1 Shift knob
‹› Remove and install together with boot => [ (Item 2) Boot ]

2 Boot
‹› Separate from shift knob => [ Boot, Disconnecting from Shift Lever and Installing on Shift Knob ]
See: Boot, Disconnecting From Shift Lever
and Installing on Shift Knob.
‹› Before installing, assemble with shift knob => [ Boot, Disconnecting from Shift Lever and
Installing on Shift Knob ] See: Boot, Disconnecting
From Shift Lever and Installing on Shift Knob.
‹› Remove and install together with shift knob
3 Clamping sleeve
4 Clamp
‹› For securing shift knob to shift lever
‹› Secure on shift knob using hose clamp pliers ( V.A.G 1275) => [ (Item 1) Shift knob ]
5 Socket
‹› Clip into rubber sound insulation
6 Rubber sound insulation
‹› Installation position: Arrows point in direction of travel

Page 7776
Tip:
Ensure proper operation of the shift interlock system before beginning diagnostics.
Page 4321
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3124
The pin - 2 - on the fuel filter must engage in the recess on the filter bracket - 1 -.
Tightening Specifications
Page 7733
- Remove lock washer - 3 - for shift cable from transmission shift lever - 1 -.
- Remove lock washer - 4 - for selector cable from actuator lever - 2 -.
- Pull selector cable and shift cable off from pins - arrows -.
Page 3633
- Cut the tube nozzle at the front mark (jet nozzle diameter approximately 1 mm).
‹› The control housing cover must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - A - onto the control housing cover as shown.
‹› The sealant bead must be 1.5 to 2.0 millimeter (mm) thick.
‹› Pay special attention to the course of the sealant bead in the area - arrow -.
- Install the control housing cover so that the alignment bushings engage in the bores in the
cylinder block.
- Install all bolts hand tight.
- First tighten all the bolts - 3 - to the cylinder block and upper oil pan to 10 Nm.
Page 3965
T 40005 - Audi Cam Align. Tool

Fuel Flow Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1472
Page 843
‹› Coolant hoses are only for a throttle valve control module heated by coolant
Installing
Installation is performed in the reverse order of removal. When doing this note the following:
‹› Replace the seal for throttle valve control module if damaged.
‹› Coolant hose connections are only for coolant heated throttle valve control modules.
‹› Make sure the air hoses - 1 and 2 - are installed securely.
‹› When replacing, erase the adaptation values and adapt the Engine Control Module (ECM) to the
throttle valve control module. Refer to vehicle
diagnosis, testing and information system "Guided Functions".
Page 5622
1 - Track Numbers

Page 1514
1 - Track Numbers

Page 1567
Ground (GND)

Page 6647
WHAT ARE TRACKS?
15-28, and so on).
Page 1847
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7147
Part 3
Page 4808
strip - 2 -.
Page 7901
Transmission Speed Sensor: Testing and Inspection Transmission Output Speed (RPM) Sensor
G195, Checking
Transmission Output Speed (RPM) Sensor G195, Checking
- Multimeter
- Wiring diagram
Requirements
- The Transmission Control Module (TCM) J217 fuse OK.
- The battery voltage must be at least 12.5 Volts.
- All electrical consumers must be switched off.
- The parking brake must be engaged.
- The selector lever must be in the "P" position.
- The Ground (GND) connections to transmission must be OK.
- Ignition switched off.
Test procedure
- Perform a preliminary check to verify the customers complaint.
Start diagnosis
- Disconnect the Transmission Output Speed (RPM) Sensor G195 electrical harness connector - 1
-.
- Repair any damage found to the electrical harness connector.
If the electrical harness connector is OK:
Checking wiring
- Install the Adapter F/VAG1598 (68 Pin) VAG1598/22.
- Remove the Transmission Control Module (TCM) J217.
- Using a multimeter, check the Transmission Output Speed (RPM) Sensor G195 electrical harness
connector terminals to the Transmission Control
Page 7379
21 ATF cooler
‹› Removing and installing => [ ATF Cooler ] See: Transmission Cooler/Service and Repair/ATF
Cooler
22 Multi-Function Transmission Range (TR) Switch ( F125)
‹› Removing and installing => [ Multi-Function Transmission Range Switch ] See: Sensors and
Switches - A/T/Transmission Position
Switch/Sensor/Service and Repair
‹› Adjusting => [ Multi-Function Transmission Range Switch, Adjusting ] See: Sensors and
Switches - A/T/Transmission Position
Switch/Sensor/Adjustments
23 Transmission Fluid Temperature Sensor (G93)
‹› Integrated in wiring harness => [ (Item 25) Wiring harness with 8-pin connector ]
24 Bolt, 6 Nm
25 Wiring harness with 8-pin connector
‹› With O-ring on connector, always replace O-ring
‹› With Transmission Fluid Temperature Sensor ( G93 )
‹› For Transmission Input Speed (RPM) Sensor ( G182 )
‹› For Transmission Output Speed (RPM) Sensor ( G195 )
‹› For Automatic Transmission Hydraulic Pressure Sensor 1 (G193) and Automatic Transmission
Hydraulic Pressure Sensor 2 (G194) (only up
to 06.04)
‹› Component locations of sensors => [ Sensor Identification ] See: Transmission Control

Systems/Locations/Sensor Identification
‹› Removing and installing => [ Wiring Harness with 8-Pin Connector ] See: Wiring Harness/Service
and Repair/Wiring Harness With 8-Pin
Connector
26 Oil seal
‹› Always replace
27 ATF drain plug, 40 Nm
28 Selector lever
‹› For gear selector rod
‹› Removing and installing => [ Valve Body ] See: Valve Body, Valve body, removing and installing
29 Washer
30 Nut, 10 Nm
‹› Note installation position of nut => [ Valve Body ] See: Valve Body, installing valve body
31 Large spring
‹› Not installed in all transmissions
32 Small spring
33 Damping plunger
34 Wiring harness with 14-pin connector
‹› With O-ring on connector, always replace O-ring

Page 4610
Installing
Locations
Hood Alarm Switch F120

Page 260
Part 3
Page 7145
Part 1
Page 5382
WHAT ARE TRACKS?
15-28, and so on).
Page 4570
Relay Arrangements On The Thirteen Position Auxiliary Relay Panel, Above Relay Panel, 9-11
Locations
Knock Sensor: Locations

2 Knock Sensor (KS) 1 (G61)

Differential Temperature Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Locations
Page 2865
Page 5983

Page 7387
- Secure wiring harnesses to transmission with tape.
- Ensure damper piston - 2 - is installed into transmission in position illustrated.
‹› If the damper piston - 2 - was removed, it must be cleaned together with both springs => [ (Item
33) Damping plunger ] See: Valve Body
Assembly Overview, => [ (Item 31) Large spring ] See: Valve Body Assembly Overview, => [ (Item
32) Small spring ] See: Valve Body Assembly Overview and => [ (Item 33) Damping plunger ] See:
Valve Body Assembly Overview and installed.
- Moisten damper piston and mounting in transmission with ATF
- Insert springs into one another and insert into damper piston.
- Insert damper piston with springs into mounting in transmission.
- In order to secure damper piston from falling out, press it as long as necessary into transmission
until valve body is installed.
- Install valve body without force.
- Ensure that wiring harnesses - 1 -, - 3 -, - 4 - and - 5 - are not jammed by valve body.
‹› Replace all bolts/screws for securing the valve body.

Page 6821
WHAT ARE TRACKS?
15-28, and so on).
Page 6646
Ground (GND)

Page 1600
- Remove ESP sensor unit (G419).
CAUTION! Sharp shaking motions can destroy the transverse acceleration sensor (G200) and
rotation rate sensor ( G202 ).
Installing
- Installation is performed in reverse order of removal.
- Code radio.
- Perform basic setting of transverse acceleration sensor ( G200) and of rotation rate sensor (
G202).
Connect (VAS 5051) and select function => [ VAS 5051, Connecting and Selecting Functions ]
See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and Procedures/VAS 5051, Connecting and Selecting Functions.
Page 2824
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3934
Part 3
Page 3663
‹› Turn the crankshaft only in the direction of engine rotation - arrow -. Do not rotate the crankshaft
back, not even slightly!
‹› The crankshaft must not be rotated past the Top Dead Center (TDC) mark. This means the bore
- 2 - in the crankshaft must not rest above the
threaded opening.
If the crankshaft was rotated past the TDC marking:
- Rotate the crankshaft back 45° in the opposite direction of engine rotation.
- Then rotate the crankshaft again into the TDC position in the direction of engine rotation.
When the crankshaft is positioned slightly in front of the TDC position (hole in crankshaft is 90%
visible), the (T40069) can be installed, although slightly more difficult.
Locations
Page 4427
Exhaust Pipe: Service and Repair
Front Exhaust Pipe with Catalytic Converter
‹› hot bolt paste (G 052 118 A3)
Removing
- Loosen the double clamp bolts - 1 -.
- Remove the crossmember nuts - arrows - and crossmember.
- Disconnect the harness connectors - 2 and 3 - for the oxygen sensors and free up the wires.
- Remove the 4 front exhaust pipe to manifold nuts - 1 - and the suspended mount bolts - 3 -.
Page 1219
Part 1
Transmission Position Switch/Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5419
Electronic Throttle Control Module: Testing and Inspection
Throttle Valve Control Module, Checking
‹› Use only gold-plated terminals when servicing terminals in harness connector of Throttle Valve
Control Module (J338).
‹› Multimeter.
Test requirements
‹› Throttle valve must not be damaged or dirty.
‹› Coolant Temperature at least 80° C.
Function
Throttle valve operation occurs by an electric motor (Throttle Drive (for Electronic Power Control
(EPC)) (G186)) in the Throttle Valve Control Module ( J338). It is operated by the Motronic Engine
Control Module (ECM) (J220) based on input from the Throttle Position (TP) Sensor
(G79)/Accelerator Pedal Position Sensor 2 ( G185).
The Throttle Valve Control Module (J338) is made up of the following components:
‹› Throttle Drive (for Electronic Power Control (EPC)) (G186)
‹› Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) (G187)
The Throttle Valve Control Module (J338) cannot be serviced separately and must be serviced as a
unit.
Test procedure
Start diagnosis
- Switch ignition ON.
- Using the scan tool, check the throttle valve position (absolute) at idle stop:
Page 6543
Page 1986
Fuel Gauge Sender: Diagnostic Aids
Page 4884
WHAT ARE TRACKS?
15-28, and so on).
Page 5917
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4552
1 - Track Numbers

Page 7084
‹› Thrust piece (T10174)
Removing
- Remove Multi-Function Transmission Range (TR) Switch (F125) => [ Multi-Function Transmission
Range Switch ] See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service
and Repair.
- Carefully pry out selector shaft seal using a screwdriver. Do not damage selector shaft when
doing this.
Installing
- Drive in new sealing ring to stop, without canting.

Page 5584
Engine Speed Sensor: Testing and Inspection
Engine Speed Sensor, Checking
‹› Use only gold-plated terminals when servicing terminals in the electrical harness connector of the
Engine Speed (RPM) Sensor (G28 ).
‹› Multimeter.
Test requirements
Function
The Engine Speed (RPM) Sensor (G28) detects RPM and reference marks. Without an engine
speed signal, the engine will not start. If the engine speed signal fails while the engine is running,
the engine will stall.
Test procedure
Start diagnosis
- Start the engine.
- Using the scan tool, check the engine speed:
- Switch ignition OFF.

Checking internal resistance
‹› Polarity of the Multimeter leads MUST be followed or the result will be in error leading to
misdiagnosis.
- Disconnect the Engine Speed (RPM) Sensor (G28 ) electrical harness connector.
- Using a multimeter, connect the RED multimeter lead to Engine Speed (RPM) Sensor (G28)
terminal 1 and the BLACK multimeter lead to terminal 2 for resistance.
Page 1004
1 - Track Numbers

Page 7847
Part 3
Page 534
Ground (GND)

Page 5085
- Remove the glove compartment.
- Remove screws - 1 -.
- Remove the Tire Pressure Monitoring Control Module (J502) - 3 -.
- Disconnect the connector - 4 - from the Tire Pressure Monitoring Control Module (J502) - 3 -.
Installing
- Tighten the screws to 5 Nm.

Comfort System Central Control Module
Owner's Manual
General Information
Comfort System Central Control Module (J393) performs the following tasks in the vehicle:
‹› Sunroof control (issues enabling)
‹› Window regulator control (issues enabling)
‹› Central locking system control
‹› Anti-theft warning system control
‹› Radio receiver
‹› Rear lid closing
‹› Comfort operation
Page 7602
- Put wheel bearing - 1 - , pressure piece - 2 - (put collar into bearing), and hollow piston cylinder -
3 - with tie bolt on wheel bearing housing.
- From inside, assemble pressure piece - 4 - with wide collar to wheel bearing housing and special
nut - 5 -.
- Press in wheel bearing by actuating pump.
- Insert securing ring with needle-nose pliers.
1. Wheel bearing 2. Thrust piece E-13-1 3. Hollow piston cylinder HKZ-15 4. Thrust piece E-10 5.
Special nut E-8-214 and tie bolt
Pressing in wheel hub
- Put wheel hub - 1 - and hollow piston cylinder - 2 - with tie bolt onto wheel bearing.
- From inside, assemble special nut - 4 - and pressure piece - 3 - with collar to special nut.
- Press in wheel hub by actuating pump.
1. Wheel hub 2. Hollow piston cylinder HKZ-15 3. Thrust piece E-5 4. Special nut E-8-214 and tie
bolt
Installation is in reverse order of removal. Note the following: -
Tighten bolts for control arm and ball joint on to old marks.
- Install wheel and tighten.
Wheel Bearing Housing
‹› Thrust plate (VW 401)
‹› Punch (VW 407)
‹› Punch (VW 408 A)
‹› Thrust disc (VW 412)

Page 6091
Fuel Pump Relay: Testing and Inspection
Fuel Primer Relay J643, Checking
- Multimeter.
- wiring diagrams.
Test requirements
- Fuse SB42 OK.
- The Ground (GND) connections at the engine and transmission OK.
- The battery voltage at least 12.5 V.
- The generator OK.
Test procedure
Start diagnosis
- Using a Multimeter, check the following wiring connection for voltage.
Fuel Primer Relay J643 socket Measure to
21/31 Engine Ground (GND)
Specified value: 12.5 V
If the specified value was not obtained:
- Check the Fuel Primer Relay J643 socket 1/30 to the Battery for an open circuit or short to
Ground (GND).
- Check the electrical harness connectors for damage, corrosion, loose or broken terminals.
- If necessary, repair the wiring connection.
If no malfunctions are found in the wiring:
Fuel Primer Relay J643 Measure to
- Crank the engine.
- Switch the ignition off.
- Check the Fuel Primer Relay J643 socket 3/86 to the Power Supply Relay (terminal 15) J329
socket 2/87 for an open circuit or short to Ground (GND).
Checking Ground (GND)
- Remove the Motronic Engine Control Module (ECM) J220.
- Using a Multimeter, check the following wiring connection for resistance.
Fuel Primer Relay Motronic Engine Control Module (ECM) J220 electrical
J643 socket harness connector T121 or test box socket
16/MOT 65
Specified value: 1.5 Ohms.

Page 1725
1 - Track Numbers

Page 5882
WHAT ARE TRACKS?
15-28, and so on).
Page 1323
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6722
^ Obtain the owners written consent (see Control Module Tuning form) for any requested repair
under warranty or outside warranty that requires flashing, which will automatically overwrite the
"Tuned" program.
Production Solution
Service
1. Ensure the Technical Bulletin stating the condition in the vehicle applies to the customer concern
and the operator has a valid GeKo user ID and
password. Only perform operations explicitly stated in the Technical
Bulletin or RVU.
Page 2604
Part 1
Page 5222
- Using a multimeter, check the Throttle Valve Control Module (J338) electrical harness connector
terminals for an open circuit according to the wiring diagram.
- Check the wiring for an open, high resistance or short to ground.
Final procedures
1. Check the DTC memory. Refer to => [ Diagnostic Mode 03 - Read DTC Memory ] See: Testing
and Inspection/Scan Tool Testing and
Procedures/Diagnostic Modes 01 - 09.

Page 5348
Part 3
Page 4704
‹› Multimeter.
Test requirements
Function
Test procedure
Start diagnosis
- Start the engine.

misdiagnosis.
Page 2923
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5573
Part 3
Page 2047
1 - Track Numbers

Page 1458
Power Seat Switch: Diagnostic Aids
Page 6332
Camshaft Position Sensor: Testing and Inspection
Camshaft Position Sensor, Checking
‹› Use only gold-plated terminals when servicing terminals in harness connector of Camshaft
Position (CMP) Sensor (G40).
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
- Disconnect the Camshaft Position Sensor electrical harness connector.
- Using a multimeter, Check the Camshaft Position (CMP) Sensor (G40) electrical harness
connector terminals 1 to 3 for voltage.
Specified value: near 5.0 V
Checking wiring
connector to the Motronic Engine Control Module (ECM) electrical harness connector T121 for an
open circuit.
Specifications
Intake Manifold: Specifications
Intake Manifold to Cylinder Head Bolts ...............................................................................................
........................................................................ 9 Nm
Tighten bolts starting inside working toward outside in diagonal sequence

Page 1589
Speedometer Vehicle Speed Sensor (VSS) G22

Page 5295
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7520
WHAT ARE TRACKS?
15-28, and so on).
Page 639
Part 2
Page 3388
Description, Fuses 23-29
Page 5516
- Using a multimeter, check the Secondary Air Injection Sensor 1 (G609) electrical harness
connector terminals to the Motronic Engine Control Module (ECM) (J220) electrical harness
connector T121 terminals for an open circuit according to the wiring diagram.
If no malfunction is detected in the wiring:
Final procedures

Page 5418
Electronic Throttle Control Module: Diagnostic Aids
Page 7536
WHAT ARE TRACKS?
15-28, and so on).
Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolts
Replace bolts First pass ......................................................................................................................

........................................................................................... 60 Nm Final pass .....................................
................................................................................................................................... Tighten 90°
(1/4) additional turn
Page 5730
Tiptronic Switch -F189-

Table of Contents
Valve Body: Service and Repair Table of Contents
Removal and Installation
=> [ Oil Pan ] See: Fluid Pan/Service and Repair
=> [ Oil Strainer ] See: Fluid Filter - A/T/Service and Repair
=> [ Valve Body ] See: Valve Body
=> [ Wiring Harness with 14-Pin Connector ] See: Wiring Harness/Service and Repair/Wiring
Harness With 14-Pin Connector
=> [ Wiring Harness with 8-Pin Connector ] See: Wiring Harness/Service and Repair/Wiring
Harness With 8-Pin Connector
=> [ Transmission Input Speed Sensor ] See: Sensors and Switches - A/T/Transmission Speed
Sensor/Service and Repair/Transmission Input Speed Sensor
=> [ Transmission Output Speed Sensor ] See: Sensors and Switches - A/T/Transmission Speed
Sensor/Service and Repair/Transmission Output Speed Sensor
=> [ Multi-Function Transmission Range Switch ] See: Sensors and Switches - A/T/Transmission
Position Switch/Sensor/Service and Repair
=> [ Selector Shaft Seal ] See: Seals and Gaskets/Service and Repair/09G Transmission/Selector
Shaft Seal
Page 5761
WHAT ARE TRACKS?
15-28, and so on).
Page 6695
1 Automatic Transmission Hydraulic Pressure Sensor 1 (G193)
‹› No longer installed as of 07.04

2 Harness connector to Transmission Input Speed (RPM) Sensor (G182)
3 Wire on Transmission Input Speed (RPM) Sensor ( G182)
5 Wire on Transmission Output Speed (RPM) Sensor ( G195)
6 Harness connector to Transmission Output Speed (RPM) Sensor (G195)
7 Bracket for Transmission Fluid Temperature Sensor (G93)
9 Wiring harness for sensors with 8-pin connector - arrow -
‹› Removing and installing => [ Wiring Harness with 8-Pin Connector ] See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Wiring Harness/Service and Repair/Wiring Harness With 8-Pin Connector

Page 698
Body Control Module: Testing and Inspection Comfort System Central Control Module
Components, Adapting
Control Modules
Comfort System Central Control Module Components, Adapting
Procedure
- Connect the (VAS 5051B).
- In (VAS 5051B), select operating mode " Guided Fault Finding".
- Using the Go to button, select "Functions/Component selection" and the following menu options in
the following sequence:
‹› Body
‹› Body repair procedures
‹› 01 - On Board Diagnostic capable systems
‹› Comfort system
‹› Comfort System functions

Page 7724
- Press down shift rod direction of - arrow 1 -.
- While pressing down shift rod, rotate bracket - A - upward in direction of - arrow 2 - and
simultaneously press it carefully in until it engages in shift rod.
- Carefully pry off cover from upper part of center console - arrows -.
- Pull off cover toward rear from upper part of center console.
- Pull rubber sound insulation toward shift lever.
Secure shift lever as follows:
- Select neutral on shift lever.
- Guide connecting pin (T10027) through hole - A - into hole - B -.

Page 4179
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids
Page 7368
Transmission Temperature Sensor/Switch: Locations 09G Transmission

Sensor Identification
Page 2054
Part 3
Page 6985
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5857
Leak Detection Pump: Service and Repair
EVAP Canister and Leak Detection Pump
Removing
- Remove the rear right wheel housing liner.
- Disconnect the vent lines - 1 and 2 -.
Press in the securing ring - A - to disengage the lines.
- Disconnect the connector - 3 -.
‹› Illustration shows a metal fuel tank. Steps for the plastic fuel tank are similar.
- Disconnect the vacuum line - 3 -.
- Remove the right rear side turn signals.

Page 3494
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5422
Final procedures

Page 6405
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7301
WHAT ARE TRACKS?
15-28, and so on).
Camshaft Position (CMP) Sensor G40

Page 3445
Part 1
Fuel Pressure Regulator and Residual Pressure
Checking, Engine Code BPS
Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure Checking,
Engine Code BPS
Fuel Pressure Regulator and Residual Pressure Checking, Engine Code BPS
‹› Observe safety precautions. Refer to => [ Safety Precautions ] See: Powertrain

Management/Fuel Delivery and Air Induction/Service
Precautions/Safety Precautions/Multiport Fuel Injection.
‹› Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] See: Powertrain
Precautions/Clean Working Conditions/Multiport Fuel Injection.
‹› Fuel inj. pressure gauge-cis (VAG 1318)
‹› Valve adapter (VAG 1318/9)
‹› Adapter (VAG 1318/17)
‹› Fuel line feed adapter (VAG 1318/23)
‹› Remote control (VAG 1348/3A)

‹› The fuel pressure regulator regulates the fuel pressure to approximately 4 bar.
‹› The fuel pressure regulator is located on the fuel filter. From May 2006, the fuel pressure
regulator is integrated in the fuel filter and cannot be
replaced.
‹› Observe the safety precautions. Refer to => [ Safety Precautions ] See: Powertrain
- Disconnect the 4 pin harness connector - arrow - from the fuel delivery unit.
CAUTION! Fuel system is under pressure!
‹› Wear protective goggles and protective clothing to prevent injuries and contact with skin.
‹› Before loosening the line connection, place a cloth around the connection point. Then release
pressure by carefully loosening the line
connection.
- Disconnect the fuel supply line - 1 - from the filter and catch any leaking fuel with a cloth.
Page 1358
Part 1
Page 552
Part 1
Page 5957
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3693
5 Bearing Shell
‹› Note the installed position, refer to => [ Bearing Shells, Installed Location ].
‹› Do not interchange used bearing shells.
‹› Axial play new: 0.10 to 0.35 millimeter (mm).
Wear limit: 0.4 mm
‹› Measure radial clearance with Plastigage(R):
New: 0.02 to 0.06 mm
Wear limit: 0.09 mm
Do not turn the crankshaft when measuring radial play.
6 Connecting Rod
‹› With a cracked bearing cap.
‹› Separate new connecting rods. Refer to => [ New Connecting Rod, Separating ] See: Connecting
Rod/Service and Repair/Procedures.
‹› Only replace as a set.
‹› Affiliation to the cylinder mark - B -.
‹› Installed position: Marks - A - point to belt pulley side.
7 Circlip
8 Piston Pin
‹› If difficult to move, heat the piston to 60 °C (140 °F).
‹› Remove and install using pilot drift (VW 222A).
9 Piston
‹› Checking, refer to => [ Pistons, Checking ] See: Testing and Inspection.
‹› Mark the installed position and cylinder allocation.
‹› Arrow on piston face points toward the belt pulley side.
‹› Install with a piston ring compressor.
‹› Checking cylinder bore, refer to => [ Cylinder Bore, Checking ] See: Testing and Inspection.
‹› Piston and cylinder dimensions. Refer to => [ Piston and Cylinder Dimensions ] See:
Specifications/Piston and Cylinder Dimensions.
10 Piston Rings
‹› Offset gaps by 120°
‹› Use piston ring pliers for removal and installation.
‹› Marks face toward the piston crown.
‹› Checking ring gap, refer to => [ Piston Ring Gap, Checking ] See: Testing and Inspection.
‹› Checking piston ring groove clearance, refer to => [ Piston Ring Groove Clearance, Checking ]
Bearing Shells, Installed Location

Page 3677
Sealing Flange, Engine Front: Service and Repair Sealing Flange, Belt Pulley Side
Sealing Flange, Belt Pulley Side
‹› Trim removal wedge (3409)
‹› Oil seal guide sleeve (T03004)
‹› Silicone sealant (D 174 003 A2)
Removing
- Remove the ribbed belt for the Air Conditioning (A/C) compressor. Refer to => [ Ribbed Belt ]
See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and
Replacement/Ribbed Belt.
- Lock the crankshaft. Refer to => [ Crankshaft, Locking ] See: Crankshaft/Service and
Repair/Procedures/Crankshaft, Locking.
- Remove the pulley from the crankshaft.
- Remove the belt tensioner - 1 -.

- Remove the bolts - 2 -.
- Begin at the alignment bushings - arrows - in order to pry off the sealing flange - 1 - using a
suitable screwdriver - A -.
Page 5889
EGR Temperature Sensor: Diagnostic Aids
Page 1574
Page 3391
Page 113
WHAT ARE TRACKS?
15-28, and so on).
Page 6633
Page 4751
Page 6754
Tool requirements:
^ VAS 5051 or VAS 5052 (with Base CD V.11.00 and the Brand CD V.11.79.01 or higher).
^ "Update - Programming" (flashing) CD W420607A5SWU.
Tip:
Additional copies of the "Update - Programming" CD (Literature Number W420607A5SWU) may be

ordered from the Volkswagen Technical Literature Ordering Center at -->
http://www.vw.resolve.com/, or by calling from 8:00 a.m. to 8:00 p.m. EST Monday through Friday.
This number can be dialed in both the United States and Canada.
Vehicle requirements:
^ MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update process
can lead to ECM failure) (use an approved battery charger INC940 to maintain battery voltage).
^ VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure.
^ VAS 5052: connected to vehicle with battery voltage requirements met.
^ Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF.
^ When performing the update programming procedure, ALL DTCs for all systems are erased.
^ DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored
DTCs for Customer concerns unrelated to the update programming procedure first.
Note:
Nonobservance of the following points may lead to ECM failure! VAS 5051 or VAS 5052 must
always be connected to the approved power supply at the approved voltages. Under no
circumstances should the power supply be interrupted or the diagnostic connector unplugged
during the update programming procedure. Any appliances with high electromagnetic radiation (i.e.
mobile phones) must be switched OFF.
Tip:
Before update programming, delete the fault memory in the ECM and TCM. Update programming
is not possible when an EEPROM fault is active. Reprogram ECM and TCM with CD - Part number
W420607A5SWU.
Note:
TCM reprogramming is only necessary if the feature for update programming is available.
Insert the programming CD into the VAS 5051 / 5052, and access the ECM.
Tip:
If the update programming button does not appear, the latest version has already been installed to
the level below.
^ Programming starts by pressing the "Update Programming" button and following the on screen
prompts.
Note:
Once update programming begins, on NO occasion should the Cancel button be selected.
^ Press the "Update Programming" button.

^ Once ECM update has been performed, access TCM and perform "Update Programming" if the
VAS 5051 / 5052 shows the "Update Programming" feature.
Tip:
Once update programming is complete, it is recommended to use 1001- Compiling Services

prompt to clear faults stored in various control modules.
Page 1613
Part 3
Page 3336
Tip:
Page 1079
- End diagnosis.
If the DTC does return and no malfunction is detected in the wiring and the voltage supply was OK:
Final procedures
1. Check the DTC memory. 2. If necessary, erase the DTC memory. 3. If the DTC memory was
erased, generate readiness code. See: Powertrain Management/Computers and Control
Systems/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes
End diagnosis.
Page 1186
Part 3
Page 3928
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 151
1 - Track Numbers

Page 3814
^ Locate the upper cap portion index mark.
^ Position the lower cap so that the molded parallel lines (black arrows) align with the handle of the
top portion, and the top piece index mark rests between the parallel lines.
^ Align the upper portion of the cap over the lower portion and press firmly together.
Tip:
The oil filler cap will not be damaged during this action and will operate as designed.
Warranty
N/A information only
No special tools required
No special parts required

Page 6882
Page 3536
Use grease packet from repair kit
Installing
Pressing wheel bearing into wheel bearing housing
- Install securing ring.
‹› Make sure securing ring is correctly seated. Opening of securing ring must point downward.
Press wheel hub into wheel bearing
Wheel Bearing and Housing Assembly Overview
‹› If it should be necessary to move a vehicle whose drive axle has been removed, then before
doing so install an outer joint in place of the drive axle
and tighten it to 50 Nm, or else wheel bearing will be damaged.

Engine Controls - Silicone Sealer/Lubricant Precautions
Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant
Precautions
00 08 04
Aug. 18, 2008
2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan
applicability.
Vehicle Information
Condition
Sealants, Liquid Gaskets and Lubricants Containing Silicone

Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants,
liquid gaskets, or lubricants containing silicone.
Production Solution
N/A
Service
Many detailing products contain silicone.
If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior
and interior trim cleaner / protectants), silicone may be drawn into the intake system and can
contaminate the MAF sensor and/or oxygen sensors.
^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or
Oxygen sensors.
In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle
with a MAF sensor or oxygen sensors:
^ Always allow the silicone to cure properly before starting and running the vehicle's engine.
Warranty
Information only.
Page 5030
Compression Check: Testing and Inspection
Compression, Checking
‹› Spark plug removal tool (3122B)
‹› Ignition coil puller (T40039)
‹› Compression tester (VAG 1763)
‹› Adapter (VAG 1381/5A)
Conditions
‹› Engine oil temperature must be at least 30° C (86° F).
‹› Voltage supply OK.
- Remove the engine cover.
- Disconnect the connectors from the fuel injectors.
- Remove the ignition coils with power output stages. Refer to => [ Ignition Coils with Power Output
Stages ] See: Ignition System/Ignition Coil/Service and Repair.
- Remove the spark plugs using (3122B).
- Check the compression using (VAG 1763) and (VAG 1381/5A).
‹› Using the tester, refer to the operating instructions.
- Have a second technician operate the starter.
- Operate the starter until the tester shows no further pressure increase.
Compression Pressure
- To conclude work, erase the Diagnostic Trouble Code (DTC) memory of the Engine Control
Module (ECM) since malfunctions were stored by disconnecting the connectors. Refer to => [
Engine Control Module DTC Memory, Checking and Erasing ] See: Computers and Control
Systems/Engine Control Module/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes.
Page 1622
- A yellow dot must be visible in the hole - arrow 1 -.
- Markings - arrows - must align.
Be sure that center position is maintained.
Rest of installation is in reverse order of removal.
- Install airbag and steering wheel.
- Perform basic setting of steering angle sensor ( G85).

Page 6971
Fluid Pressure Sensor/Switch: Testing and Inspection
Automatic Transmission Hydraulic Pressure Sensor, Checking
NOTE: This procedure is used to diagnose Automatic Transmission Hydraulic Pressure Sensor 1
G193 and Automatic Transmission Hydraulic Pressure Sensor 2 G194
- Multimeter
- Wiring diagram
Test procedure
Start diagnosis
- Disconnect the Automatic Transmission Hydraulic Pressure Sensor electrical harness connector -
1 -.
Checking wiring

Intake Air Temperature (IAT) Sensor G42

Page 7158
- Shift transmission into position "P" using lever - 3 -, by pressing lever - 3 - toward rear until it
stops.
- Shift transmission into position "N" using lever - 3 -. Move lever - 3 - two engaged positions
toward front in direction of travel.
- Install spring washer - 2 - and nut - 1 - onto selector shaft - 4 -.
- Tighten nut - 1 - to 13 Nm.

Page 5128
If indication remains at approx. 140.0° C:
Checking wiring
- Disconnect the ECM harness connector.
- Disconnect the ECT harness connector at the sensor.
- Using a multimeter, check the signal circuit of the Engine Coolant Temperature (ECT) Sensor
(G62 ) electrical harness connector terminal 3 to engine ground.
Specified value: OL or no continuity.
- Check the wiring for a short circuit to Ground.
Final procedures

Page 5627
Part 1
Page 4357
Water Pump: Service and Repair
Coolant Pump
‹› Engine and transmission jack (VAG 1383A)
‹› Spring type clip pliers (VAS 5024A) or hose clip pliers (VAS 6340)
‹› Step ladder (VAS 5085)
‹› Engine holder bracket (T03000)
‹› Hose clamps up to 25 mm dia. (3094)
‹› Old oil collecting and extracting device (VAG 1782)
‹› Adapter set for engine and transmission support (VW 540/1 A)
‹› M8 x 100 bolt
‹› Cable tie
‹› To perform this procedure, the ground cable must be disconnected from the battery. Check
whether a coded radio is installed. If so, obtain the
anti-theft code beforehand.
‹› The engine is removed downward together with the transmission.
‹› All cable ties which are opened or cut off when removing the engine, must be replaced in the
same position when installing the engine.
CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the
following due to clearance issues:
‹› Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant,
refrigerant, brake fluid and vacuum)
and electrical wiring so that the original path is followed.
‹› To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot
components.
Removing
- Remove the intake hose - 1 - and connector - 2 - from the Mass Air Flow (MAF) sensor.
Page 1922
Page 3324
- Check brake fluid level and top off if necessary.
- Screw in sealing cap in brake fluid reservoir.
- Remove brake pedal depressor.
- Check pedal pressure and brake pedal free play. Free travel: maximum 1/3 of the pedal travel

Page 3481
Part 2
Page 1469
Part 2
Page 5568
Ground (GND)

Page 583
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2466
Part 1
Page 3379
Fuse: Application and ID Fuse Arrangements In Fuse Bracket/Battery, From July 2005
Fuse Arrangements In Fuse Bracket/Battery
Shift Lock Solenoid N110
Shift Interlock Solenoid: Locations Shift Lock Solenoid N110
Shift Lock Solenoid -N110-

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4775
- Check the wiring for an open, high resistance, short circuit to each other, or Ground.
- Using a multimeter, check the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter
(TWC) (G130) electrical harness connector terminal 2 to the Motronic Engine Control Module
(ECM) (J220) electrical harness connector T121 terminal 6 for an open circuit according to the
wiring diagram.
Final procedures

Page 5531
Ground (GND)

Page 712
Ground (GND)

Page 3402
[ Battery A, Disconnecting and Connecting ] See: Starting and Charging/Battery/Service and
Repair/Procedures/Battery A, Disconnecting and Connecting.
Connecting.
Removing
- Loosen both nuts - C - and all connectors - D -.
- Remove the relay panel - B - and relay carrier - A - downward.
Installing
- Tighten the nuts - C - to 3 Nm and the threaded connections - D - to 9 Nm.
Current relay assignments.
A-Pillar Connector Station

Page 4939
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 1836
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4044
Spark Plug: Service and Repair
03 - Service Procedures
Spark Plugs, Replacing
‹› Replacing spark plugs, 2.5L gasoline fuel injection engines
‹› Spark plug wrench (3122 B)
‹› Puller (T40039)
‹› Removal/installation tool (T10029)

Page 4798
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Tire Pressure Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3196
Repeat work procedure on left side of vehicle at rear.

- Connect collector bottle bleeder hose - 1 - to a front bleeder screw, open bleed screw and allow
the quantity to flow out (see table). Close bleeder screw.
Repeat work procedure on left side of vehicle at front.
Sequence and Brake Fluid Capacity Table
Total quantity: approximately 1 Liter
* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.
- Fit cover caps to bleed screws of wheel brake cylinder and brake caliper.
- Move filler lever on (VAS 5234) to position - B - (see user manual).
- Take filler hose off adapter.
- Unscrew adapter from brake fluid reservoir.

Page 2657
Page 1341
WHAT ARE TRACKS?
15-28, and so on).
Page 2052
Part 1
Page 5511

- Erase the DTC memory. Refer to => [ Diagnostic Mode 04 - Erase DTC Memory ] See: Testing
and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09
Generate readiness code. Refer to => [ Readiness Code ] See: Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes/Readiness Code.
Cooling System - Coolant Identification/Mixing
Coolant: Technical Service Bulletins Cooling System - Coolant Identification/Mixing
19 10 03
March 18, 2010
2022548 Supersedes T.B. Group 19 number 10-02 dated March 17, 2010 to improve coolant table
view.
Condition
Identifying and Mixing Factory Fill Engine Coolants
Discontinuation and mixing of Volkswagen approved engine coolants.
Coolants G11, G12 and G12+ have been replaced by an improved version. New coolant G12++
will be introduced on all engines.
Production Solution

Service.
Identify which coolant the vehicle was filled with from the factory. The photo shows the color of
each type of engine coolant.
The table identifies which coolant can be added to the factory coolant.
Tip: If a vehicle is found to have the incorrect coolant, the cooling system should be flushed using
the repair manual procedures in Elsa Web and then filled with the correct coolant.
Locations
Hood Alarm Switch F120

Page 1438
Part 1
Page 6565
Control Module: Locations 09G, 6 Speed A/T
Transmission Control Module (TCM) J217, 09G, 6 Speed A/T
Control module - arrow - is located beneath inner plenum chamber cover.

Page 3591
Part 3
Page 3732
5 Accessory Bracket
6 Bolt, 25 Nm
7 Bolt, 25 Nm
8 Generator
‹› To facilitate installing the generator, slightly drive back the threaded bushings for the generator
bolts.
9 Bolt, 25 Nm
10 Idler Pulley with Bracket
‹› For the ribbed belt for the generator, power steering pump and coolant pump.
‹› Do not remove the pulley.
11 Bolt, 25 Nm
12 Bushing
‹› Quantity: 2
13 Air Conditioning (A/C) Compressor
14 Bolt, 25 Nm
15 Ribbed Belt, for the Generator, Power Steering Pump and Coolant Pump
‹› Ribbed belt routing, refer to => [ Ribbed Belt Routing ].
‹› Before removing, mark the direction of rotation using chalk or a felt tip pen.
‹› Check for wear.
‹› Do not kink.
‹› Removal and installation, refer to => [ Ribbed Belt ] See: Ribbed Belt.
16 Ribbed Belt, for the A/C Compressor
‹› Do not kink.
17 Crankshaft Pulley/Vibration Damper
‹› To remove and install, lock the crankshaft. Refer to => [ Crankshaft, Locking ] See: Cylinder
Block Assembly/Crankshaft/Service and
Repair/Procedures/Crankshaft, Locking.
18 Bolt, 50 Nm + 90° (1/4) additional turn
‹› Quantity: 5
‹› Replace
‹› Only use N 907 630 04 bolts (strength category 10.9).

Page 2023
Part 1
Page 135
Global Positioning System Module: Diagnostic Aids
Page 6826
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2525
- Unlock the lever on the lock cylinder with the steel wire - arrow - and pull the lock cylinder out of
the steering lock housing.
1. Lock Cylinder
2. Steel wire (approximately dia. 1.2 mm)
3. Securing lever
Installing
Page 5007
3 Fuel Supply Line
‹› Black
4 Fuel Return Line
‹› Blue
‹› 4 bar
6 Gasket
‹› Replace
7 O-ring
‹› Replace
8 Fuel Supply Line
‹› Black
9 Bolt, 3 Nm
10 Bracket

Page 4071
Water Pump: Tools and Equipment
Water Pump Wrench
AST tool# VAG 1590
Water Pump Wrench.
- Made in Germany

Page 4721
WHAT ARE TRACKS?
15-28, and so on).
Page 4175
Part 2
Page 6867
Information only.
Additional Information All part and service references provided in this Technical Bulletin are subject
to change and/or removal.
Page 1747
Part 2
Page 1202
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5300
Service and Repair
Transmission Mount: Service and Repair
Transmission Mounts
‹› Engine support bridge (10 - 222 A)
‹› Adapter (10 - 222 A /8)
‹› Shackle (10 - 222 A /12)
‹› Torque wrench (V.A.G 1331)
‹› Engine/transmission jack (V.A.G 1383 A)
Removing
- Remove power steering reservoir from battery holder, do not kink hoses while doing this.
- Connect reservoir to lock carrier.

- Remove battery and battery holder.
- Disconnect Secondary Air Injection (AIR) pump hose - 3 - from air filter housing.
- Remove bolts - 4 -, - 5 - and - 6 -.
- Insert engine support bridge (10 - 222 A) with adapter (10 - 222 A /8).
Page 2921
Part 2
Page 2544
Part 3
Page 2710
1 - Track Numbers

Page 2839
WHAT ARE TRACKS?
15-28, and so on).
Page 1748
Part 3
Page 3466
Part 3
Page 7825
Part 1
Page 3935
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4173
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2251
Electronic Throttle Actuator Position Sensor: Diagnostic Aids
Page 1112
Ground (GND)

Page 1918
Part 1
Page 6151
Part 1
Page 20
- Antenna Selection Control Module -J515- (Diversity box) -3-:
^ Location Wagon; behind left luggage compartment side trim, below rear side window.
^ Location, Sedan: under rear parcel shelf.
Antennas:
All models use four antennas -1-, -8-.
^ Location Wagon: Integrated with rear side windows.
^ Location Sedan: Integrated with rear window.
Antenna amplifiers:
All models use four antenna amplifiers -2-.

^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side
windows.
^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim.
Touareg
Page 5366
Heater
‹› Multimeter.
‹›
Test requirements
Test procedure
Start diagnosis
arrows -.
correct resistance.
- Start the engine.

Page 7405
Tip:
Page 7526
Locations
Brake Fluid Pressure Sensor/Switch: Locations
Electrical and Electronic Component Locations, from MY 2006

8 Brake pressure sensor 1 (G201)
‹› Only in vehicles with ABS/EDL/ASR/ESP

Page 4689
WHAT ARE TRACKS?
15-28, and so on).
Page 7212
Shift Lock Solenoid
Removing
Board ] See: Shifter A/T/Service and Repair/Removal and Replacement/Selector Mechanism
Cover and Circuit Board.
- Raise vehicle.

Page 4155
Part 2
Diagrams
Wiper Switch: Diagrams
Windshield Wiper/Washer Switch and Multifunction Display Connector Assignments
as described in the Repair Information, refer to => [ Battery A, Disconnecting and Connecting ]
Connecting.
4-pin connector A, 4-pin
1. not used
2. not used
3. not used
4. not used
5. Windshield Wiper Intermittent Regulator (E38 ) for the Wiper/Washer Intermittent Relay (J31 )
6. Windshield Wiper Intermittent Regulator (E38 ) -> terminal 31
8-pin connector B, Windshield Wiper/Washer Intermittent Switch (E22)
1. Terminal 53
2. Terminal 31
Page 5158
Ground (GND)

Page 2497
09.

Code.
Page 3781
Pr-Sh
Page 1980
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2893
Sensors are installed above valve body in transmission housing.
1 Transmission Input Speed (RPM) Sensor (G182)
2 Transmission Output Speed (RPM) Sensor (G195)

Page 2304
Part 3
Page 1906
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7177

Instruments - Trip Computer Fuel Mileage Information
Fuel Distance/Mileage Module: Technical Service Bulletins Instruments - Trip Computer Fuel
Mileage Information
90 07 02
Mar. 23, 2007
2005497
Supersedes T.B. Group 90 number 03-01 dated April 4, 2003 due to the additional models, model
years and inclusion into ElsaWeb.
Affected Vehicles
Condition
Multi-function Trip Computer, Accuracy Concerns with Average Trip Fuel Consumption Calculation
Customer is concerned with the accuracy of the trip computer fuel consumption calculation and its
correlation with fuel gauge.
If a Customer voices concerns that the trip computer does not correlate with the fuel gauge:
- Explain to the Customer, the reasons for the margin of error as listed in this technical bulletin.
No repair is necessary.
Production Solution
Service
The trip computer approximates the fuel consumption and the distance until empty based on a wide
variety of driving conditions.
Miles to empty is calculated using, average fuel consumption and comparing this figure with the
current consumption and amount of fuel remaining in tank.
This computation is affected by climate conditions, terrain, distance driven, speed driven, change of
speed, Air Conditioner usage. Therefore a safety margin of 6 to 20 miles has been built in to the
system.
The trip computer is designed to error on the side of safety so that the vehicle does not run out of
fuel.
This helps in the following ways:

- Helps protect the driver from being stranded
- Helps to ensure that Diagnostic Trouble Codes are not set due to lean fuel mixture condition
(related to extreme low fuel level)
- Helps to prevent misfire (related to extreme low fuel level)
- Helps to prevent catalytic converter damage, which may be caused by misfire (related to low fuel
level) which could potentially cause the need for expensive repairs.
- Helps ensure that the vehicle continues to operate within Federally mandated emission
guidelines.
If a Customer voices concerns that the trip computer does not correlate with the fuel gauge:
- No repair is necessary.
Page 2467
Part 2
Page 4938

Page 4754
- Remove the Engine Control Module (ECM) (J220). Refer to the Repair Information.
- Using a multimeter, check the Manifold Absolute Pressure (MAP) Sensor (G71) electrical harness
connector T121 for resistance.
Specified Value: 1.5 ohm max.
- Check the wiring for an open circuit, high resistance, short circuit to each other, Battery (+) or
Ground.
- Replace Manifold Absolute Pressure (MAP) Sensor ( G71).
If the specified voltage supply was Not obtained:
- Install the test box. Refer to the Repair Information.
connector T121 terminals for resistance.
Ground.
If no malfunction is detected in the wiring and if the voltage supply was Not OK:
Final procedures
Page 1920
Part 3
Steering Column Position Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Locations
Pressure Regulating Solenoid: Locations


Page 4883
Ground (GND)

Page 4378
Part 3
Page 796
Main Relay (Computer/Fuel System): Testing and Inspection
ECM Voltage Supply, Checking
‹› Multimeter.
Test requirements
‹› Vehicles with automatic transmission, selector lever in position " P" or "N".
Test procedure
Start diagnosis
- Remove the Motronic Engine Control Module (ECM) Power Supply Relay (J271).
Checking voltage
- Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay Box
socket 2 (relay terminal 30) to Ground.
- Check the wiring connections from the Load Reduction Relay J59 to the Motronic Engine Control
Module (ECM) Power Supply Relay (J271) socket 2 for an open or a short circuit. Note: Fuse
S-237 is between the J59 Load Reduction relay and the J271 ECM relay. Check for an open S-237
fuse. If open, check for a short to ground between the fuse and ECM J271 relay.
- Check the wiring for open or short and connections for damage, corrosion, loose or broken
terminals.
- If necessary, repair the faulty wiring or connection.

socket 3, (relay terminal 86) to Ground.

Page 5209
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 381
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7269
‹› Maintain a distance of at least 5 mm to ATF cooler when routing selector lever cable.
- Install exhaust system and tunnel bridge.
- Connect battery Ground (GND) cable.
- Check shift mechanism => [ Selector Mechanism, Checking ] See: Shifter A/T/Testing and
Inspection.
- Install air filter housing.
- Code radio.
- Initialize power windows, set clock.

Page 759
Page 5919
Exhaust Temperature Sensor: Diagnostic Aids
Page 5886
Part 3
Page 3524
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing, Hub and Inner Race, With Wheel Bearing Housing Installed
Front Wheel Bearing, Hub and Inner Race, with Wheel Bearing Housing Installed
‹› Thrust piece (40 - 105)
‹› Hub puller (3283)
‹› Collar F/wheel brg. inner race (3423)
‹› Engine/transmission jack (V.A.G 1383 A) with universal transmission support (V.A.G 1359/2)
‹› Puller (Kukko 18/0 )
‹› Foot pump with high pressure hose (V.A.G 1389 A/1 )
‹› Wheel bearing tool (V.A.G 1459 B)
‹› Hollow piston cylinder (HKZ-15) with thrust piece (E-0-204-T) hydraulic
‹› Tie bolt (E-0-217+218)
‹› Special nut (E-8-214)
‹› Thrust piece (E-5)
‹› Thrust sleeve (E-13-1)
‹› Pressure bolt (E-15)
‹› Supplementary set (V.A.G 1459 B/2)
‹› Bell (E-40)
If there is a hand pump ( V.A.G 1389/1) available it can also be modified for use as a foot pump.
To do so, use conversion kit (V.A.G 1389/4 ).
Removing
- Lift vehicle enough that the front axle is no longer burdened.
- Remove 12 point nut.
- Raise vehicle to installation height.
- Remove wheel.
- Remove brake carrier with brake caliper or brake caliper and hang on body with tie wire.
- Mark installation position of bolts - arrows - for ball joint - 1 - on control arm - 2 -.
Page 2822
Part 2
Page 447
Part 2
Page 803
Page 976
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Crankshaft Specifications
Crankshaft: Specifications Crankshaft Specifications
Main Bearing Cap Bolts

.......................................................................................................................................... 40 Nm plus
an additional 1/4 turn (90°)
Replace
Crankshaft
Axial play
New .....................................................................................................................................................
............................................... 0.07 to 0.21 mm Wear limit ..................................................................
.................................................................................................................................... 0.30 mm
Radial clearance
New .....................................................................................................................................................
........................................... 0.023 to 0.043 mm Wear limit ..................................................................
.................................................................................................................................... 0.07 mm
Identification Of Top Crankshaft Bearing Shells
From the factory, the upper bearing shells are allocated to the cylinder block with the correct
thickness. Colored spots serve to identify bearing thicknesses.
The letters marked on lower sealing surface of cylinder block identify which bearing thickness must
be installed in which location.
G - Yellow B - Blue W - White
Note: ^
- Arrow - points in direction of travel.
^ If color markings can no longer be read, use blue bearing shell.
^ The lower crankshaft bearing shells are always shipped as replacement part with "yellow" color
marking.
Crankshaft Dimensions
(Dimensions in mm)
Crankshaft dimensions
Air Door Position Sensor / Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4008
‹› Multimeter.
Test conditions
Test procedure
Start diagnosis
pressure.

Page 5292
legend.
wiring diagram.
harness.


question.)
19 - Legend



A/T - High Launch RPM's/DTC P0716/P0740
Transmission Speed Sensor: Customer Interest A/T - High Launch RPM's/DTC P0716/P0740
Condition
Transmission, DSG*, Intermittent Engagement Delay Upon Acceleration
* DSG is Volkswagen Group's trademark for double clutch transmission.
Intermittent delay in power transfer upon acceleration.May be accompanied by a slight jerking

sensation when pulling away on vehicles with DSG transmission.
Upon acceleration engine RPMs may reach between 2000 rpm and 4000 rpm before the vehicle
will pull away.The complaint occurs mainly on warm engine.
37 06 07 Dec. 22, 2006 2012681
Failure of the sensor for the transmission RPM input -G182- and for the clutch temperature sensor
-G509-, caused by:
- Wiring harness connector not correctly slotted.
- Sensor faulty or wiring harness damage.
Either one of the fault entries may be logged in the fault memory:
17100 or P0716 Input Turbine/Speed Sensor (A) Circuit Range/Performance
18148 or P1740 Clutch Temperature Monitoring
Production Solution
Improved production.
Service
NOTE: It is not necessary to replace the Mechatronics Unit.
- Ensure that the wiring harness connector is fully seated and locked into position, then recheck
DTCs.
If DTCs are still present, further diagnosis is needed.

Mass Air Flow (MAF) Sensor G70

Page 7588
‹› Thickness 22 mm
‹› Wear limit: 19 mm
‹› Pads on both sides of axle must always be replaced together
‹› Remove brake caliper housing before removing
‹› Do not separate brake discs from wheel hub with force or rust solvent, otherwise brake discs will
be damaged.
3 Brake pads
‹› Vehicles up to model year 2000
‹› Checking thickness => 14.1
‹› Removing and installing => [ Brake Pads ] See: Brakes and Traction Control/Disc Brake
System/Brake Pad/Service and Repair/Removal and
Replacement.
‹› Wear limit: 7 mm including backing plate
4 Brake caliper housing
‹› Do not remove brake hose when replacing brake pad
‹› Removing and installing => [ Brake Caliper ] See: Brakes and Traction Control/Disc Brake
System/Brake Caliper/Service and
Repair/Removal and Replacement/Brake Caliper.
‹› Servicing => [ Front Brake Caliper Assembly Overview ] See: Brakes and Traction Control/Disc
Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Front Brake Caliper Assembly Overview.
5 Guide pins, 28 Nm (18 ft lb)
6 Concealment cap
‹› Remove
7 Brake hose with ring supports and banjo fitting, 35 Nm
8 Wheel bearing housing
9 Socket-head bolt 8 Nm
10 Right front ABS wheel speed sensor (G45)/left front ABS wheel speed sensor (G47)
‹› Before inserting sensor, clean inner surface of hole and coat with securing grease (G 000 650)
11 Cover plate
12 Hex bolt, 10 Nm
13 Wheel bearing
‹› Always replace after removal
14 Circlip
15 Wheel hub with rotor
16 Brake pads
Page 6990
Page 1877
High Pressure Sensor / Switch: Testing and Inspection High Pressure Sensor, Electrical Testing
High Pressure Sensor, Electrical Testing
- Check voltage and ground supply to sensor using wiring diagram.
- Check wiring for short to one another.
- Check wiring for short to B+ and ground.
- Check wiring for short circuit between High Pressure Sensor (G65) and Coolant Fan Control (FC)
Module (J293) using wiring diagram.
- If no wiring faults can be determined, replace High Pressure Sensor (G65).

Page 5296
Part 1
Page 3447
Part 3
Page 347
Part 3
Page 4149
1 - Track Numbers

Page 2579
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Engine Controls - Avoiding Unnecessary ECM
Replacement
Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary
ECM Replacement
01 07 54
July 10, 2007
2011168
Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year
and to add DTC 01314.
Condition
Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs)
Unnecessary ECM replacement.
Vehicle Information
Diagnostic aid.
Production Solution
No production change required
Service
Prior to replacing an ECM for any DTC:

Page 1326
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4690
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4536
Motronic Engine Control Module (ECM) J220

Page 1410
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7087
- Carefully drill 2 to 4 mm hole in outer metal ring of oil seal using a commercially available drill - B
-.
‹› Grease drill bit - B - so that drill shavings remain held.
‹› Drill through metal ring - C - only, otherwise transmission may be damaged.
- Install a metal bolt (approx. 4 mm diameter) into drilled hole of seal - arrow -.
‹› Do not screw in metal bolt too deeply to prevent damage to bearing behind it.
- Pull seal out using Puller T10055 (T10055) and adapter (T10055/2).
- Remove cloth and thoroughly clean transmission and opening for drive axle.
CAUTION! No metal fillings may enter the transmission or the opening for the axle shaft. Clean the
area of metal particles using a vacuum cleaner if necessary.
If only the metal ring could be removed when pulling out:
- Carefully pry out rest of seal using a screwdriver - A -.

Page 1025
Part 1
Page 4561
Page 3257
- Remove center section of noise insulation below engine/transmission.
Clean transmission.
CAUTION! To drain gear oil, journal for shift forks in transmission must be removed.
To avoid that the position of the shift forks is changed, e.g. by involuntarily operating shift
mechanism, shift rod must be secured.
Secure Shift Rod as Follows
- Press down shift rod - direction of arrow 1 -.

Page 2091
Hazard Warning Switch: Diagnostic Aids
Page 840
Checking wiring

Page 3482
Part 3
Page 7355

Page 66
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 274
Part 2
Main Relay (Computer/Fuel System): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 953
Steering Column Control Module: Diagnostic Aids
Page 2371
Part 1
Page 4253
Part 2
Page 571
Part 1
Page 6411
Ignition Coil: Service and Repair
Ignition Coils with Power Output Stages
Removing
- Disconnect the harness connector from the Secondary Air Injection (AIR) solenoid valve (N112) -
arrow -.
In order to prevent damage to the wire guide, remove the ignition coils with power output stage as
follows:
- Using (T40039), pull all ignition coils only approximately 10 millimeters (mm) out of the spark plug
holes, starting with ignition coil - 1 -.
- Then, pull out all ignition coils a further 10 mm in the same sequence.
- Disengage all connectors and pull them out only slightly.
- After that, pull off all connectors - A -, starting at ignition coil - 1 -, and remove the ignition coils
from the spark plug holes.
Page 4486
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3136
- Install dust cap -arrow- hand-tight in oil filter housing.
Replacing oil filter (Diesel engines)
Removing
Note: Observe waste disposal regulations! Oil new O-rings before installation.
- Loosen sealing cap -arrow- e.g. using ring wrench AF 36 or using socket insert AF 36 T10125.
Note: Loosen cap before draining/extracting so that engine oil can flow out of filter housing.
- Clean sealing surfaces at cap and at oil filter housing.
Installing
- Install oil filter -3-
- Replace O-rings -2 and 4-.

Page 4951
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6067
WHAT ARE TRACKS?
15-28, and so on).
Page 6034
WHAT ARE TRACKS?
15-28, and so on).
Page 5992
Fuel: Technical Service Bulletins Fuel System - Neutralizing Fuel For Fuel Tank Disposal
20 08 06
Oct. 13, 2008
2011499 Supersedes T.B. Group 20 number 06 01 dated February 17, 2006 due to additional
model and model year applicability.
Vehicle Information
Condition
Fuel Tanks Removed from Vehicles, Neutralizing Fuel
Flush procedure using emulsifier to neutralize fuel tanks before shipping.
Production Solution
Service
This Technical Bulletin applies to fuel tank replacement, whether covered under warranty or carried
out at the customer's expense.
Once a fuel tank has been replaced in a vehicle, the old tank must be flushed to properly neutralize
any remaining gasoline or diesel fuel.
This procedure pertains to any fuel tank, whether being returned to the Warranty Test Center or
being disposed of by other means.
WARNING:
The fuel tank must be neutralized before shipment or disposal.
To obtain the emulsifier, order Qty. 1 of Part No. D 200 201L (1 Liter). This Liter can be used to
neutralize two (2) fuel tanks.
Flushing / Neutralizing
Fuel tank removed.
^ Pour 0.5 Liter of emulsifier into tank.
^ Add 4 Liters water, then cap off all openings.

^ Agitate tank for at least 30 seconds, turning tank assembly in all directions to allow emulsifier to
reach all areas inside the tank.
^ After agitation, drain neutralized mixture into special container labeled "Waste
Material-Hazardous" and dispose of properly in accordance with local, state and Federal EPA
regulations.
For warranty repairs, add 0.5 Liter of the emulsifier to the warranty claim, using Qty. 0.5 of Part No.
D 200 201L.
NOTE:
If a fuel tank is requested to be shipped to the Warranty Test Center: Ship only after tank has been
neutralized with the emulsifier. DO NOT ship fuel tank by air.
Warranty
N/A
Page 1389
WHAT ARE TRACKS?
15-28, and so on).
Page 2961
Window Shade Switch: Diagnostic Aids
Page 2846
Shift Interlock Switch: Diagnostic Aids
Page 5163
Part 3
Page 484
A/T Shift Indicator Module: Diagnostic Aids
Page 5439
Page 6064
1 - Track Numbers

Throttle Drive Angle Sensor 2 (For Electronic Power
Control (EPC)) G188
Throttle Drive Angle Sensor 2 (For Electronic Power Control(EPC)) G188

Page 6567
Function
Page 7928
Page 4560
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1712
Ground (GND)

Page 2284
Intake Air Temperature Sensor: Testing and Inspection
Intake Air Temperature Sensor, Checking
‹› The Mass Air Flow sensor and the Intake Air Temperature sensor are combined as a unit.
MAF / IAT sensor (G70 / G42).
‹› Multimeter.
Test procedure
Start diagnosis
- Engine must be at Room Temperature.
- Using the scan tool, check the intake air temperature:
- Fault is intermittent. Check for proper connection, damaged wiring or loose terminals.
- Disconnect the MAF / IAT sensor (G70 / G42) electrical harness connector.
- Using a multimeter, check the MAF / IAT sensor ( G70 / G42) terminals 1 to 2 for resistance.
Use the chart below for the specified values:
Specified values:
Page 666
Page 3664
Crankshaft: Removal and Replacement
Crankshaft Assembly Overview

‹› Replace
‹› Fully threaded
‹› Tighten to 40 Nm (but not any further) to measure the radial play in the crankshaft.
2 Bearing Cap
‹› Bearing cap 1: Belt pulley side.
‹› Retaining tabs on the bearing shells and cylinder block/bearing caps must lie above one another.
3 Bearing Shell, for the Bearing Cap
‹› Without a lubricating groove.
‹› Do not interchange used bearing shells (mark them).
4 Crankshaft
Wear limit: 0.30 mm

Page 4862
WHAT ARE TRACKS?
15-28, and so on).
Page 4705
Specified value: 13.7 M ohms
If any of the specified values are not obtained:
- Replace the Engine Speed (RPM) Sensor (G28).
Checking wiring
- Using a multimeter, check the Engine Speed (RPM) Sensor (G28) electrical harness connector
terminals for an open circuit.
- Remove the Engine Speed (RPM) Sensor (G28) and check the sensor wheel for proper seating,
damage and runout Refer to the Repair Information.
If the sensor wheel is OK:
Final procedures

Page 6191
Checking wiring

Page 1387
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3087
5 Accessory Bracket
6 Bolt, 25 Nm
7 Bolt, 25 Nm
8 Generator
‹› To facilitate installing the generator, slightly drive back the threaded bushings for the generator
bolts.
9 Bolt, 25 Nm
10 Idler Pulley with Bracket
‹› For the ribbed belt for the generator, power steering pump and coolant pump.
11 Bolt, 25 Nm
12 Bushing
‹› Quantity: 2
13 Air Conditioning (A/C) Compressor
14 Bolt, 25 Nm
15 Ribbed Belt, for the Generator, Power Steering Pump and Coolant Pump
‹› Do not kink.
16 Ribbed Belt, for the A/C Compressor
‹› Do not kink.
‹› To remove and install, lock the crankshaft. Refer to => [ Crankshaft, Locking ] See: Engine,
Cooling and Exhaust/Engine/Cylinder Block
Assembly/Crankshaft/Service and Repair/Procedures/Crankshaft, Locking.
‹› Quantity: 5
‹› Replace

Page 6112
Fuel Supply Line: Tools and Equipment
Fuel Line Adapter Kit
AST tool# VAG 1318-10
Fuel line adapter kit. Contents: VAG 1318-10: 12mm x 1.5 thread & 8mm hose/barb. VAG 1318-11:
8mm x 1.0 thread & 8mm hose/barb. VAG 1318-12: 12mm x 1.5 thread & 14mm x 1.5 thread.
- Made in Germany

Page 98
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1169
Part 1
Page 714
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4538
Engine Control Module: Description and Operation
Engine Control Module
The ECM regulates fuel injection, throttle valve control module, oxygen sensor regulation, ignition,
knock control, evaporative emission purge valve, engine speed limitation through the fuel injectors
or the power supply relay, as well as OBD functions.
Page 2819
WHAT ARE TRACKS?
15-28, and so on).
Page 4671
WHAT ARE TRACKS?
15-28, and so on).
Page 4724
Part 2
Page 134
Page 2972
Part 1
Page 5822
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7422
Did the Power supply and Ground circuits to the Data Bus On Board Diagnostic Interface Module
(J533 Gateway) and TCM (J217) test OK?
Yes: Contact technical assistance, select the "Technical Assistance" tab in Elsaweb and follow the
instructions to obtain a 6 digit pin.
No: Repair harness wiring as necessary.
Warranty
Information only.
removal.
Page 6059
If specified value is achieved:
- Switch off ignition.
- Now check for leaks and residual pressure (entire system). Observe pressure drop on the (VAG
1318).
‹› After 10 minutes there must be a residual pressure of at least 3.0 bar.
If the holding pressure drops below 3 bar:
- Start the engine and run at idle speed.
- Wait until the pressure has built up, then switch off the ignition. Shut off lever on the (VAG 1318)
must be closed at the same time (lever perpendicular to direction of flow - arrow -).
- Observe the pressure drop (engine side) on the (VAG 1318).
If the pressure drops again:
- Check line connections, O-rings at fuel rail and injectors for leaks. Refer to => [ Fuel Injectors,
Checking Injection Quantity and for Leaks ] See: Fuel Injector/Testing and Inspection/Fuel
Injectors, Checking Injection Quantity and For Leaks.
- Check the (VAG 1318) for leaks.
‹› Before removing the (VAG 1318) , place clean cloths around the line connection which is to be
disconnected.
If the pressure does not drop:
- Check line connections to the fuel tank and check valve in the fuel pump. Refer to => [ Fuel Pump
Check Valve, Checking ] See: Fuel Pump/Testing and Inspection/Fuel Pump Checking, Engine
Code BPS (Plastic Fuel Tank).
- If the check valve is OK, replace the fuel pressure regulator - item 5 - in => [ Fuel Pressure
Regulator ] See: Fuel Tank/Service and Repair/Removal and Replacement.
‹› From May 2006, the fuel pressure regulator is integrated in the fuel filter and cannot be replaced.
- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] See: Fuel Tank/Description
and Operation.
Page 346
Part 2
Page 532
1 - Track Numbers

Page 6965
- Remove oil pan bolts - arrows - using diagonal and alternating sequence.
‹› A small amount of ATF remains in the oil pan as not all the oil can drain through opening - A -.
- Remove oil pan together with gasket.
Installing
- Clean two magnets located in webs of oil pan. Ensure magnets have full contact with oil pan.
- Insert oil pan with a new gasket.
- Make sure oil pan gasket is seated correctly.
- Lines must not be jammed when installing oil pan.
- Tighten oil pan bolts - arrows - in diagonal sequence and in stages => [ (Item 5) Bolt, 7 Nm ] See:
Valve Body/Service and Repair/Valve Body Assembly Overview.
Page 7690
^ Remove transmission drain plug -1- and bearing pin -2-, allow transmission to totally drain.
^ Install bearing pin -2- using new grommet.
^ Install drain plug -1-.
^ Turn bracket -A- back to original position so the selector shaft -1- can move freely.
Transmission, filling:
^ ADD new transmission oil Part No. G 055 726 A2 to oil already in catch container until total
volume is 1.9L (2 qt.).
^ Remove back up light switch arrow -1-.
^ Connect a rubber hose (approx. 600 mm (24 in.) long with a 10 mm (3/8 in.) diameter) to a
funnel.
^ Insert hose into hole of back up light switch and fill transmission.
^ Install back up light switch.
^ Check the operation of shifter. install air filter housing.
^ Install sound insulation.
02J Manual 5 Speed Transmission, Draining and Re-filling
See Repair Manual Group 34, Manual Transmission - Controls, Housing.

Page 6398
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7517
1 - Track Numbers

Page 1146
Ground (GND)

Page 40
If reception does not return:
^ Problem is located further forward in the system.
For problems forward of the antenna system:
- Continue with Section 3a.
For problems at antenna system:
Skip to Section 3b.
For problems at antenna systems:
Tip:
All checks should be done outdoors away from buildings.
Section 3a - Problems forward of antenna system
- First verify connection at Radio (check for bent or crushed connections and proper fit).
If all connections appear ok:
- Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception).
If reception returns:
^ Problem is located between radio and antenna.
- Check connections near center console:
If connections are OK:
- Check resistance of cable from end to end.
^ If More than .4 ohms:
- Replace cable.
If reception does not return;
- Replace radio unit.
Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8)
If concern is only AM poor / no reception;
Locate AM antenna amplifier.
^ Touareg: located above left side window.
^ Passat W8: Sedan above rear window.
^ Passat Wagon: located on left rear window.
- Check for proper connections at amplifier both from diversity box and to glass.
If connection issue is at glass or on glass:
- Glass must be replaced.
If connection problem to amplifier:

- Repair connection (replace cable or amplifier).
Page 62
1 - Track Numbers

Page 7614
7 Brake caliper
8 Stub axle
‹› Straightening work prohibited.
‹› Do not re-cut threads.

ESP Sensor Unit G419, Removing and Installing, Vehicles
From 12.0
Lateral Accelerometer: Service and Repair ESP Sensor Unit G419, Removing and Installing,
Vehicles From 12.0
ESP sensor unit G419, removing and installing, Vehicles from 12.0
The sensor for transverse acceleration G200 and the sender for rotation rate G202 are assembled
together in one housing on a new bracket, at the same place in the vehicle.
The ESP sensor unit G419 - 1 - is fixed with a bracket on the steering column bearing bracket - a -.
When the ESP sensor unit G419, is replaced, a zero compensation of the sensor for transverse
acceleration G200 and the sender for rotation rate G202 must be performed.
Removing
- Disconnect connector - arrow - from the ESP sensor unit G419.
- Remove bolt - 1 - and ESP sensor unit G419.
- Remove nuts - a - from the ESP sensor unit G419 - 1-.
- Remove ESP sensor unit G419.
CAUTION: Strong vibrations can destroy the lateral acceleration sensor G200 and the yaw rate
sender G202.
Installing
- Installation is carried out in the reverse sequence of removal.
- Enter radio code.
- Perform basic settings on the sensor for transverse acceleration G200 and sender for rotation
rate G202.

Page 6147
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6046
Fuel Injector: Testing and Inspection Fuel Injectors, Checking Injection Quantity and For Leaks
Fuel Injectors, Checking Injection Quantity and for Leaks
‹› Observe safety precautions. Refer to => [ Safety Precautions ] See: Service Precautions/Safety
Precautions/Multiport Fuel Injection.
‹› Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] See: Service
Precautions/Clean Working Conditions/Multiport Fuel
Injection.
‹› Adapter cable (VAG 1348/3-2)
‹› Injection rate tester (VAG 1602)
‹› Connector test set (VAG 1594C)
Checking for Leaks
‹› Fuel pressure must be OK, checking. Refer to => [ Fuel Pressure Regulator and Residual
Pressure Checking, Engine Code BPS ] See: Fuel
Pressure/Testing and Inspection/Fuel Pressure Regulator and Residual Pressure Checking,

Engine Code BPS.
- Remove the fuel rail - 2 - with injectors installed. Refer to => [ Fuel Injectors ] See: Service and
Repair/Fuel Injectors, and place it on a clean cloth.
Do not disconnect the battery and do not disconnect the fuel supply line at the quick acting
coupling or at the fuel rail.
‹› Harness connectors must be disconnected from the fuel injectors.
- Fold the rear seat bench forward.
- Remove the cover from fuel delivery unit.
- Disconnect the 4 pin connector from the fuel delivery unit.
- Using an adapter cable, connect terminal - 1 - of the fuel pump to the battery positive (+).
Service and Repair
Front Crankshaft Seal: Service and Repair
Chain case cover sealing ring, replacing
Conditions
^ Chain case cover removed
^ Bearing driver VW 195
^ Tube VW 415 A
^ Fitting sleeve 3241/4
Driving out sealing ring

Active Spoiler Switch: Description and Operation
Interior Lamps and Switches
‹› When removing and installing components in visible area (switches, covers, trim panels), cover
by taping the areas at which a prying tool (plastic
sedge, screwdriver) will be positioned using commercially available adhesive tape.
Rear Spoiler Switch
The Rear Spoiler Switch (E127) " manually" extends and retracts the rear spoiler.
The Rear Spoiler Switch (E127) - arrow - is located under the instrument panel near the steering
column.
The rear spoiler will extend all the way out when the ignition is turned on and the switch is in
position - 1 -.
The rear spoiler will extend in steps all the way out when the ignition is turned on and the switch is
in position - 2 -.
CAUTION! Danger of injury!
Make sure there is enough clearance when "manually" extending or retracting the spoiler using the
switch.
‹› When removing and installing components in visible area (switches, covers, trim, etc.), cover by
taping the areas at which a prying
Page 5165
Page 6238
Part 3
Page 2716
Part 2
Steering Mounted Controls Communication Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 35
- Antenna Selection Control Module -J515- (Diversity box) -3-:
^ Location Wagon; behind left luggage compartment side trim, below rear side window.
^ Location, Sedan: under rear parcel shelf.
Antennas:
All models use four antennas -1-, -8-.
^ Location Wagon: Integrated with rear side windows.
^ Location Sedan: Integrated with rear window.
Antenna amplifiers:
All models use four antenna amplifiers -2-.

^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side
windows.
^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim.
Touareg
Page 4374
WHAT ARE TRACKS?
15-28, and so on).
Page 7125
Part 1
Page 640
Part 3
Page 5697
Part 2
Page 3498
Part 1
Page 55
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3227
- Remove ATF inspection plug from oil pan.
The ATF present in the overflow tube runs out.
If ATF drips out of drilling:
ATF does not need topping off. -
Install new seal to plug and tighten to 15 Nm. This completes the ATF check.
If no ATF drips out of inspection hole: -
Top off ATF Topping Off ATF.
Topping Off ATF

Topping Off ATF, 09G, 6 Speed A/T
Page 2090
Page 2543
Part 2
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Page 4669
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4328
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3098
11 Air Duct
‹› Secured to the battery holder.
12 Lower Air Filter Housing
13 Intake Tube
‹› For warm air.

Page 679
Exhaust Temperature Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Combination Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3452
Installing

Owner's Manual
General Information
Page 3293
Oil filter insert, installing
- Press new oil filter insert - 2 - onto oil filter housing center tube - 4 - as far as stop.
Oil filter housing, installing
- Install oil filter housing - 4 - with new sealing ring - 3 - and new oil filter insert - 2 - by hand until
almost on oil filter housing stop - 1 -.
- Tighten the oil filter housing - 2 - to 25 Nm.

Locations


Page 3346
Tip:
Page 1538
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5384
Part 1
Page 6566
Control Module: Locations 09G Transmission
1 Transmission Control Module (TCM) (J217 )

Page 5259
removal.
Page 3172
Power Steering Line/Hose: Service and Repair Pressurized Line and Return Hose Overview
1.8L, 2.0L and 2.5L With Automatic Transmission 09G

Pressurized Line and Return Hose Overview
1 Automatic transmission
2 Double bolt
‹› M10 x 20 - M8 x 12
‹› Tightening specification => [ Pressurized Line to Automatic Transmission 09G ] See:

Specifications/Pressurized Line Mount to Transmission
Tightening Specifications.
3 To reservoir
4 Hex nut
‹› M8

5 Pressurized line
6 From steering gear

Page 4359
- Remove the pendulum support bolts - arrows -.
- Drain the coolant. Refer to => [ Draining and Filling ] See: Service and
- Bring the lock carrier into service position. See: Body and Frame/Lock Carrier
- Support the lock carrier using a sleeve - B -, 80 millimeters (mm) in length, for example, from (VW
540/1 A) and a M8 x 100 bolt - A -.
- Empty the power steering reservoir using (VAG 1782) and remove it.
- Remove the bracket nuts - 2 - for the power steering reservoir.

Wiring Harness, 8-Pin
Wiring Harness, 8-pin

Tools and Equipment
Ignition Coil Pack: Tools and Equipment
VW/Audi Coil Pack Puller
AST tool# 6639
Used for removing and installing ignition coils with final output stage. Comparable to factory tool #
T 40039. Applicable to the following engines: 1.8T, 2.0T, 2.5T, 2.7L Bi-Turbo, 2.5L, 3.0L, 3.2L and
4.2L engines. Compact size, only 2 inches in length.
- Made in U.S.A.
- Compact size, only 2" in length
Assenmacher Specialty Tools

Page 2071
Part 1
Page 2656
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6199
- Using a multimeter, check the following wiring connections for voltage.
Page 7386
Installing
‹› Routing of lines must be followed exactly so that they are not jammed when installing valve body.
- Route wiring harness - 5 - corresponding to illustration in the recess provided in the transmission.
Distance - a - must be maintained so that wiring harness - 5 - does not touch planetary gear while
driving and is therefore damaged.
- Place wiring harnesses - 1 -, - 3 -, - 4 - and - 5 - over edge of transmission according to

illustration.
Page 6180
Part 2
Page 3827
- Install screw cap -arrow- and tighten to 25 Nm.
Installation is reverse of removal.

Locations
Radiator Cooling Fan Control Module: Locations
Cooling system components (on body), assembly overview
1 - Radiator After replacing replace entire amount of coolant
2 - Air shroud
3 - O-ring Replace if damaged

4 - Upper coolant hose Secured to radiator with a retaining clip
5 - Coolant Fan Control (FC) Control Module J293
6 - 5 Nm
7 - Bolt
8 - Fan wheel
9 - Fan ring
10 - Cover
11 - Coolant fan motor
12 - 5 Nm
13 - Washer
14 - Bolt
15 - Connector
16 - 5 Nm
17 - Lower coolant hose Secured to radiator with a retaining clip Ensure seated tightly Coolant
hose connection diagram = Coolant hose connection diagram
Page 7905
Removing
- Remove valve body => [ Valve Body ] See: Automatic Transmission/Transaxle/Valve

Body/Service and Repair/Valve Body.
Installing
See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Valve Body Assembly
Overview.
- Install valve body => [ Valve Body ] See: Automatic Transmission/Transaxle/Valve Body/Service
and Repair/Valve Body.
Page 3484
Multi-Function Transmission Range (TR) Switch F125
Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch

F125
Multi-function Transmission Range (TR) Switch F125
Multi-function Transmission Range (TR) Switch -F125-

Page 5331
Part 3
Fuel Pump (FP) Relay J17

Accelerator Pedal Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3425
Control module identification and the coding will be displayed - arrow -.
- Press the arrow button - 1 - on the screen display.
Indicated on display:
Adapting engine oil quality:
- Press "10 - Adaptation" - arrow - on the display.
Page 4272
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2502
1 - Track Numbers

Page 4525
Page 3623
Part 3
Page 1699
Wiring Harness: Customer Interest A/T - High Launch RPM's/DTC P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 6711
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5223
Electronic Throttle Control Module: Service and Repair
Throttle Valve Control Module J338, Removing And Installing
- Hose Clamps Up to 25 mm dia. 3094
- Torque wrench V.A.G 1410
- Spring-type clip pliers VAS 5024 A
Removing
NOTE: Observe rules for cleanliness.
- Remove intake hose - 4 - between Throttle Valve Control Module J338 and Mass Air Flow (MAF)
Sensor G70. To do so, disconnect air hoses - 1 - and - 2 - (compress securing ring) and remove
spring clamp - 3 -.
Page 1238
Page 6392
Vehicle Information
Condition
MIL ON, Misfire DTCs P0300-0312 Stored after performing Technical Bulletin 2021320 or 28F3/P1
Campaign
Note:
Due to multiple causes for engine misfire, ensure all campaigns and applicable TB's have been
performed and/or addressed.
Repeat repairs must be carefully addressed to identify the root cause of the concern. Utilize proper
diagnosis steps to ensure that the vehicle is repaired properly and that the concern has been
identified, repaired and verified.
Symptoms:
^ MIL ON.
^ Rough idle.
^ The MIL is flashing or constantly illuminated.
^ One or more of the following DTCs are stored:
^ DTC P0300 (Random/Multiple Cylinder Misfire Detected).
^ DTC P0301 P0312 (Cyl.1 Misfire Detected - Cyl.12 Misfire Detected).
^ Engine may have reduced performance without significant loss of power or stalling.
Production Solution
Vehicles are out of production.

Service
Obtain information from the customer
To repair the vehicle correctly, obtain as much information as possible from the customer about the
symptoms of the condition and when it occurred.
^ In what situation (turning, etc.) does the condition occur?
^ Under what environmental conditions (road conditions, weather, temperature, start conditions,
etc.) does the condition occur?
^ What is the operating situation of the vehicle (activated electrical equipment, gear selection, etc.)
when the condition occurs?
Page 7680
‹› Seal driver-frt wheel bearing (40 - 21)

‹› - 1 - Internal extractor (Kukko 21/7 )
‹› - 4 - Support (Kukko 22/2 )

Page 2351

Page 2953
Ground (GND)

Page 6471
Page 1644
Left Front ABS Wheel Speed Sensor G47

Fuel Injector: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7394
‹› If wires are too short to be able to be installed, they were routed incorrectly or are jammed by the
valve body. Valve body must be removed again
and wires routed correctly.
- Engage wiring harness into bracket - 8 - and route it as depicted in illustration.
- Install oil strainer => [ Oil Strainer ] See: Fluid Filter - A/T/Service and Repair.
- Install oil pan => [ Oil Pan ] See: Fluid Pan/Service and Repair.
- Fill with ATF, check ATF level and top off => [ ATF Level ] See: Fluid - A/T/Testing and
- Code radio.
- Initialize electric window regulators, set clock.
- Connect diagnostic operation system ( VAS 5051 A) and advance program until
See: Testing and Inspection/Scan Tool Testing and Procedures.
- After that "6 Spd. Automatic Transmission 09G".

Page 1133
Part 3
Page 7671
Differential: Overhaul
Table of Contents
Disassembly and Assembly
=> [ Differential ] See: Differential
Differential
Differential
‹› Taper roller bearing puller (V.A.G 1582)
‹› Attachment (V.A.G 1582/3)
‹› Thrust piece (VW 473)
‹› Thrust pad (30 - 205)
‹› Press support-R&I; wheel brg's. (3144)
‹› Thrust pad (2007)
‹› Torque wrench 40 to 200 Nm (V.A.G 1332)
‹› Seal driver-frt wheel bearing (40 - 21)

‹› Internal extractor (Kukko 21/7)
‹› Support (Kukko 22/2 )
Pressing tapered roller bearing outer race out from clutch housing
- Remove mounting sleeve for flange shaft seal first.
Pressing outer race/tapered roller bearing into clutch housing

Page 2306
Transmission Speed Sensor: All Technical Service Bulletins A/T - High Launch RPM's/DTC
P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 6825
Part 3
Page 3569
1 - Track Numbers

Page 24
- Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM).
- Press mix button briefly again.
^ Screen indicates number of stations broadcasting close to frequency band of selected station.
^ As the number increases for [mp] and (adj], static and signal crossing will increase.
To exit service mode:
- Depress and hold the mix button or switch radio OFF then back ON
Navigation units
^ No internal diagnosis functions. Continue to antenna lead diagnosis.
Section 3 - Antenna Lead Diagnosis
After initial radio diagnosis using internal service functions, use the following procedures:
- Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base.
- Check for proper connection. (follow steps for your type of system).
- For all systems, locate cable end-point at either diversity box or antenna mast base.
- Disconnect cable from either diversity box or antenna mast base.
- Carefully ground center wire in cable to chassis.
^ Cable and radio are ok.

Fuel Pressure Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 674
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6468
Part 2
Page 4765
Specified value: 2.5 to 19.0 ohms (at approx. 20° C)
- Replace the Heated Oxygen Sensor (HO2S) (G39).

- Start the engine.
- Using a multimeter, check the Heated Oxygen Sensor (HO2S) (G39) electrical harness connector
terminal 4 to engine ground for voltage.
Turn the ignition switch OFF.
terminal 3 to the Motronic Engine Control Module (ECM) (J220) electrical harness connector T121
terminal 5 for an open circuit.

Page 1858
1 - Track Numbers

Pressure Regulating Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 828
Part 1
Page 3386
Page 758
Page 7964
End diagnosis.
A/C - Does Not Get Cold Enough
Control Module HVAC: Customer Interest A/C - Does Not Get Cold Enough
87 07 17
Nov. 14, 2007
2016734
Vehicle Information
Condition
Air Conditioning Not Cold
Air conditioning is not cold after replacing or unplugging the A/C control unit or ambient
temperature sensor.
If the ambient temperature sensor or a/c control unit -E87- is unplugged or replaced for any reason,
the ambient temperature sensor -G17- must be reset in order to function properly.
Production Solution
Service
To reset/calibrate the A/C control unit perform one of the following methods:
^ Drive vehicle at 25 mph (41 kph).
^ With vehicle in PARK, let engine run for 20 minutes.
Warranty
Information only.
to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest
information.
Page 7235
- Using a multimeter, check the Solenoid Valve terminals 1 to 2 at the Solenoid Valve electrical
harness connector for resistance.
- Replace the faulty Solenoid Valve.
If the specified values are obtained:
Checking wiring
- Install the test box. Install the Adapter F/VAG1598 VAG1598/22.

Page 3123
Fuel Filter: Service and Repair Removal and Installation
Fuel Filter
‹› Fuel container
Removing
Management/Fuel Delivery and Air Induction/Fuel
Tank/Description and Operation.
- Place the container underneath the fuel filter.
‹› Before loosening the line connections, place a cloth around the connection point. Then release
connection.
- Disconnect the fuel lines - 1, 2 and 3 -, press in the securing ring to do so.
- Remove the bolt - 4 -.
- Remove the fuel filter.
Installing
The direction of flow is marked on the filter housing with arrows.
- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Tank/Description and Operation.
Fuel Filter Installed Position

Page 1517
WHAT ARE TRACKS?
15-28, and so on).
Power Steering System Overview
Power Steering Line/Hose: Service and Repair Power Steering System Overview
1.8L, 2.0L and 2.5L With Automatic Transmission 09G

Assembly notes for pressurized line and intake hose on power steering pump => [ Pressurized Line
and Intake Hose to Power Steering Pump Overview ] See: Pressurized Line and Intake Hose to
Power Steering Pump Overview.
Assembly notes for pressurized line and intake hose on automatic transmission => [ Pressurized
Line and Return Hose Overview ] See: Pressurized Line and Return Hose Overview.
Assembly notes for pressurized line and intake hose automatic transmission, with 2.5L engine => [
Pressurized Line and Return Hose Overview ] See: Pressurized Line and Return Hose Overview.
1 Refill tank
2 Power steering pump
‹› Checking delivery pressure => [ Low Mounted Power Steering Pump, Checking Delivery
Pressure ] See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Testing and Inspection/Low Mounted

Power Steering Pump, Checking Delivery Pressure.
‹› Before installing, fill with power steering fluid => [ Low Mounted Power Steering Pump ] See:
Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair/Low Mounted Power Steering Pump.
3 Pressurized line mount

Page 5541
The temperature value must increase uniformly in increments of 1.0° C.
- Turn the ignition switch OFF.
If the engine shows problems in certain temperature ranges, if the temperature does not climb
uniformly or the temperature signal is intermittent.
- Replace the the Engine Coolant Temperature (ECT) Sensor ( G62 ).
- Using a multimeter, check the Engine Coolant Temperature (ECT) Sensor (G62 ) terminals 3 to 4
for resistance.
If the specified value from the chart was Not obtained:
Testing if display is approx. - 40.0 C
- Using a jumper wire, connect the Engine Coolant Temperature (ECT) Sensor ( G62) electrical
harness connector terminals 3 to 4.

Page 6930
Ground (GND)

Page 2382
- Disconnect connector - 2 - from Multi-Function Transmission Range (TR) Switch (F125).
- Remove nut - 1 -.
- Pull spring ring - 2 - and lever - 3 - off selector shaft - 4 -.
- Bend back hooks of locking washer - 2 - using a screwdriver.
‹› If one or more hooks of the locking washer break off while bending, replace locking washer.
Page 2110
Headlamp Alignment Sensor: Testing and Inspection
Left Rear Level Control System Sensor G76, Checking
NOTE: The rear level control system sensor is not externally adjustable. However, it must be
checked after installation is complete,
- Vehicle Diagnostic Testing and Information System VAS 5051 / VAS 5052.
Prerequisites
- Vehicle must be standing on all four wheels on a flat level surface.
- Handbrake lever must be in off position and a drive gear must not be selected.
- Steering must be in straight-ahead position.
- Vehicle must be unoccupied and not loaded.
- Vehicle must not be moved during basic settings process (i.e.: opening and closing of doors,
people leaning on vehicle, people entering vehicle is not permitted).
- If vehicle was raised using a lifting platform/hoist or a vehicle/workshop jack, then it must be rolled
back and forth several times so that the springs etc. settle, before starting adjustments.
- Vehicle Diagnostic Testing and Information System VAS 5051 /VAS 5052, selecting functions.
- See On Board Diagnostic Function

Page 1024
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7824
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6820
Ground (GND)

Page 2578
WHAT ARE TRACKS?
15-28, and so on).
Page 633
1 - Track Numbers

Page 5775
Vehicle Speed Sensor (VSS) G68

Page 4087
After-Run Coolant Pump: Diagnostic Aids
Page 3919
Exhaust Side
‹› If the valve keepers were removed from the (VAS 5161/18), they must be inserted into the (VAS
5161/18) next.
‹› Press the (VAS 5161/8) onto the insertion device from above and take up valve keepers.
- Press down the (VAS 5161/8) using (VAS 5161/2), tap lightly against the (VAS 5161/8) in the
lower area, rotate the knurled bolt for the (VAS 5161/8) back and forth and pull upward while doing
this.
- Release the (VAS 5161/2) with the knurled bolt pulled.

Page 4786
Part 2
Page 1149
Part 1
Page 7222
Ground (GND)

Page 1521
Part 3
Page 5984
Air Flow Meter/Sensor: Testing and Inspection
Mass Air Flow Sensor Checking
‹› Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
‹› Fuse (SB44) OK.
‹› The Fuel Primer Relay (J643) OK.
Test procedure
Procedures/Preliminary Check.
Start diagnosis
- Start engine and let it run at idle.

- Using the scan tool, Check the air flow quantity of the Mass Air Flow (MAF) Sensor (G70) at idle:
If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF)
Sensor (G70):
- Check voltage supply of Mass Air Flow (MAF) Sensor (G70).
- Disconnect the Mass Air Flow (MAF) Sensor (G70 ) electrical harness connector.
Page 303
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Locations
Coolant Temperature Sensor/Switch (For Computer): Locations

6 Engine Coolant Temperature (ECT) Sensor (G62 )
Page 2254
Final procedures

Page 2244
WHAT ARE TRACKS?
15-28, and so on).
Page 1621
- Disconnect connectors - 1 - and - 2 -.
- Carefully lift hooks - arrows - and disconnect Steering angle sensor (G85).
Installing
Steering angle sensor (G85) must be in center position before installation.
- Position steering angle sensor (G85) until tabs engage.
- Remove transport protection.

Page 3275
Fu-Lo
Page 4266
Ground (GND)

Page 5976
11 Air Duct
13 Intake Tube

Page 1301
Part 2
Page 3272
AC-Bu
Page 4206
Ground (GND)

Page 1330
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7762
No Communication from TCM
Are any of the following DTCs stored in Fault Memory?
Yes: Follow guided Fault Finding Test Plan for repair, use table below for correct Pin assignment.
No: Follow Testing Power Supply and Grounds above.
Did the connections test OK between the Data Bus On Board Diagnostic Module Interface Module
(J533 Gateway) and TCM (J217) circuits?
Yes: Test the Power Supply and Grounds circuits to Data Bus On Board Diagnostic Interface
Module (J533, Gateway) and TCM (J217) listed below
Page 318
- Remove inner Torx bolts E 5 - arrows - from ABS control module (J104) and remove ABS
hydraulic unit (N55).
CAUTION! The hydraulic pump must not be separated from the hydraulic unit.
- Carefully disconnect hydraulic unit with hydraulic pump upward at interface - 1 - from control
module.
When removing control module, be sure that the valve domes of the hydraulic unit do not jam or
get bent in the magnetic coils of the control module.
Cover control module magnetic coils with a lint free cloth.
Use transport protection for valve domes after disconnecting from control module and hydraulic
unit.
The dome, supplied for the control module as a replacement part, can only be clipped once and not
be removed.
Installing
‹› Do not remove sealing plugs at new hydraulic unit until the corresponding brake line is about to
be installed.
‹› If the sealing plugs are removed too early, brake fluid can escape. If this occurs, the unit may not
be sufficiently filled or adequately bled.
‹› When attaching control module and hydraulic unit, be sure that the valve domes of the hydraulic
unit do not jam or get bent in the magnetic coils
of the control module.
- Bolt control module to hydraulic unit using new bolts. Note tightening specification: max. 4 Nm.
- Bolt ABS unit to bracket.

Page 3778
Fu-Lo
Page 3669
Crankshaft: Tools and Equipment Counter-hold - AST Tool # T 10172
Counter-hold
AST tool# T 10172
Tool is used to turn the crankshaft when checking timing. Also used to counter-hold the oil pump
and camshaft chain sprockets. Also applicable to Camshaft of 2.0L BBW gas engines.
- Made in Germany

Page 4181
for resistance.

Page 5586
Page 1347
Page 3251
Warranty

Page 4542
Interface J533 electrical terminals J220 electrical harness connector T121
harness T20 connector terminals or test box sockets
6 (Can_Bus Low) 58
16 (Can_Bus High) 60
- Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground (GND).
If no malfunction is found in the wiring:
- Replace the Data Bus On Board Diagnostic Interface J533.
If the DTC does not return: Repair complete, Generate readiness code. See: Computers and
Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes
- End diagnosis.
- Replace the Motronic Engine Control Module (ECM) J220.
Final procedures
erased, generate readiness code. See: Computers and Control Systems/Testing and
Inspection/Monitors, Trips, Drive
End diagnosis.
‹› Multimeter.
Test requirements
Test procedure
Page 6685
G195, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
-.
Checking wiring
Page 4063
Water Pump: Service and Repair
Coolant Pump
‹› Engine and transmission jack (VAG 1383A)
‹› Step ladder (VAS 5085)
‹› Engine holder bracket (T03000)
‹› Old oil collecting and extracting device (VAG 1782)
‹› Adapter set for engine and transmission support (VW 540/1 A)
‹› M8 x 100 bolt
‹› Cable tie
‹› To perform this procedure, the ground cable must be disconnected from the battery. Check
whether a coded radio is installed. If so, obtain the
anti-theft code beforehand.
‹› The engine is removed downward together with the transmission.
‹› All cable ties which are opened or cut off when removing the engine, must be replaced in the
same position when installing the engine.
components.
Removing
- Remove the intake hose - 1 - and connector - 2 - from the Mass Air Flow (MAF) sensor.
Page 7777
Page 4079
Ground (GND)

Page 2599
1 - Track Numbers

Page 6176
Ground (GND)

Page 6809
Shift Solenoid: Testing and Inspection
Solenoid Valves In Valve Body, Checking
This procedure is used to diagnose all Solenoid Valves in the valve body.
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
- Disconnect the Solenoid Valve electrical harness connector - 2 -.
Checking resistance
Locations
Main Relay (Computer/Fuel System): Locations
Motronic Engine Control Module (ECM) Power Supply Relay J271

Reading and Clearing Diagnostic Trouble Codes
Engine Control Module: Reading and Clearing Diagnostic Trouble Codes
Engine Control Module DTC Memory, Checking and Erasing
‹› Vehicle diagnostic tester
- Connect the vehicle diagnosis, testing and information system to the vehicle.
Only if engine does not start:
- Switch on the ignition.
Selecting operating mode
- Press button on display for "Vehicle On Board Diagnostic (OBD)".
Selecting vehicle system
- Press button "01 - Engine electronics" on display.
The control module identification with coding - 2 - as well as Vehicle Identification Number (VIN) in
the center area and identification of anti-theft immobilizer appear on the display.
‹› The (VAS 5051B) can create a printout. Press the "print" button if required.
Selecting diagnosis function
- Press button "02 - Check DTC memory" on display.
- If no malfunction is stored in the Engine Control Module (ECM), "0 DTC(s) detected" is displayed.
- If malfunctions are stored in the ECM, these are shown one below another on the display.
- Press the <- key.
- Press button "05 - Erase DTC memory" on display.
- Press function "06 - End output".
‹› If the Diagnostic Trouble Code (DTC) memory was erased, the readiness code must be
generated again. Refer to vehicle diagnosis, testing and
information system "Guided Fault Finding".

Page 7220
1 - Track Numbers

Throttle Valve Control Module J338

Page 771
Page 314
Electronic Brake Control Module: Locations ABS Mark 60
Electrical/electronic components and installing locations
1- ABS hydraulic unit -N55
^ Located on left of engine compartment.

^ The ABS hydraulic pump -V64- and the inlet/outlet valves in the hydraulic unit are checked by On
Board Diagnostic (OBD)
^ The ABS hydraulic pump -V64- and valve block must not be separated from one another
^ When changing the hydraulic unit, always seal the old part with the plugs from the repair set Part
No. 1 HO 698 311 A
2- ABS Control Module (w/EDL) -J104
^ Location- on hydraulic unit on left of engine compartment
^ Checked by On Board Diagnostic (OBD)
^ Do not disconnect multi-pin connector before successfully completing OBD. Switch ignition off
before separating connection.
Vehicles with ABS/ESP only
- When the ABS Control Module (w/EDL) -J104- is replaced, a zero compensation must be
performed
- Initiate basic settings, Perform display group numbers 060, 063 and 066
Page 1629
Ground (GND)

Page 1788
‹› Light Emitting Diode (LED) must not light up.
- If LED lights up, replace the oil pressure switch (1.4 bar).
If the LED does not light up:
- Start the engine and increase the engine speed.
‹› The LED must illuminate at 1.2 to 1.6 bar. Replace the oil pressure switch if it does not.
- Increase engine speed further.
‹› At higher engine speeds the oil pressure must not exceed 7.0 bar
‹› At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure must be 2.7 to 4.5 bar.
If the specification is not obtained:
- Check the screen in the oil intake pipe for contamination.
‹› Also, mechanical damage, for example, bearing damage can also be the cause of too low oil
pressure.
If no malfunction can be found:
- Replace the oil pump. Refer to one of the following:
‹› => [ Oil Pump, through MY 2007 ] See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Oil Pump/Service and Repair/Oil Pump,
Through MY 2007.
‹› => [ Oil Pump, from MY 2008 ] See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil
Pump/Service and Repair/Oil Pump, From MY
2008.
If the specification is exceeded:
- Check the oil passages.
- Replace the oil filter bracket if necessary.

Page 5122
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 287
WHAT ARE TRACKS?
15-28, and so on).
Page 395
Part 3
A/T - 'PRNDS' Indicator ON/DTC's Set/Emergency Mode
Control Module: Customer Interest A/T - 'PRNDS' Indicator ON/DTC's Set/Emergency Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
Transmission, "PRNDS" Indicator Illuminated in Instrument Cluster
Automatic transmissions may switch to emergency mode when DTCs are present.
DTCs are displayed correctly on VAS 5051/5052 Scan Tool:
DTC Description
00293 Multi-function switch - F125
00258 Solenoid valve 1 - N88
Illumination of "PRNDS" Indicator may be caused by:

1. Multi-function switch implausible signal or solenoid valve (N88, N89, N90, N91, N92, N93, N282,
N283) open/short to b+, open/short to ground
or electrical fault in circuit.
2. DTC 00293 caused by damaged wiring between TCM and T10 connector to multi-function
switch.
3. Remaining DTCs may be caused by damaged wiring between TCM and T14 connectors.
Production Solution
Service
1. Connect VAS 5051/5052 Scan Tool to view fault memory and run through Guided Fault Finding
(GFF) test plan.
2. Read fault memory and run through (GFF) test plan.

09G, 6 Speed A/T
Fluid - A/T: Service and Repair 09G, 6 Speed A/T
ATF Level, Checking and Topping Off
ATF Level, Checking and Topping Off, 09G, 6 Speed A/T
Observe these notes as well. ^
About filler tube
^ Torque wrench V.A.G 1331
^ Used oil collection and extraction unit V.A.G 1782
^ Vehicle diagnosis, testing and information system VAS 5051
^ Drip tray for workshop hoist VAS 6208
^ Adapter for filling oil VAS 6262
^ Adapter VAS 6262/2
If ATF must be added, use only ATF listed.

Page 4290
Part 1
Page 3010
- Slide subframe far enough until camber is equal on both sides.
- Check caster angle.
Caster angle may be changed by sliding subframe!
- Tighten subframe with new bolts.
Rear Axle Camber, Adjusting

Rear Axle Camber, Adjusting
Camber cannot be adjusted.
If values are outside tolerance, transverse inclination must be checked first and compensated if
necessary => [ Vehicle Transverse Inclination Neutral Position ] See: Wheel Alignment, Preparing
to Measure.
If measured values are still not within specified range, check axle beam for damage and replace if
necessary.
Wheel Alignment Sequence
Wheel Alignment Specifications
=> [ Front Axle ]
=> [ Rear Axle ]
=> [ Vehicle Alignment ]
Front Axle
Page 3992
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage

wiring diagram.
Page 375
Ground (GND)

Page 1993
Pin in rest position: Closed
Pin pressed in the - direction of the arrow -: Open
‹› Before installing change over valve, remove the cover from the fuel tank.
Pressure Retention Valve Checking
The pressure retaining valve is opened in both flow directions - arrow 1 - on the gravity valve side.
It is only open in one flow direction - arrow 2 - from the T-piece of the EVAP canister/solenoid valve
1.
Page 1220
Part 2
Page 2717
Part 3
Page 3662
The rest of the installation follows the reverse of the removal procedures.
Crankshaft, Locking to Check/Adjust Valve Timing
Crankshaft, Locking to Check/Adjust Valve Timing
- Remove the cylinder head cover. Refer to => [ Cylinder Head Cover ] See: Cylinder Head
Assembly/Valve Cover/Service and Repair.
- Perform the same work steps as for "Crankshaft, Locking". Refer to => [ Crankshaft, Locking ]
See: Crankshaft, Locking.
‹› If the threaded holes in the camshafts - arrows - do not point upward, the crankshaft must be
rotated one rotation (360°) in the direction of engine
rotation.
In order to be able to precisely check and adjust valve timing, always note the following:
EGR Temperature Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7841
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6723
2. Ensure that the following tester requirements are met:
^ VAS 5051A Minimum Base CD Version 15.00 installed
^ VAS 5051B/5052 Minimum Base CD Version 15.0 installed
^ Minimum Brand CD Version 15.96 installed regardless of tester used
^ VAS 5051X is plugged into a 110V AC Power supply at all times
^ Connect 5051B and 5052 to the Local Network
^ Connect 5051A to the Local Network before tester startup
Note:
Prior to launching VAS-PC application and starting control module update process, confirm tester
screen saver and power settings in accordance with Special Tools and Equipment - Service
Information Document # VSE-08-18. Failure to do so may result in the tester entering power save
mode during data transfer, and subsequent control module failure.
When using a VAS 5051B or VAS 5052A tester in conjunction with a VAS 5054A wireless
transmitter head for a flash procedure, please connect a USB cable between the transmitter head
and the tester. Failure to do so may lead to errors during the flash procedure.
3. Ensure the following vehicle requirements are met:
^ Connect vehicle to a powered Volkswagen approved Midtronics/InCharge 940 (INC-940)

tester/charger
^ Battery MUST have, and MUST maintain a minimum no-load charge of 12.5V
^ Turn off the radio and all other accessories, and when necessary, switch running lights off
^ Turn off any appliances with high electromagnetic radiation (i.e. mobile phones)
4. The Owner's Control Module Tuning Consent Form has been completed as necessary.
5. In the VAS Tester enter into GFF program. Allow GFF to interrogate all control modules before
proceeding.
6. Address or record all DTCs related to a customer concern before continuing. Sporadic
communication DTCs will be created during the flash
procedure and must be erased with all other sporadic DTCs by GFF after exiting the flash test plan.
Note:
If GFF does not interrogate all control modules, manually select and interrogate remaining modules
before proceeding
7. Enter the SVM test plan by selecting the following inside GFF: Go to >> Function/Component
Selection >> Software Version Management >>
Adapting Software.
8. Follow the on screen prompts for the SVM update procedure and enter the SVM Unit Code
(Action Code) found in the Conditional Technical
Bulletin when requested.
9. Enter your GeKo ID when requested and data will be transmitted to the SVM server, which will
respond with instructions to continue. The procedure
may include one, or any combination of the following for one or multiple control modules as
specified in the Technical Bulletin/RVU:
^ Check a Control Module
This will occur when SVM does not recognize the control module as valid for the vehicle. If there is
no customer concern and no DTC regarding this control module, report the issue to the Technical
Helpline.
^ Update a Control Module (flash)
^ Code a Control Module
10. During the flash procedure, an estimated time will be shown which is not used for actual SRT
calculation at this time.
ALWAYS continue until the following text is displayed: "Vehicle conversion/update has been
successfully performed. The changes have been stored in the system. Thank you".
Tip: The SVM Process must be completed in it's entirety so the database receives the update
confirmation response.
A warranty claim may not be reimbursed if there is no confirmation response to support the claim or
action is carried out that is not explicitly stated in the Technical Bulletin/RVU.
11. Verify that all steps or special procedures mentioned in the Technical Bulletin/RVU have been
carried out, and then finish the test plan and Exit
GFF via the Go to button. Answer the Warranty questions accordingly and print out or save the
Diagnostic Log when prompted.
Page 1531
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6247
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6544
Page 2248
Part 3
Page 4205
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2053
Part 2
Page 5136
1 - Track Numbers

Page 6175
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6594
Part 3
Diagrams
Drive Belt: Diagrams
Ribbed belt routing
Ribbed belt routing
1. Power steering pump 2. Belt pulley - generator 3. Lower idler pulley 4. Ribbed belt for generator,
vane pump and coolant pump 5. Belt pulley - air conditioning compressor 6. Ribbed belt for A/C
compressor 7. Belt pulley - crankshaft 8. Tension roller for A/C compressor ribbed belt 9.
Tensioning roller for ribbed belt for generator, vane pump and coolant pump
10. Belt pulley - coolant pump

Page 7571
Part 3
Page 6660
- Remove nut - 1 -.
Page 2481
Part 1
Page 7862
Ground (GND)

Page 1917
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Transmission Position Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4364
- Install the ribbed belt. Refer to => [ Ribbed Belt ] See: Engine/Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Removal and Replacement/Ribbed Belt.
- Install the battery.
- Fill with coolant. Refer to => [ Draining and Filling ] See: Service and Repair/Procedures/Draining
and Filling.
- Install noise insulation.
- Fill the power steering system with hydraulic oil.
Page 1331
Page 129
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4592
Ground (GND)

Page 6838
Ground (GND)

Page 3139
‹› Replace
‹› 1.4 bar, black
‹› Checking, refer to => [ Oil Pressure and Switch, Checking ] See: Engine, Cooling and
Exhaust/Engine/Engine Lubrication/Engine Oil
Pressure/Testing and Inspection.
5 from Intake Hose
‹› See - item 1 - in => [ Intake Tube ] See: Air Cleaner Housing/Service and Repair/Removal and
Replacement.
6 Vent Hose
‹› Due to 4 point lock, only disconnect when the oil filter bracket is to be removed.
7 Dust Cap
8 Oil Filter Housing, 25 Nm
‹› Remove and install using oil filter wrench (3417 ).
‹› Draining, refer to => [ Oil Filter Housing, Draining ] See: Engine, Cooling and
Exhaust/Engine/Engine Lubrication/Oil Filter Housing/Service
and Repair.
9 Seal
‹› Replace
‹› Insert when oiled.
‹› Note the installed position:
Service flag must be at the top.
10 Oil Filter Element
‹› Drain the oil filter housing before removing, refer to => [ Oil Filter Housing, Draining ] See:
Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Oil Filter Housing/Service and Repair.
11 Gasket
‹› Replace
12 Oil Cooler
‹› See note in => [ General Repair Information ] See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Description and
Operation/General Repair Information.
‹› Ensure sufficient clearance to surrounding components.
‹› Coolant hose connection diagram, refer to => [ Coolant Hose Connection Diagram ] See:
Diagrams/Mechanical Diagrams/Cooling
System/System Diagram.
13 Bolt, 25 Nm
14 to Thermostat Housing
15 Gasket
‹› Replace
Engine Oil, Draining or Extracting, Changing Oil Filter and Filling Oil
Locations
Air Filter Element: Locations
Air Filter Assembly Overview

1 Intake Tube
‹› To the throttle valve control module.
2 Spring Type Clip
3 Mass Air Flow (MAF) Sensor (G70) with Intake Air Temperature (IAT) Sensor (G42)
4 O-ring
‹› Replace
5 Bolt, 2 Nm
6 Upper Air Filter Housing
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
‹› Secured in the wheel housing.
10 Bolt, 8 Nm
Page 6791
Part 1
Page 1588
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1550
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6136
Fuel Gauge Sender: Service and Repair Removal and Installation
Fuel Level Sensor
Removing
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] See: Service and Repair/Removal
and Replacement/Removal and Installation/Fuel Delivery Unit.
- Disengage the connector prongs for wires - 3 and 4 - and disconnect.
- Pry up the retaining tabs - 1 and 2 - using screwdriver and remove the sensor downward in the -
direction of the arrow -.
Installing
- Insert the sensor into the guides on the fuel delivery unit and press up until engagement.
- Insert the connector prongs for the wires and engage.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] See: Service and Repair/Removal
and Replacement/Removal and Installation/Fuel Delivery Unit.
Page 3573
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Specifications
Wheels: Specifications
Tightening Torque For Wheel Bolts
Tightening torques
Wheel bolt to wheel hub for all vehicles

..........................................................................................................................................................
120 Nm
Page 7574
Differential Temperature Sensor/Switch: Diagnostic Aids
Page 2108
Page 6305
Part 2
Page 4865
Part 2
Page 4142
Page 155
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1733
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7875
Transmission Position Switch/Sensor: Service and Repair
Multi-Function Transmission Range Switch
‹› Setting Gauge (T10173)
Removing
- Move selector lever to position "N".
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 1833
Part 1
Page 3694
Bearing shell - 1 - with oil bore - arrow - for connecting rod.
Bearing shell - 2 - without oil bore for connecting rod cover.
- Place the bearing shells centrally into the connecting rod and connecting rod cap.
Dimension - a - must be the same at left and right.

Page 3301
‹› If fluid level is above specified range, fluid must be extracted off.
‹› If the fluid level is below the specified level, check the power steering system for leaks (repair
measure). It is not sufficient just to add fluid. If
power steering system is properly sealed, fill with fluid (G 002 000).
- Screw in sealing cap hand-tight (using screwdriver).
Fluid at operating temperature (from approx. 122 °F (50 °C)):
- With engine not running, move front wheels in straight-ahead position.
4-cylinder Engines:
- Guide a suitable screwdriver into recess on sealing cap - arrow - and unscrew sealing cap with
fluid dipstick.
5-cylinder Engines:
Page 7719
- Press down shift rod direction of - arrow 1 -.
- While pressing down shift rod, rotate bracket - A - upward in direction of - arrow 2 - and
- Pull rubber sound insulation toward shift lever.
Secure shift lever as follows:
- Select neutral on shift lever.
- Guide connecting pin (T10027) through hole - A - into hole - B -.

Page 4394
Part 3
Page 610
Installing
CAUTION! Make sure the seal is seated properly when installing the Left HID Lamp Control
Module (J343). It is destroyed by ingress of water into headlamp.
- Tighten the screws to the tightening specification. Refer to => [ HID Assembly Overview ] See:
Lighting and Horns/Headlamp/Service and Repair/Removal and Replacement/HID Assembly
Overview.
- Make sure the headlamp is working correctly.
- Perform basic setting of headlamp, refer to => [ HID Headlamp, Basic Setting ] See: Lighting and
Horns/Headlamp/Service and Repair/Procedures/HID Headlamp, Basic Setting.
Page 718
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Auxiliary Water Pump Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Control Module HVAC: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1236
Part 3
Page 6546
Page 4636
Final procedures

Page 5534
Part 1
Page 2322
Heater
‹› Multimeter.
‹›
Test requirements
Test procedure
Start diagnosis
arrows -.
correct resistance.
- Start the engine.

Page 7351
Warranty

Page 7290
- Do not place adapter (10 - 222 A /8) on to mounting bolts for front fender.
- If hose and cable connections are found in the area of engine lifting eyes for engine support
bridge (10 - 222 A), they must be removed now.
- If necessary, secure hook of left spindle (on transmission side) using shackle (10 - 222 A /12) on
engine lifting eyelet.
- Take up weight of engine/transmission assembly on spindles.
Vehicles with 2.5L 5-cylinder engine
- Disconnect wires - 1 - from transport strap - 3 -.
- Remove bolts - 2 - and remove transport strap - 3 -.
- Insert a shackle (10 - 222 A /12) into engine eyelet - arrow -.
- Attach engine support bridge (10 - 222 A) with adapter (10 - 222 A /8) and adapter (10 - 222 A /3)
in front of gas-filled strut for hood.
Page 4371
1 - Track Numbers

Page 1569
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4438
‹› Using the body repair saw (VAG 1523), cut at a right angle through the connecting pipe at the
separation point. Refer to => [ Cut the exhaust
pipe at the separation point using at a right angle. ] See: Front and Rear Mufflers, Separating and
Connecting.
7 Nut, 20 Nm
8 Suspended Mount
9 Rear Muffler
10 Suspended Mount
‹› With retaining ring.
11 Tunnel Bridge
12 Nut, 25 Nm
Installed Position of Double Clamp
- Align the double clamp - 1 - to the mark on the catalytic converter - 2 -.
- a - = 5 millimeter (mm)
Clamp bolts must not project beyond the lower edge of the double clamp.
Locations
Air Injection Pump: Locations

11 Secondary Air Injection (AIR) Pump Motor (V101 )
Page 4829
stops.

Overview
Fuel Gauge Sender: Service and Repair Overview

1 Cap
2 Seal
‹› Replace if damaged.
3 Bolt
4 Fuel Filler Door Unit
‹› With rubber gasket.
5 Bolt, 10 Nm
6 Vent Line
‹› Ensure the line is securely seated.
7 Switch Over Valve
‹› To remove the valve, unclip sideways out of the support.
‹› Before installing, remove the cap - item 1 -.

Page 2915
1 - Track Numbers

Page 7048

Page 5063
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3772
Pe-Ca
Page 3015
To do this, use an open-end wrench on hex head - arrow - of tie rod.
Be sure boot is not twisted after turning tie rods.
Twisted boots wear out quickly.
- Tighten lock nut - 1 - to 50 Nm and check toe value again.
Setting may change slightly after lock nut - 1 - is tightened.
The setting is OK however if setting value deviates from specified value no greater than 2'.
Steering Angle, Checking
Steering Angle, Checking
This test is only required then, if
‹› Wheel locks are different by more than 2 degrees from one another starting from steering center
‹› One side there is contact between tire and a front axle component or body at full lock
‹› Turning circles on left and rights are different
Distance between front axle components and tires - arrow - must be equal at maximum wheel lock.
If distance is uneven, distance can be correct by rotating the left and right tie rods.
Example:
When right wheel lock is less than the left;
- Loosen lock nuts of tie rods.
- Rotate left tie rod (unscrew from tie rod end).
- Rotate right tie rod the same distance in opposite direction (screw into tie rod end).
- Check total toe.
After adjusting, total toe must match prescribed specified value!
- Tighten lock nuts.
Setting may change slightly after lock nut - 1 - is tightened.

Page 3385
Page 458
Ground (GND)

Page 6171
Page 804
Air Injection Pump Relay: Locations Component Location Overview
AIR Pump Relay (J299) (13)
In 10 Pin Auxiliary Relay Carrier above Central Electronics (10)


Page 2361

Page 3872
Part 1
Page 3171
‹› For power steering pumps manufactured by Kayaba
6 Clamp
7 Hex bolt
‹› M8 x 28

8 Spring clip
9 Intake hose
10 Bracket
‹› On cylinder block
11 Bracket
12 Hex bolt
‹› M10 x 25

Page 2287
- Replace the MAF / IAT sensor (G70 / G42).
If the indication remains at approx. 140 °C:
Checking wiring
- Disconnect the T60 connector.
- Using a multimeter, check for continuity between the MAF / IAT sensor (G70 / G42) harness
connector terminal 2 to an engine ground, refer to the wiring diagram.
connector terminal 2 to terminal 1, refer to the wiring diagram.
- Repair the short to ground in the circuit.
Final procedures

09.

Code.
Page 2075
Page 4753
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Manifold Absolute Pressure Sensor, Checking
‹› Use only gold-plated terminals when servicing terminals in harness connector of Manifold
Absolute Pressure (MAP) Sensor (G71 ).
‹› Multimeter.
Test conditions
‹› The Engine Control Module (ECM) (J220) OK.
‹› The parking brake must be applied, otherwise daytime running lights are switched on.
‹› On vehicles with automatic transmission, selector lever must be in position "P" or "N".
‹› The Ground connections between engine and body must be OK.
Function test
- Using the scan tool, Check the specified value of the Manifold Absolute Pressure (MAP) Sensor
(G71) at idle:
- Condition is not present at this time. Check connections for loose or damaged terminals and
check harness for an intermittent short.
- Erase the DTC. Generate readiness code. Refer to => [ Readiness Code ] See: Computers and
Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness
Codes/Readiness Code.
Test sequence
- Disconnect the Manifold Absolute Pressure (MAP) Sensor (G71) electrical harness connector.

Specification: Near 5 V
Checking wiring

Page 7734
- Remove cable mounting bracket from transmission - arrows -, unclip hose line - A - at bracket - B
- if necessary.
- Remove front exhaust pipe bracket from subframe - arrows -.
- Disconnect exhaust system from double clamp - A - and secure exhaust pipe to front body.
Page 6275
WHAT ARE TRACKS?
15-28, and so on).
Page 4926
Part 1
Page 7393
‹› Counterparts of connector must have the same identification as the respective connector.
- Install bracket to Transmission Fluid Temperature Sensor (G93) - 7 -.

- Insert Transmission Fluid Temperature Sensor ( G93) together with bracket into valve body.
- Tighten bolt - 6 - to 11 Nm.
- Connect connectors vertically to hydraulic pressure sensors - 1 - and - 4 -.
- Tighten bolts - 3 - of bracket for harness connectors - 2 - and - 5 - => [ (Item 14) Bolt, 7 Nm ] See:
Valve Body Assembly Overview.
Page 3468
Page 6680
Transmission Speed Sensor: Locations 09G Transmission


Page 3369
WHAT ARE TRACKS?
15-28, and so on).
Page 350
Auxiliary Water Pump Relay: Diagnostic Aids
Page 7648
WHAT ARE TRACKS?
15-28, and so on).
Locations
Page 5068
Part 2
Page 5677

Page 26
If no apparent connection problems:
- Replace amplifier.
If concern is poor FM reception:
- Disconnect all amplifiers, tune radio to high-powered station for your area.
- Connect amplifiers one at a time.
If reception is indicated:
- Disconnect that amplifier and move on to next amplifier.
If at any point in reconnecting amplifiers there is a loss in reception and there are no connection
issues:
- Replace that amplifier and check again.
If there is no reception change when disconnecting and reconnecting all amplifiers:
- Replace diversity/antenna selection box.
Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast)
- Check connections at antenna base.
- Check for corrosion at mounting.
If corrosion is found:
- Clean mount and apply anti-seize gel to mounting.
If concern is no AM and/or little or poor AM/FM reception,
- Replace antenna base.
Section 4- Antenna cables

If antenna cables are required:
- Antenna cables - single DIN (Premium V) radio.

Page 1845
Ground (GND)

Page 1470
Part 3
Page 1053
Warranty
Information only.
removal.
Page 5571
Part 1
Page 1585
Part 1
Page 6000
1 - Cap
2 - Seal -
Replace if damaged
3 - Bolt
With rubber gasket
5-
10 Nm
6 - Vent line -
- Checking
8 - O-ring -
Replace if damaged
In long member
12 - Vent line -
13 - 10 Nm
15 - Fuel tank -
16 - Heat shield
Engine Oil: Capacity Specifications
Engine Oil
Filling quantities With filter ...................................................................................................................

................................................................................ 6.0 liters (6.3 qts)

Page 5868
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3400
Fuse Block: Service and Repair Fuse Panel on Battery
Connecting.
Fuse Panel on Battery
Connecting.
Removing and installing, refer to => [ Battery A ] See: Starting and Charging/Battery/Service and
Repair/Removal and Replacement
Page 6261

Page 6279
Part 3
Page 1868
Humidity Sensor: Diagnostic Aids
Page 2799
1 - Track Numbers

Page 5681

Page 198
After rotary position has been verified:
1. Check coding of comfort module.
After coding of comfort module has been verified:
1. Check wiring between door control module and lock before replacing any components.
To Check Door Ajar Switch (all vehicles):
1. Roll windows down and close all doors.
2. Open Door, instrument cluster should display open door.
3. Manually position door latch to closed position
4. Wait for instrument cluster open door display to turn OFF.
5. Move door back and forth and observe the open door display in instrument cluster.
The state of the door ajar should not change while performing this test.
If the state of the door ajar does change:
1. Verify mechanical adjustments and check wiring between door control module and lock before
replacing any components.
Warranty
Information Only.
removal.
Locations
Relay and Fuse Arrangements on Relay Panel (Relays)
Page 5125
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 25
If reception does not return:
^ Problem is located further forward in the system.
For problems forward of the antenna system:
- Continue with Section 3a.
For problems at antenna system:
Skip to Section 3b.
For problems at antenna systems:
Tip:
All checks should be done outdoors away from buildings.
Section 3a - Problems forward of antenna system
- First verify connection at Radio (check for bent or crushed connections and proper fit).
If all connections appear ok:
- Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception).
^ Problem is located between radio and antenna.
- Check connections near center console:
If connections are OK:
- Check resistance of cable from end to end.
^ If More than .4 ohms:
- Replace cable.
If reception does not return;
- Replace radio unit.
Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8)
If concern is only AM poor / no reception;
Locate AM antenna amplifier.
^ Touareg: located above left side window.
^ Passat W8: Sedan above rear window.
^ Passat Wagon: located on left rear window.
- Check for proper connections at amplifier both from diversity box and to glass.
If connection issue is at glass or on glass:
- Glass must be replaced.
If connection problem to amplifier:

- Repair connection (replace cable or amplifier).
Testing and Inspection
Variable Induction Control Module: Testing and Inspection
‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 186
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1392
Part 2
Page 3975
‹› The sealant bead must be 1.5 to 2.0 mm thick.
- Coat the seal of the chain compartment cover lightly with engine oil and slide the chain
compartment cover onto the coolant connection.
- Install all bolts and tighten them in a diagonal sequence.
following:
‹› Install the battery.
Page 7940
Ground (GND)

Page 6404
Part 3
Page 2641
Page 2632
1 - Track Numbers

Page 619
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1580
1 - Track Numbers

Page 5532
WHAT ARE TRACKS?
15-28, and so on).
Page 776
Start diagnosis
Checking voltage
terminals.
terminals.
- Repair as necessary.
Checking activation
- Using a diode test lamp (12 V) connected to Battery +, check the Motronic Engine Control Module
(ECM) Power Supply Relay Box socket 1 (relay terminal 85) while cranking the engine.
The test lamp should be ON.
If the test lamp was ON:
- Replace the Motronic Engine Control Module (ECM) Power Supply Relay (J271):.
Page 7598
- Install wheel and tighten => [ Wheel Bolt Tightening Specifications ] See: Maintenance/Wheels
and Tires/Wheel Fastener/Specifications.
Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed
Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed
^ Thrust piece 40 - 105
^ Hub puller 3283
^ Collar F/Wheel Brg. Inner Race 3423
^ Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2
^ - 2 - Puller Kukko 18/0
^ Foot pump with high pressure hose V.A.G 1389 A/1
If there is a hand pump V.A.G 1389/1 available it can also be modified for use as a foot pump. To
do so, use conversion kit V.A.G 1389/4.
Page 6485
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
Page 7963
- Using a multimeter, check the Solenoid Valve electrical harness connector terminals to the
Transmission Control Module (TCM) J217 electrical harness connector T52 terminals for an open
circuit.
- End diagnosis.
Final procedures
Page 7855

Page 3370
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7871
Transmission Position Switch/Sensor: Testing and Inspection
Multi-Function Transmission Range (TR) Switch F125, Checking
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
- The Control Module with indicator unit in the Instrument Cluster Control Module J285 must be OK.
- The selector lever cable adjustment OK.
Test procedure
Start diagnosis
- Switch the ignition on.
- Depress the brake pedal and maintain depressed.
- Shift the selector lever into all positions.
The selector lever position must correspond to the display of the Control Module with the indicator
unit in the Instrument Cluster Control Module J285.
If the selector lever position does not correspond to the display of the Control Module with indicator
unit in the Instrument Cluster Control Module J285 :
- Disconnect the Multi-Function Transmission Range (TR) Switch F125 electrical harness
connector - 2 -.
If the electrical harness connector is not OK:
- Repair the malfunction.
Checking voltage
- Using a multimeter, check the Multi-Function Transmission Range (TR) Switch F125 electrical
harness connector terminal 10 to Ground (GND) for voltage.
Specified value, Battery voltage.
- Check the wiring from the Multi-Function Transmission Range (TR) Switch F125 electrical
harness connector terminal 10 to the Fuse (on
Page 7381
Valve Body: Service and Repair Valve Body
Valve Body
Removing
- Observe general repair notes => [ General Repair Information ] See: Description and
Operation/09G Transmission/General Repair Information.
- Remove oil pan => [ Oil Pan ] See: Fluid Pan/Service and Repair.
- Remove oil strainer => [ Oil Strainer ] See: Fluid Filter - A/T/Service and Repair.
- Draw up a diagram of all sensors and solenoid valves with the corresponding connectors similar
to the illustration.
- Before disconnecting harness connectors at sensors and solenoid valves, mark solenoid valve or
sensor and the corresponding connector.
‹› The sketch and markings are absolutely necessary to prevent interchanging of sensor and
solenoid valve connections when reinstalling the valve
body.
Page 3893
- Remove the wiring harness - 3 - from the transport strap.
- Pull all clamps - 4 - and retaining ring - 5 - from the locking mechanism.
- Remove bolts - 7 - and remove the transport strap.
- Remove the throttle valve control module (J338 ). Refer to => [ Throttle Valve Control Module ]
See: Powertrain Management/Fuel Delivery and Air Induction/Relays and Modules - Fuel Delivery
and Air Induction/Variable Induction Control Module/Service and Repair. The coolant hoses remain
connected, if equipped.
- Disconnect the connector - 1 - and hose for the crankcase ventilation - 3 -.
- Remove the wiring harness - 2 -. To do so, carefully press off clips - arrows -.
- Support lock carrier using a sleeve - B -, 80 millimeters (mm) in length, for example, from (VW
540/1 A) and a M8 x 100 bolt - A -.
Page 3609
- Turn over the guide frame again.
- Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).
- Lightly apply an even bead of sealant into the clean grooves of the guide frame - 1 through 8 -.
Width of sealant bead:
‹› Grooves - 1 through 5 -: approximately 3.0 mm
‹› Grooves - 6 through 8 -: approximately 4.0 mm

Page 5885
Part 2
Page 5870
Part 2
Page 7541
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5883
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1200
Part 2
Page 4451
Part 1
Page 4315
Radiator Cooling Fan Temperature Sensor / Switch: Diagnostic Aids
Page 2465
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3857
Oil Pan: Service and Repair Upper Oil Pan
Upper Oil Pan
‹› Locking pin (T10115)
‹› Adapter plates (2036/1)
‹› 3 M8 x 20 bolts and washers
Removing
- Loosen the camshaft gears. Refer to => [ Valve Timing, Adjusting ] See: Cylinder Head
Assembly/Adjustments.
- Remove the control housing cover. Refer to => [ Control Housing Cover ] See: Camshaft, Lifters
and Push Rods/Variable Valve Timing Cover / Housing/Service and Repair.
- Tension the chain tensioner - 1 - and secure it using (T10115).

- Remove the guide rail - 2 -.
- Remove the belt pulley side sealing flange. Refer to => [ Sealing Flange, Belt Pulley Side ] See:
Cylinder Block Assembly/Sealing Flange, Engine Front/Service and Repair/Sealing Flange, Belt
Pulley Side.
- Remove the lower oil pan. Refer to => [ Lower Oil Pan ] See: Lower Oil Pan.
- Remove the bolts - 2 and 4 - and the oil intake pipe.

Page 1450
Ground (GND)

Page 2059
7 - Headlamp dimmer/flasher switch - terminal 56
8 - Headlamp dimmer/flasher switch - terminal 56b
9 - Parking light switch - terminal PL
10 - Parking light switch - terminal PR
11 - Turn signal switch - terminal R
12 - Headlamp dimmer/flasher switch - terminal 56a
Cruise Control System Switch, 10-Pin Connector - D -
1 - Open
2 - Switch for CCS - On/Off
3 - Switch for CCS - Set / accelerate
4 - Switch for CCS - Reset / Resume
5 - Switch for CCS - Reset / Resume
6 - Switch for CCS - On/Off

7 - Switch for CCS
8 - Open
9 - Open
10 - Open
Turn Signal, High and Low Beam, Flasher and Parking Lamp Switch Connector Assignments
Turn Signal, High and Low Beam, Flasher and Parking Lamp Switch Connector Assignments
Connecting.
Multi-pin Connector C, 12-pin

Page 7821
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2581
Part 2
Page 1064
Page 293
Page 4986
- Open shut off valve on gauge and start the engine. Allow to idle.
- Slowly close the pressure gauge shut off and note the fuel pressure.
‹› Pressure must increase to 6 bar.
When 6 bar is reached: Open shut off tap immediately!
If pressure has increased during test:
- Fuel pump is OK. Pressure relief valve in fuel filter is malfunctioning.
If pressure did not increase:
- Fuel pump is faulty
- Replace the fuel pump. Refer to the Repair Information.
Final procedures

Page 3735
- Rotate the belt tensioner - 2 - using a 15 mm box end wrench - A - in the - direction of the arrow -
and secure using (T10060A).
- Remove the ribbed belt for the generator, power steering and coolant pumps.
Installing
Installation is performed in reverse order. When doing this note the following:
- Place the ribbed belt for the generator, power steering and coolant pumps onto the pulleys, then
lastly onto the idler pulley - 3 -.
- Before tensioning the ribbed belt for the generator, power steering and coolant pumps, rotate the
A/C compressor belt tensioner and check the belt for correct seating in the pulley.
- Before installing the ribbed belt for the A/C compressor, secure the tensioner using (T10060A).
‹› When installing the belt, note the direction of rotation of the belt and be sure that it is seated
correctly on the pulley.
- Start the engine and check the belt running.

Page 2389

Page 3618
Ground (GND)

Locations

Page 410
Part 3
Page 361
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4489
- Slowly depress the accelerator pedal to Wide Open Throttle (WOT) stop while observing the
percentage display. The percentage display must increase uniformly.
- Using the scan tool, check the throttle valve position (absolute) at Wide Open Throttle (WOT)
stop:
If the specified values are Not obtained:
- Remove the Throttle Valve Control Module (J338 ) far enough so that the electrical connector
terminals are reached.
- Disconnect the Throttle Valve Control Module ( J338) electrical harness connector - arrow -.
Checking resistance
- Using a multimeter, check the Throttle Drive (for Electronic Power Control (EPC)) (G186) at the
Throttle Valve Control Module (J338) terminals 3 to 5 for resistance.
Page 4297
for resistance.

Page 4390
WHAT ARE TRACKS?
15-28, and so on).
Page 5297
Part 2
Page 7846
Part 2
Page 7742
6 Hex bolt, 20 Nm
‹› 3x
‹› For mounting bracket
7 Mounting bracket
8 Grommet
‹› Bearing for mounting bracket to transmission
9 Spacer
10 Cable retainer
‹› For selector cable on linkage lever
‹› Do not interchange! Cable retainers for selector lever cable on linkage lever and on transmission
shift lever are different => [ Allocation of
Cable Retainers ]
11 Cable retainer
‹› For shift cable on transmission shift lever
‹› Do not interchange! Cable locking mechanisms for selector lever cable on linkage lever and on
transmission shift lever are different => [
Allocation of Cable Retainers ]
12 Lock washer
13 Lock washer
14 Bearing bushing
15 Relay lever
‹› Installed position => [ Installation Position of Transmission Shift
Lever/Actuator Lever ]
‹› Adjust shift mechanism after installing => [ Shift Mechanism, Adjusting ] See: Shifter
M/T/Adjustments.
16 Shoe
17 Transmission shift lever
‹› With counterbalance weight
‹› Insert so that master spline aligns with shift rod
Lever/Actuator Lever ]
‹› Adjust shift mechanism after installing => [ Shift Mechanism, Adjusting ] See: Shifter
M/T/Adjustments.
18 Self-locking hex nut, 23 Nm
Allocation of Cable Retainers

Page 4338
WHAT ARE TRACKS?
15-28, and so on).
Page 7944
Part 2
Cabin Temperature Sensor / Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 96
Ground (GND)

Page 4730
If the specified value in the chart was Not obtained:
- Continue the test according to the following table:

Checking Component and wiring
- Using a multimeter, connect the positive lead to the MAF / IAT sensor (G70 / G42) harness
connector terminal 2 and the negative lead to an engine ground.
Specified value: Near 5 V
- Check the harness connector for damage, corrosion, loose or broken terminals.
If voltage was not present and no malfunction is detected in the signal circuit:
- Using a multimeter, connect the positive lead to Battery + and the negative lead to the MAF / IAT
sensor (G70 / G42) harness connector terminal 1.

Page 7971
legend.
wiring diagram.
harness.


question.)
19 - Legend



Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolts

........................................................................................... 60 Nm Final pass .....................................
................................................................................................................................... Tighten 90°
Page 2720
Ride Height Sensor: Diagnostic Aids
Page 7549
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4189
1 - Track Numbers

Page 3571
Ground (GND)

Page 2556
Impact Sensor: Service and Repair Driver/Front Passenger Airbag Crash Sensor G283 and G284
Airbag
CAUTION! ‹› Advanced airbags of passenger side in New Beetle sedan or convertible which only
partially deployed, can cause severe injuries when
second stage suddenly deploys.
‹› When working with airbag systems and transporting airbag units that have not deployed or have
not completely deployed, strictly
follow safety precautions.
‹› Never dispose of advanced passenger side airbag units of New Beetle sedan or convertible in
waste or together with other materials to
be scrapped.
Driver/Front Passenger Airbag Crash Sensor G283 and G284
Removal
- Disconnect the battery ground cable.
- Remove the front side.
- Remove harness connector - 3 - and combination nuts - 2 -.
Installation
- Switch ignition on after installing all components.
- Close doors.
P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Control Module: All Technical Service Bulletins A/T - 'PRNDS' Indicator ON/DTC's Set/Emergency
Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Sunroof / Moonroof Switch: Description and Operation
Sunroof
Sunroof Function
The slide/tilt sunroof is opened and closed via the rotary switch when ignition is switched on/tilted
out and closed.
After switching off ignition, slide/tile sunroof can still be opened and closed as long until driver's or
passenger's door is opened.
On the rotary switch, there are markings for preset sliding and tilt positions of the glass panel.
However, any other intermediate tilt position can be selected by turning the switch in the
corresponding direction.
In switch position - 1 -, the opening of the slide/tile sunroof in the so-called comfort position
decreases driving wind noise which can occur at complete opening in switch position - 2 -.
Page 2252
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 1530
1 - Track Numbers

Page 491
Ground (GND)

Page 2407
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6430
Camshaft Position Sensor: Locations Component Locations Overview

1 Camshaft Position (CMP) Sensor (G40)
Page 4630
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 6382
Note
^ Complete the Campaign Completion Label and mark 28F3 in the SAGA CODE field.
^ Ensure Campaign Completion label does not cover any existing label(s) and the area where it is
affixed is clean and free from dirt or debris.
^ PLACE CAMPAIGN COMPLETION LABEL NEXT TO VEHICLE EMISSION LABEL UNDER THE
HOOD IN THE ENGINE COMPARTMENT.
^ In the United States and Canada, vehicles repaired under the 28F3 Campaign (or this interim
Technical Bulletin) are required to be identified with a Campaign Completion Label (see below).
^ Order labels at no cost from Archway Marketing Services (formerly Resolve Corporation) at
1-800-544-8021. The part number for the Campaign Completion label is CAMP 010 000.
^ If Misfire complaint is not corrected after the replacements of the ignition coils diagnose the
condition and perform necessary repairs with the use of Guided Fault Finding, the repair manual
and applicable Technical Bulletins.
Tip:
Additional repairs should not be claimed under this Technical Bulletin.
Warranty
It is still possible to claim this TSB for vehicles outside of the limited new vehicle warranty.
Page 2724
Ride Height Sensor: Application and ID Left Rear Level Control System Sensor Overview
Left Rear Level Control System Sensor Overview

General notes => [ Vehicle Level Sensor with Automatic Headlight Vertical Aim Control ] See:
Service and Repair/Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
Basic Setting of headlights
1 Left rear level control system sensor (G76)
‹› Checked electrically via On Board Diagnostic (OBD)
‹› For complaints => perform basic setting in "Guided Fault Finding" using VAS 5051
To do so, enter "Function/Component selection" via the Go to button.
2 Mounting bracket for rear axle
3 Coupling rod of left rear level control system sensor (G76)
‹› Do not remove coupling link from ball head!
4 Bracket
5 Axle beam
6 Hex bolt
Page 6390
Page 6572
- End diagnosis.
Final procedures
End diagnosis.
Page 3403
Connecting.
Driver Side
The connector station is located in the left front footwell behind the footwell trim panel.
1. Central locking
2. Power window regulator, red
3. Power mirror adjustment, blue
The connector station on the driver side A-pillar is identical.
Connecting.
Connecting.
Removing and installing, refer to => [ Battery A ] See: Starting and Charging/Battery/Service and
Page 7941
WHAT ARE TRACKS?
15-28, and so on).
Page 3009
The 0-line on roof symbolizes the horizontal position (zero position) of the vehicle.
- If necessary, correct the existing difference.
At the front axle, it can be compensated by applying weights on to corresponding suspension strut
dome in engine compartment.
At the rear axle, it can be compensated by applying weights in luggage compartment on the
corresponding vehicle side.
For example, sand bags of approximately 10 kg are suitable as weights.
Front Axle Camber, Adjusting

Front Axle Camber, Adjusting
to Measure.
Only by moving the subframe is it possible to center the camber within specified range.
- Loosen bolts - 1 - and - 2 -.


Page 6184
Main Relay (Computer/Fuel System): Diagnostic Aids
Page 4027
Installed Position Of Fuel Delivery Unit
Tab - 2 - on fuel delivery unit must lie between tabs - 1 - and - 3 -
NOTE:
- Fuel deliver unit can only be installed in this position.
Checking switch-over valve
Pin in rest position: Closed Pin pressed in direction of - arrow - : Open
NOTE: Before installing change-over valve, remove cover from fuel tank.
Checking pressure retention valve
The pressure retaining valve is opened in both flow directions - arrow 1 - on gravity valve side. It is
only open in one flow direction - arrow 2 - from T-piece of EVAP container/solenoid valve 1.
Page 1455
Part 3
Page 7185
Removing
- Remove valve body => [ Valve Body ] See: Valve Body/Service and Repair/Valve Body.
Installing
See: Valve Body/Service and Repair/Valve Body Assembly Overview.
- Install valve body => [ Valve Body ] See: Valve Body/Service and Repair/Valve Body.
Page 3794
Oil filter insert, removing
- The oil filter housing can be loosened using the oil filter wrench (VAS 3417).
- Then unscrew by hand and remove together with oil filter insert.
- Remove oil filter insert - 2 - from oil filter housing center tube - 4 -.
Sealing ring, removing
CAUTION! The oil filter housing sealing ring - 3 - must be replaced each time the oil filter insert is
changed - 2 - or every other time the oil filter housing is loosened.
The sealing ring is equipped with a so-called "service flag " - A -.
‹› The sealing ring can be gripped at the "service flag" - A - with a suitable tool and then removed
from the seal groove.
- Remove sealing ring - 1 - from oil filter housing seal groove - 2 - by pulling sealing ring out with
needle-nose pliers - 3 - on the "service flag" - arrow -.
Page 4404
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7926
Part 3
Page 7307
Wiring Harness: All Technical Service Bulletins A/T - High Launch RPM's/DTC P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.


Page 3368
Ground (GND)

Page 3561
- Slide adapter into anti-theft wheel bolt until it stops.
- Slide wheel wrench on to adapter until it stops.
- Perform final tightening of wheel mounting bolts to the correct tightening torque.
Retighten wheel securing bolts
‹› Ensure that wheel bolts are tightened in diagonal sequence.
Tightening specification: 120 Nm

Page 652
WHAT ARE TRACKS?
15-28, and so on).
Page 5608
Intake Air Temperature Sensor: Diagnostic Aids
Fluid - A/T: Capacity Specifications
Planetary gearbox Initial filling .............................................................................................................

.......................................................................................... approx. 5.3 L Changing ............................
..............................................................................................................................................................
.................. Filled for life
Final drive Initial filling .........................................................................................................................

............................................................................ approx. 0.75 L Changing ........................................
..............................................................................................................................................................
...... Filled for life
Planetary gearbox and final drive Initial filling .....................................................................................

................................................................................................................. 7.2 L (7.6 qts)
..........................................................................................................................................................
Initial filling ...........................................................................................................................................

............................................................ approx. 7.0 L Changing ..........................................................
.................................................................................................................................................. Filled
for life
Page 1436
WHAT ARE TRACKS?
15-28, and so on).
Page 1218
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7326
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2375
Page 2852
Transmission Position Switch/Sensor: Locations 09G Transmission

13 Tiptronic Switch (F189)

Clutch Assembly Overview, Sachs
Pressure Plate: Service and Repair Clutch Assembly Overview, Sachs

‹› Make sure alignment sleeves for centering engine/transmission are installed in cylinder block;
install if necessary.
‹› If centering sleeves are not present, problems with shifting, changing gears and possibly a noisy
transmission (idler rattling) may occur.
1 Dual-mass flywheel
‹› Make sure centering pins are in place and seated correctly
‹› Contact surface for clutch lining must be free of grooves, oil and grease
2 Clutch plate
‹› Removing and installing => [ Clutch, Sachs ] See: Service and Repair/Clutch, Sachs.
‹› Only replace together with pressure plate
‹› Installed position => [ Installation Position of Clutch Plate ] See: Service and Repair/Clutch,
Sachs
3 Pressure plate
‹› With adjustment mechanism
Page 7803
1 - Track Numbers

Page 3833
Sealing ring, installing

Page 7504
‹› Only replace together with clutch plate
4 Bolt M6, 13 Nm
‹› Loosen and tighten in a diagonal sequence and in stages

Page 3821
- Loosen oil filter -arrow- from below using tension strap or oil filter wrench VAS 3417 as an aid.
Note: Observe waste disposal regulations!
- Clean sealing surface on oil cooler.
- Lightly oil rubber gasket on new filter. This achieves the best possible seal when tightening the
filter.
- Tighten filter by hand.
Replacing oil filter, TDI - Diesel engines:
- Oil filter wrench VAS 3417

Transmission Control Module (TCM) J217
Control Module: Locations Transmission Control Module (TCM) J217

Shift Interlock Relay: Testing and Inspection
Starting Interlock Relay J207, Checking
‹› New Beetle
- Remove cover in driver's side footwell.
- Turn ignition key to position "start".
- Move selector lever from "S" to "P" and back.
Starting Interlock Relay (J207) must activate audibly and sensible to touch.
As long as there is no malfunction, starter can be operated in selector lever position "N" or "P".
If relay does not trigger:
- Check Starting Interlock Relay (J207) and wire connections according to wiring diagram.
Page 1652
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2281
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1612
Part 2
Page 5369
- Replace the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) (G130)..
Checking wiring
- Using a multimeter, check the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter
(TWC) (G130) electrical harness connector terminals to the Engine Control Module (ECM) ( J220)
electrical harness connector T121 terminals for resistance.
- Check the wiring for an open, high resistance, short circuit to each other, Battery (+) or Ground.
If no malfunction is detected in the wiring and the voltage supply was Not OK:
- Replace the Engine Control Module (ECM) (J220 ). Refer to the Repair Information.
Final procedures


Page 6152
Part 2
Page 2327
- Using a multimeter, connect the negative lead to engine ground. Start the engine, and check the
Heated Oxygen Sensor (HO2S) (G39) electrical harness connector terminals 2, 3, 4 and 6 for
voltage.
Specified value: 2.40 V - 4.99 V
Checking wiring
Page 1503
Seat Memory Switch: Diagnostic Aids
Page 6810
Checking wiring

Page 6595
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1011
Part 3
Page 6363
Page 2678
1 - Track Numbers

Page 5702
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 5991
Texaco Petro-Canada Sunoco-Canada
- For the fast removal of existing carbon deposits from injectors, combustion chambers and intake
valves (intake valves apply to MPI engines only) gasoline additive G00170003 can be used. Mix
additive directly with gasoline in fuel tank following mix ratio described on additive container.
(example 20 ml per 10 liters of gasoline, 150 ml per 20 gallons of gasoline).
Warranty
Information only.
No Special Parts required. No Special Tools required.
Page 5797
- Using a multimeter, check the Secondary Air Injection (SAI) Pump Motor (-V101-) electrical
harness connector terminal 2 to the Secondary Air Injection (SAI) Pump Relay (-J299-) connector
terminal 2 (relay 87).
Specified value: 0.5 ohms or less.
- Check the voltage supply circuit between the Secondary Air Injection (SAI) Pump Relay (-J299-)
and the Secondary Air Injection (SAI) Pump Motor (-V101-) for an open or high resistance. Refer to
Wiring Diagrams.
- Repair the circuit as necessary.
- Perform the Secondary Air Injection Pump Relay test to find cause of no voltage to the SAI pump
motor.
Final procedures
After the repair work, the work steps below must be performed in the following sequence:

Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Exhaust Manifold
Exhaust Manifold: Service and Repair Exhaust Manifold
Exhaust Manifold
Removing
- Remove the wiper arms.
- Remove the outer plenum chamber cover and the plenum chamber end plate.
- Remove the heat shield.
- Remove the protective cap for the right inner Constant Velocity (CV) joint from the engine.
- Remove the bolt - 1 - and nut - 3 - and remove the exhaust manifold brace - 2 -.
- Loosen the nuts for the double clamp.
- Remove the 4 front exhaust pipe to manifold nuts - 1 - and suspended mount bolts - 3 -.
- Remove the front exhaust pipe - 2 - from the manifold and tie up firmly to the side.
Page 5648
Final procedures


Page 3643
Connecting Rod: Removal and Replacement
Piston and Connecting Rod Assembly Overview

1 Bolt, 30 Nm + 90° (1/4 additional turn)
‹› Replace
‹› Lubricate the threads and contact surfaces.
‹› Tighten to 30 Nm to measure radial play, do not turn further.
2 Pressure Relief Valve, 27 Nm
‹› Opening pressure 1.3 to 1.6 bar pressure.
3 Oil Spray Jet
‹› For piston cooling.
4 Connecting Rod Bearing Cap
‹› Note the installed position.
‹› Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position
and only onto the respective connecting rod.
‹› Installed position: Marks - A - point to the belt pulley side.

Page 5744
Page 5049

- Erase the DTC memory. Refer to => [ Diagnostic Mode 04 - Erase DTC Memory ] See: Testing
and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09
Generate readiness code. Refer to => [ Readiness Code ] See: Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes/Readiness Code.
Page 289
Part 1
Page 6407
Ignition Coil: Diagnostic Aids
Page 4845
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7076
Part 3
Page 2436
1 - Track Numbers

Page 7783
Function
Page 3128
- oil filter insert -2-
- oil filter housing sealing ring -3-
- oil filter housing center tube -4-
Pumpe Duse PD-TDI Diesel
- oil filter -3-
- O-rings -2 and 4-
Page 4410
Part 3
Page 7249
‹› Can only be replaced as complete unit
2 - Circuit board
3 - Frame
‹› With cover strips
Selector Mechanism Frame Assembly Overview
Selector Mechanism Frame Assembly Overview
1 - Frame, upper section

2 - Cover strip
‹› With 2 magnets - arrows - for Tiptronic Switch (F189) and selector lever display
‹› Magnets must be secured firmly to cover strip
3 - Frame, lower section
‹› Guides cover strip
- Removing and installing selector mechanism cover and circuit board => [ Selector Mechanism
Cover and Circuit Board ] See: Selector Mechanism Cover and Circuit Board.
Selector Lever Handle
Selector Lever Handle
Removing
- Slide sleeve - 1 - downward.


F125

Page 533
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5349
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 990
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1570
Part 1
Page 3278
Pr-Sh
Page 6514
1 - Track Numbers

Page 3751
Engine Mount Control Solenoid: Diagnostic Aids
Page 1606
1 - Track Numbers

Page 2424
Page 1443
Power Seat Motor Position Sensor: Diagnostic Aids
Page 1441
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 492
WHAT ARE TRACKS?
15-28, and so on).
Page 1082
- Installation is performed in the reverse order of removal, note the following:
- Check the identification of the new Transmission Control Module (TCM) J217 to ensure it
matches the old Transmission Control Module (TCM) J217.
- Code the Transmission Control Module (TCM) J217.
Final procedures
Page 5276
Engine Control Module: Service and Repair
‹› If the Engine Control Module (ECM) will be replaced, connect the vehicle diagnostic tester and
perform the " Replacing Engine Control Module"
guided function.
Removing
- Switch off the ignition.
- Remove the inner cover of the left plenum chamber.
- Carefully press off the mounting bracket - arrow -.
- Disengage the connectors from the control module and then disconnect the connectors.
- Remove the control module.
Installing
- Connect and engage the harness connectors at the control module.
- Insert the new control module in the retaining frame.

Page 5985

Code.
Specifications
Idle Speed: Specifications
Technical Data
‹› 1 Applies to manual and automatic transmission. If voltage supply of ECM drops below 12 volts,
idle speed is raised in stages up to 780 RPM.
Idle speed is not adjustable.
‹› 2 Replace the ECM. Refer to => [ Engine Control Module ] See: Computers and Control
Systems/Engine Control Module/Service and Repair.
Page 2177
09.

Code.
Locations


Page 7910

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Active Exhaust System Actuator: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1634
Part 3
Page 5405
Electronic Throttle Control Module: Locations Component Location Overview

13 Throttle Valve Control Module (J338)
Page 2700
Part 2
Page 2940
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1853
Discharge Air Temperature Sensor / Switch: Diagnostic Aids
Page 2909
- Replace the Transmission Fluid Temperature Sensor G93.
Checking wiring
- Install the Adapter F/VAG1598 VAG1598/22.
- Using a multimeter, check the Transmission Fluid Temperature Sensor G93 electrical harness
connector terminals to the Transmission Control Module (TCM) J217 electrical harness connector
T52 terminals for resistance.
Transmission Fluid Transmission Control Module (TCM)
Temperature Sensor G93 J217 electrical connector T52
electrical harness connector terminals or test box sockets
terminal 1
45
28

- End diagnosis.
Final procedures
End diagnosis.
Page 1913
1 - Track Numbers

Page 7826
Part 2
Page 3137
- Install screw cap -arrow- and tighten to 25 Nm.

Page 2872
- Remove nut - 1 -.
Page 6122
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2133
1 - Track Numbers

Page 4696
Page 6657
End diagnosis.
Page 7938
1 - Track Numbers

Page 1187
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 268
1 - Track Numbers

Page 5572
Part 2
ATF Cooler Assembly Overview
Transmission Cooler: Service and Repair ATF Cooler Assembly Overview
ATF Cooler Assembly Overview

Disassembly and assembly sequence => [ ATF Cooler ] See: ATF Cooler
1 Transmission housing
2 O-ring
3 ATF cooler
4 Bolt, 36 Nm
5 Dished washer
‹› Installation position: Must make contact on washer => [ (Item 6) Washer ] , the side bulged
outward must point upward
6 Washer
7 O-ring
Page 6038
Part 3
Page 5021
‹› Puller (T40039)

Page 6054
- Slide the retaining clip - 3 - as shown into the groove of the injector. Collar - 4 - must be located
correctly in the cutout of the retaining clip on both sides.
- After assembling, check all injectors for correct installation.
- Install the fuel rail with secured injectors to the intake manifold and press it in uniformly.
- Secure the fuel rail to the intake manifold.
following:
- Bleed the fuel supply system. Refer to one of the following:
‹› Engine code BPS, refer to => [ Fuel System, Bleeding ] See: Fuel Tank/Description and
Operation.
‹› Engine code BPR, refer to => [ Fuel System, Bleeding ] .
- Connect the battery.
Page 5267

Page 4811
1 - Track Numbers

Page 4355
Example
- Only suspect coolant pump leak, and consider replacement if the following conditions occur
- Vehicle arrives with excessive coolant leak.
- Vehicle arrives with coolant light ON.
- Vehicle arrives with the temperature warning at its highest level.
- Pressure drops in the coolant pump during Pressure test, see Group 19, Cooling System,
Checking for Leaks in ElsaWeb.
Warranty
Information Only.
Temperature Gauge: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2136
WHAT ARE TRACKS?
15-28, and so on).
Page 7121
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5101
WHAT ARE TRACKS?
15-28, and so on).
Page 4543
Start diagnosis
Checking voltage
terminals.
terminals.
Checking activation
Page 7611
- Pull off bearing inner race from stub axle.
Only use puller - A - with tension bracket, e.g. (Kukko 204-2) (commercial type)..
Installing
- Push wheel bearing/wheel hub unit onto stub axle as far as it will go.
- Install on installation sleeve wheel brg. (3420 ) and pull on wheel bearing/wheel hub unit until it
stops.
Make sure that wheel hub/wheel bearing unit is not tilted!
- Remove installation sleeve wheel brg. (3420).
- Use a new 12 point nut - A - and tighten, tightening specification => [ Rear Axle ] See:
Specifications/Mechanical Specifications/Steering and Suspension/Suspension/System
Specifications/Rear Suspension/Rear Axle Component Tightening Specifications.
Page 3839
VW/Audi Oil filter housing drain. This tool is used for draining the oil filter housing on 2005 1/2-2008
VW/Audi models with the new 2.0L Turbo (engine codes; BPG, BPY, BWT) and the 2.5L inline 5
cyl VW engine.
- Prevents spillage during oil filter change and allows for drainage of oil from the filter housing
- Used for draining the oil filter housing on 2005 1/2-2008 VW/Audi models with the new 2.0L Turbo
(engine codes; BPG, BPY, BWT) and the 2.5L inline 5 cyl VW engine
- Easy to use

Page 5552
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2638
Part 2
Page 1467
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Overview
Fuel Gauge Sender: Service and Repair Overview

1 Cap
2 Seal
3 Bolt
4 Fuel Filler Door Unit
‹› With rubber gasket.
5 Bolt, 10 Nm
6 Vent Line
7 Switch Over Valve
‹› To remove the valve, unclip sideways out of the support.
‹› Before installing, remove the cap - item 1 -.

Page 1818
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5962
Page 5629
Part 3
Page 2576
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6954
- Switch off engine.
- Remove ATF inspection plug from pan - arrow -.
- Remove overflow tube - 1 - through inspection hole.
- Drain ATF.
- Install overflow tube.
- Install plug hand-tight.
- Add 3 liters of ATF through filler tube.
- Start engine, shift through all selector lever positions with vehicle stationary, leaving selector lever
in each position for about 10 seconds.
- Finally, check ATF level and top off.

Page 1216
Ground (GND)

Page 3874
Part 3
Page 2770
Ground (GND)

Page 5408
1 - Track Numbers

Page 1302
Part 3
Page 7089
- Install left drive axle.
- Check ATF level and top off => [ ATF Level ] See: Fluid - A/T/Testing and Inspection/ATF Level.
Right Side Flanged Shaft Seal
Right Side Flanged Shaft Seal
‹› Drip tray (V.A.G 1306)
‹› \
‹› Puller (T10055)
‹› \
‹› Adapter (T10055/2)
‹› Standard drill
Removing right flange shaft seal
- Remove noise insulation - arrows -.

Page 326
Ground (GND)

Page 1240
Parking Assist Distance Sensor: Service and Repair
Parking Aid
Rear Parking Aid Sensors
‹› Release Tool (T10345)
Sensor in the rear bumper cover:
‹› Left Rear Center Parking Aid Sensor (G204)
‹› Left Rear Inner Parking Aid Sensor (G334)
‹› Right Rear Inner Parking Aid Sensor (G335)
‹› Right Rear Center Parking Aid Sensor (G205)
Removal and installation is the same for all sensors so the following information describes only one
of them.
Removing
- Remove rear bumper cover.
CAUTION! ‹› Always follow the sensor removal sequence.
‹› Otherwise, the sensor may be damaged. Hairline cracks which lead to sensor failure can develop
if too much force is used on the
sensor.
‹› First remove the sensor from the bracket and then disconnect the sensor connectors.
- Disengage retaining tabs - arrows - with Release Tool (T10345) and remove sensor with
connector connected from bumper cover.
Page 6090
Page 4650
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4136
WHAT ARE TRACKS?
15-28, and so on).
Locations

Page 5218
Page 2211
Part 3
Page 3860
- Loosen the bolts again slightly.
- Secure the (2036/1) from the (2036) onto the cylinder block as shown.
- Press the upper oil pan firmly onto the (2036/1) and tighten the bolts again hand tight.
- Install the remaining bolts and tighten by hand.
Make sure that upper oil pan makes contact on the (2036/1 ).
- Tighten all bolts in a diagonal sequence from the inside working toward the outside.
- Install new seal - 5 - into the oil pump - 6 -.
- Secure the oil intake pipe - 1 - and the bracket - 4 - with the bolts - 2 and 3 -.
- Install the guide rail - 2 -, relieve the tension on the chain tensioner - 1 - and pull out the (T10115).

Page 5022
‹› Spark Plug Connector Pliers (V.A.G 1922)
‹› Puller (T10112)
Page 5495
terminals.
Checking activation
If the test lamp was not ON:
- Using a multimeter, check the Motronic Engine Control Module (ECM) Power Supply Relay
socket 1 (relay terminal 85), to the Motronic Engine Control Module (ECM) (J220) electrical
harness connector T121 terminal 23 for resistance.
- Check the wiring connection for an open circuit, high resistance or short circuit to Battery (+).
If no malfunction is found in the wiring and ground was not present from the ECM during crank:
Final procedures


Engine Mount Control Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5661
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 946
WHAT ARE TRACKS?
15-28, and so on).
Page 4413
Page 1745
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1452
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Specifications
Spark Plug: Specifications
Test Data and Spark Plugs
1) Assignment according to Vehicle Identification Number (VIN).

Page 4937

Page 3885
‹› At 2000 RPM and an oil temperature of 80° C (176° F), the oil pressure must be 2.7 to 4.5 bar.
pressure.
‹› => [ Oil Pump, through MY 2007 ] See: Service and Repair/Oil Pump, Through MY 2007.
‹› => [ Oil Pump, from MY 2008 ] See: Service and Repair/Oil Pump, From MY 2008.

Page 5502

Page 7754
3. Check affected solenoid resistance at connector plug T14 or T10 on transmission housing and at
wiring harness connection to Transmission
Control Module (TCM). Target values are in GFF test plan. (Refer to pin assignment in GFF test
plan)
Tip: Check pins according to DTCs that are stored in the Scan Tool.
4. If resistance on solenoid is within specification:
- Using appropriate wire from VAS 1978 Repair kit, run an overlay wire from plug T14 or T10 to
TCM.
5. Perform vehicle test drive.
If fault does NOT return:
- Repair wiring harness with wiring harness repair kit VAS 1978.
If fault returns or resistance on transmission housing connector is not within specification:
- Contact technical assistance by selecting "Technical Assistance" tab in ElsaWeb and follow
Warranty
Information only.
Tool Description Tool No:
Wiring Harness Repair Kit VAS 1978*
* Call Volkswagen Tools and Equipment Program (EQS), which is Equipment Solutions for product.
Page 1284
Part 3
Page 1905
Part 3
Page 535
WHAT ARE TRACKS?
15-28, and so on).
Page 2406
Part 3
Page 2823
Part 3
Page 723
Checking wiring

Page 2369
WHAT ARE TRACKS?
15-28, and so on).
Page 825
Ground (GND)

Page 2073
Part 3
Page 6277
Part 1
Page 3108
- Guide frame with tabs - 1 - into corresponding recess in filter housing and press frame with filter
element downward.

Page 7939
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 474
1 - Track Numbers

Page 6627
WHAT ARE TRACKS?
15-28, and so on).
Page 7052
- Check the wiring connection for damage, corrosion, lose or broken terminals.
Final procedures
Systems/Testing and
End diagnosis.
Page 7057
Final procedures
Page 6803
- Remove tunnel bridge - B - located beneath exhaust system.
- Remove heat shields - C - and - D -.
- First remove 4 nuts - arrows A -.
- Remove two bolts - arrows B -.
- Unclip Shift Lock Solenoid (N110) out of retainer - arrows A -.

Page 1304
Page 7669
3 Tapered roller bearing outer race
‹› Pulling out => [ Pulling outer race/tapered roller bearing out
of transmission housing ] See: Overhaul/Differential
‹› Pressing in => [ Pressing outer race/tapered roller bearing into
transmission housing ] See: Overhaul/Differential
4 Tapered roller bearing inner race
‹› Pulling off => [ Pulling off inner races/tapered roller bearing ] See: Overhaul/Differential
‹› Pressing on => [ Pressing on inner races/tapered roller bearing ] See: Overhaul/Differential
5 Differential housing
‹› With drive gear for final drive
‹› Thrust washer union installed to differential housing => [ On some transmissions the thrust
washer union
was made with a ridge in area of holes. ] See: Overhaul/Differential
6 Tapered roller bearing inner race
‹› Pulling off => [ Pulling off inner races/tapered roller bearing ] See: Overhaul/Differential
‹› Pressing on => [ Pressing on inner races/tapered roller bearing ] See: Overhaul/Differential
7 Tapered roller bearing outer race
‹› Pressing out => [ Pressing tapered roller bearing outer race out
from clutch housing ] See: Overhaul/Differential
‹› Pressing in => [ Pressing outer race/tapered roller bearing into
clutch housing ] See: Overhaul/Differential
8 Clutch housing
9 Sleeve
‹› For mounting of seal => [ (Item 10) Seal ]
‹› Removing and installing => [ Transmission and Clutch Housing ] See: Service and
Repair/Overhaul/Transmission and Clutch Housing.
10 Seal
‹› Replace with transmission installed => [ Removal and Installation ] See: Table of Contents.
11 Oil seal and sleeve as one part
‹› If seal is damaged, replace seal and sleeve together => [ Removal and Installation ] See: Table
of Contents.
12 Countersunk screw, 25 Nm
‹› Screw together with threaded piece => [ (Item 20) Threaded piece ]
13 Flange shaft
‹› Removing and installing => [ Removal and Installation ] See: Table of Contents.
14 Spring for flange shaft
‹› Rear flanged shaft installed
15 Thrust washer
Page 3375
Page 4545
guided function.
Removing
Installing

Page 446
Part 1
Page 2114
- Remove the Left Rear Level Control System Sensor (G76) and bracket.
- Disconnect the connector.
Installing
Make sure the coupling rod bracket fits correctly on the rear axle.
- Check the position of the Left Rear Level Control System Sensor (G76) after installing.
‹› The Left Rear Level Control System Sensor (G76) cannot be adjusted, but it must be checked
after it has been installed to make sure the voltage
signal is within the specified value range of 2.0 to 3.5 volts.
‹› If the voltage is outside of the tolerance, then check the following points:
‹› Left Rear Level Control System Sensor (G76) loose in the bracket.
‹› The coupling rod on the Left Rear Level Control System Sensor (G76) is bent.
‹› Electrical connection is properly inserted and engaged.
‹› If there are no malfunctions here, then perform Guided Fault Finding.

Page 7110
Page 2470
Page 5157
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5535
Part 2
Page 382
Page 2539
Ground (GND)

Overview
Fuel Filter: Service and Repair Overview

Fuel Filter Assembly Overview
1 Fuel Filter
‹› New version with integrated fuel pressure regulator.
‹› Direction of flow is marked with arrows.
‹› Do not interchange connections.
‹› Removal and installation, refer to => [ Fuel Filter ] See: Fuel Tank/Service and Repair/Removal
and Replacement.
‹› Installed position: Pin on filter housing must engage in the recess in the filter bracket. Refer to =>
[ Fuel Filter Installed Position ] See: Fuel
Tank/Service and Repair/Removal and Replacement.
2 Retaining Clip
‹› For the fuel pressure regulator.
‹› Check clip for secure seating.
3 Fuel Supply Line

Page 2169
Trunk Lamp Switch: Service and Repair Luggage Compartment Light Switch
Luggage Compartment Light Switch
The Luggage Compartment Light Switch (F5) is integrated into the rear lid lock and cannot be
replaced separately.
If the Luggage Compartment Light Switch (F5) is faulty, then the entire rear lid lock must be
replaced.
Page 5836
1 - Track Numbers

Page 2325
Checking wiring
Final procedures

09.

Code.
Page 665
Power Distribution Relay: Locations Relay Arrangements on Thirteen Position Auxiliary Relay
Panel, Above Relay Panel, From July 2005
ABS Light Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1272
Shock Sensor: Diagnostic Aids
Page 1658
Wheel Speed Sensor: Diagnostic Aids
Locations

Page 1127
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5630
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Shift Interlock Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2603
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6406
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 1663
10 Wheel hub with wheel bearing and rotor
‹› Replace only as complete unit
11 Axle beam
Page 3610
‹› Sealant beads must be applied according to exact specifications, otherwise excess sealant could
get into the camshaft bearings.
‹› Installing and securing the guide frame should be performed without interruption because the
sealant begins to harden immediately as soon as it
contacts the sealing surfaces.
‹› Note the expiration date of the sealing compound.
- Install the guide frame onto the cylinder head immediately.
- Gently tighten the bolts from the inside working toward the outside in several stages.
- Then tighten the bolts to 8 Nm in the sequence indicated.
- After that, continue to tighten all bolts an additional 90° (1/4) further.
- Sealant must bulge outward slightly, even in the area of chain compartment - arrows -.
- Wipe off the sealant on the sealing surface facing the chain compartment cover.
- Carefully press in the sealing plugs - A - until they reach the end of the chamfer - arrows -.
Page 3213
Final Drive Fluid: Fluid Type Specifications
Planetary gearbox
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
162
Final drive
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
145
Initial filling ...........................................................................................................................................

.......................................................... 7.2 L (7.6 qts)

........................................................................................................................................................
Lubricant ..............................................................................................................................................
...................................................................... DSG oil
Initial filling ...........................................................................................................................................

........................................................... approx. 7.0 L
Changing .............................................................................................................................................
.............................................................. Filled for life
Lubricant ..............................................................................................................................................
......................................................... ATF G 055 025
Page 104
Communications Control Module: Diagnostic Aids
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Overview

1 Fuel Filter
‹› Removal and installation, refer to => [ Fuel Filter ] See: Powertrain Management/Fuel Delivery
[ Fuel Filter Installed Position ] See:
Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal

and Replacement.
2 Retaining Clip

Page 4769
Oxygen Sensor: Testing and Inspection Oxygen Sensor After Catalytic Converter, Checking
Oxygen Sensor after Catalytic Converter, Checking
‹› Use only gold-plated terminals when servicing terminals in the electrical harness connectors of
the Oxygen Sensor (O2S) 2 Behind Three Way
Catalytic Converter (TWC) (G130).
‹› Multimeter.
Test requirements
‹› Engine Control Module (ECM) (J220) fuses OK.
Test procedure
Start diagnosis
- Perform the function test in Diagnostic Mode 06.
If specified values are obtained:
- Check for possible intermittent connection or rub through of harness.
- Erase the code. Drive the vehicle and generate the readiness code.
- Remove the black plastic cover (right side) underneath the vehicle to access the O2S connector.
Checking primary voltage
- Disconnect the Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) (G130)
electrical harness connector.

(TWC) (G130) electrical harness connector terminals 3 to 4 for voltage.
Specified value: 0.400 to 0.500 Volts

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4268
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3590
Part 2
Page 1867
Page 5396
Control Modules
Procedure
‹› Body

Page 5070
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3689
Piston: Testing and Inspection
Piston, Rings and Cylinder Bore, Checking
Piston Ring Gap, Checking
‹› Feeler gauge
- Insert the ring into the bottom of the cylinder opening at a right angle from above, approximately
15 millimeter (mm) from cylinder edge.
Piston Ring Groove Clearance, Checking

Page 7788
- End diagnosis.
Final procedures
Systems/Testing and
End diagnosis.
Page 5751
- Remove nut - 1 -.
Page 1340
Ground (GND)

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1783
Part 3
Page 3119
NOTE:
Page 3757
‹› At 2000 RPM and an oil temperature of 80° C (176° F), the oil pressure must be 2.7 to 4.5 bar.
pressure.
‹› => [ Oil Pump, through MY 2007 ] See: Oil Pump/Service and Repair/Oil Pump, Through MY
2007.
‹› => [ Oil Pump, from MY 2008 ] See: Oil Pump/Service and Repair/Oil Pump, From MY 2008.

Page 4271
Part 3
Page 7382
‹› Interchanged connection could possibly destroy the transmission.

- Carefully pry out retainer tabs of connectors at solenoid valves - 2 - to - 9 - using a small
screwdriver and disconnect connectors.
‹› If a connection is damaged, replace the wiring harnesses or the valve body with solenoid valves.
- Disconnect connectors from hydraulic pressure sensors - 1 - and - 4 -.

Page 4097
‹› Freeze protection must be guaranteed to approximately -25 °C (approximately -35 °C in
countries with an arctic climate).
‹› If climate conditions make greater freeze protection necessary, the amount of G 12 can be
increased up to 60% (Freeze protection to
approximately -40 °C). Adding more coolant reduces the freeze protection and reduces the cooling
efficiency.
- If freeze protection is insufficient, drain off required quantity shown in freeze protection table and
add coolant additive -G 12- which corresponds to TL VW 774 F.
Coolant Level, Checking and Filling
- Check the coolant level in the coolant reservoir with the engine cold.
‹› Delivery inspection: coolant level at max. marking - arrow -
‹› Inspection service: coolant level between the min. and max. marks.
- If coolant level is too low, fill with coolant mixture.
‹› If fluid losses are greater than can be reasonably expected, rectify malfunctions.
Mixture Ratio
‹› Coolant additive -G 12- according to TL VW 774 F prevents freezing and corrosion damage,
scaling and also raises boiling point of coolant. For
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6619
- Using a multimeter, check the Automatic Transmission Hydraulic Pressure Sensor electrical
harness connector terminals to the Transmission Control Module (TCM) J217 electrical harness
Automatic Transmission Transmission Control Module (TCM)
Hydraulic Pressure Sensor 1 J217 electrical connector T52
G193 electrical harness terminal or test box
connector terminal socket
7 24
8 25
- Replace the faulty Automatic Transmission Hydraulic Pressure Sensor.
- End diagnosis.
Final procedures
End diagnosis.
Page 5400
Some of the functions listed above can be adapted. Refer to => [ Comfort System Central Control
Module Components, Adapting ] See: Testing and Inspection.
The Comfort System Central Control Module (J393 ) is equipped with OBD.
Use the "Guided Fault Finding".
The Comfort System Central Control Module (J393 ) is located behind the trim on the trim on the
left side of the steering column.
Removing
- Remove the cover on the driver side footwell and the trim on the bottom of the steering column.
- Disconnect the connectors - 1 - and - 2 - and remove them from the Comfort System Central
Control Module (J393) - 4 -.
‹› The number of electrical connections depends on vehicle equipment level and market version.
- Remove the Comfort System Central Control Module (J393) - 4 -.

Installing
After installing a new Comfort System Central Control Module (J393), it must be coded. Refer to=>
[ Comfort System Central Control Module, Coding ] See: Testing and Inspection.
Page 1496
WHAT ARE TRACKS?
15-28, and so on).
Page 4995
Air Filter Element: Service and Repair

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 6625
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3155
‹› Checking pressure relief valve in cap. Refer to => [ Cooling System, Checking for Leaks ] See:
Engine, Cooling and Exhaust/Cooling
System/Testing and Inspection/Component Tests and General Diagnostics.
6 Intake Manifold
‹› Connection only for coolant heated throttle valve control module.
8 Quick Release Coupling
9 Heater Core
‹› Replace coolant after replacing.
10 Transmission Oil Cooler
‹› Only for vehicles with a automatic transmission.
11 Coolant Line
12 Coolant Distribution Housing

Page 6828
Solenoid: Diagnostic Aids
Page 3422
- Release the button - 1 -.
Resetting the "INSP" Service
- Press the button - 1 - quickly until "INSP " appears.
- Press the button - 1 - for at least 10 seconds. When doing this, "INSP" will switch to "OIL" or "
OEL" and after 10 seconds the "OIL" or "OEL" Service will be reset. Three dashes will appear in
the display.
- Turnoff the ignition after the Service is reset.
The instrument cluster will be in "standard mode" the next time the ignition is turned on.
‹› It is necessary to reset the service interval display at each delivery inspection, each oil change
and each Inspection Service.
Service Interval Display from 05.1999
With the introduction of the flexible service intervals, only " service" will appear in the display.
Pre-service warning:
A pre-service warning for an upcoming service occurs first 3000 km before interval has elapsed.
The following will appear in the odometer display for 20 seconds after the ignition is turned on:
Service:
After the pre-warning has run to the end, service requirement is displayed:
The following will appear in the odometer display, blinking, for 20 seconds after the ignition is
turned on:
‹› In instrument clusters with mileage display, pre-warning distance is set to 2000 miles.
‹› By resetting via adjustment button on instrument cluster, service interval is set to 10,000 miles
(15,000 km).
‹› It is only possible to set (adapt) the other service intervals using the (VAS 5051B).
‹› Be sure to read the information regarding the flexible service interval display.
Service Interval Display Resetting from 05.1999,
The service interval display must be reset at
‹› Delivery inspection
‹› Each inspection service
There are two ways to reset the service interval display:
using the Vehicle Diagnosis, Testing and Information System (VAS 5051B) under "Guided Fault
Finding"
‹› Connect the Vehicle Diagnosis, Testing and Information System (VAS 5051B).
‹› In Vehicle Diagnostic, Testing and Information System (VAS 5051B), select operating mode
"Guided Fault Finding ".
Page 6708
Part 1
Page 4848
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Power Distribution Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Fuel Door Lock Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 114
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1523
Service and Repair
Radiator: Service and Repair
Radiator
Refractometer (T10007)
Drip tray (VAG 1306) or drip tray for VAS 6100 (VAS 6208)
Spring type clip pliers (VAS 5024A) or hose clip pliers (VAS 6340)
Cooling system charge unit (VAS 6096)
Adapter (VAG 1274/8)
Removing
CAUTION! Hot steam may escape when opening the expansion tank cap. Wear protective goggles
and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and
open very carefully.
- Remove the fan shroud with the coolant fan (V7 ). Refer to => [ Fan Shroud with Coolant Fan ]
See: Fan Shroud/Service and Repair.
Vehicles with Air Conditioning (A/C)
- Remove the bolt - arrow - for the refrigerant line - A -.

Continuation for All Vehicles
- Remove the bolts - arrows - from the radiator.

Page 4081
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3231
ATF does not need topping off.
- Drain ATF until it drips.
- Install new seal to plug and tighten to 15 Nm. This completes ATF check.
If no ATF drips out:
- Add another liter => [ ATF, Filling ] See: ATF, Filling.
CAUTION! An ATF level which is too low or too high will impair the function of the transmission. But
if the transmission was 2 liters low, it must be carefully inspected. There is probably a "major" leak.
ATF, Draining and Filling


Page 5083
Body Control Module: Testing and Inspection Comfort System Central Control Module, Coding
Control Modules
Comfort System Central Control Module, Coding
‹› Body
‹› Coding Comfort System Central Control Module

Page 7192
Transmission Temperature Sensor/Switch: Testing and Inspection
Transmission Fluid Temperature Sensor G93, Checking

- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
- Disconnect the Transmission Fluid Temperature Sensor G93 electrical harness connector - 1 -.
Checking resistance
- Using a multimeter, check the Transmission Fluid Temperature Sensor G93 terminals 1 to 2 for
resistance.
ATF Temperature Specified Values
Approx. - 30 degrees C 37.0 - 51.0 KOhms
Approx. 10 degrees C 5 - 8 KOhms
Approx. 25 degrees C 3.0 - 5.0 KOhms

Page 47
1 - Track Numbers

Air Injection Flow Sensor: Testing and Inspection
Secondary Air Injection Sensor 1, Checking
‹› Multimeter
Test requirements
‹› The fuel filter OK.
‹› The battery voltage at least 12.5 V.
‹› All electrical consumers switched off (radiator fan must NOT run during test).
‹› The fuel tank at least 1/4 filled.
‹› The ignition switched OFF.
Test procedure
Start diagnosis
- Remove the engine cover with air filter. Refer to the Repair Information.
Checking voltage
- Disconnect the Secondary Air Injection Sensor 1 ( G609) electrical harness connector.
connector for voltage using the chart below.

- Replace the Secondary Air Injection Sensor 1 ( G609).
Checking wiring connections
Page 7275
If torque converter is incorrectly installed this distance is considerably less.
The torque converter is properly inserted when it can easily be turned by hand and is seated
equally deep in transmission around the entire circumference.
CAUTION! When the torque converter is incorrectly installed the torque converter drive or the ATF
pump will be destroyed when the transmission is connected to the engine.
Pay particular attention to the following point when installing transmission afterward:
Keep checking whether the torque converter behind the drive plate can be moved when tightening
of the bolts at engine/transmission flange.
If the torque converter cannot be moved, it must be assumed that it has not been inserted properly
and that the coupling plate of the torque converter or the ATF pump will be destroyed during final
tightening of the bolts.
Page 466
Solar Cell Isolation Relay: Diagnostic Aids
Page 4134
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7200
- Pull locking cable out of steering lock - 1 -.
- Remove selector lever handle => [ Selector Lever Handle ] See: Shifter A/T/Service and
Repair/Removal and Replacement/Selector Lever Handle .
- Remove center console.
- Loosen bolt on support bracket - arrow A - of locking cable.
- Carefully pull locking cable out of selector mechanism - arrow B - and disengage from locking
lever - arrow C -.
- Pull locking cable out of instrument panel.
Installing
‹› Do not kink locking cable.
‹› Adjust locking cable after installation => [ Locking Cable, Adjusting ] See: Adjustments.
Installation position of locking cable

Anti-Theft Wheel Bolts, Installing
Wheel Fastener: Service and Repair Anti-Theft Wheel Bolts, Installing
Anti-Theft Wheel Bolts, Installing
Vehicles with light-alloy wheels are supplied with a wheel securing set.
The wheel securing set consists of:
1 Anti-theft wheel bolt for inserting adapter
2 Adapter for wheel bolt
- Assemble these 4 anti-theft wheel bolts on vehicle as follows:
‹› Unscrew one of the wheel mounting bolts each per rim and replace it with anti-theft wheel bolt.
‹› Insert adapter until it stops in wheel bolt and tighten wheel bolt using torque wrench.
‹› Then tighten all wheel mounting bolts to the specified torque.
Wheel bolts: tighten to specification => [ Wheel Bolts, Tightening Specifications ]
- After completion of work, return adapter and hook for wheel cover to vehicle tool kit.
Page 288
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Power Seat Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1014
Suspension Control Module: Diagnostic Aids
Page 1488
Power Trunk / Liftgate Lock Switch: Diagnostic Aids
Page 7652
Part 3
Rear Suspension
Axle Nut: Specifications Rear Suspension
Axle nut
Use a new 12-point nut - A - and tighten.
Wheel Bearing to Stub Axle - M20 x 1.5 ...... 175 Nm

Page 7035
plan)
TCM.
Warranty
Information only.
Page 4046
‹› Puller (T10094 A)
‹› Seal puller (T10118)
Spark Plugs, 2.5L, Replacing

Page 6726
If any of the listed troubleshooting procedures and/or checks result in errors or yield no solution
and further assistance is required, please follow these steps:
1. Utilize the information contained in the Function Description button in the tester at the point of
the error
2. Report the problem to the shop network administrator for further investigation
3. Contact the responsible support team for further assistance:
^ Service Department Applications: (this includes: GeKo, ElsaWeb, Hotline Channel,

Telediagnosis, and Service Net)
^ VAS 5051/5052 Software Subscriptions
^ VAS 5051/5052 Software Support

Page 4813
Ground (GND)

Page 5450
order)
Tip:
Page 4927
Part 2
EGR Control Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1700
Page 213
Part 3
Page 6499
Part 1
Page 7911

‹› Removing and installing => [ Wiring Harness with 8-Pin Connector ] See: Automatic
Transmission/Transaxle/Wiring Harness/Service and
Repair/Wiring Harness With 8-Pin Connector

Page 3838
Oil Filter: Tools and Equipment
VW Oil Filter Housing Drain
AST tool# T 40057

Page 584
Ground (GND)

Page 5370
Oxygen Sensor: Testing and Inspection Oxygen Sensor Before Catalytic Converter, Checking
Oxygen Sensor before Catalytic Converter, Checking
Heated Oxygen Sensor (HO2S) (G39 ).
‹› Multimeter.
Test requirements
‹› The Heated Oxygen Sensor (HO2S) (G39) fuse OK.
‹› The Oxygen Sensor (O2S) Heater (Z19) before catalytic converter OK.
‹› Exhaust system between catalytic converter and cylinder head properly sealed.
Test procedure
Start diagnosis
- Disconnect the Heated Oxygen Sensor (HO2S) (G39 ) electrical harness connector - 1 -.
Page 457
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7523
Part 2
Page 1729
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Electronic Throttle Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1533
WHAT ARE TRACKS?
15-28, and so on).
Page 1280
WHAT ARE TRACKS?
15-28, and so on).
Page 2321
Final procedures

09.

Code.
Page 6014
Ground (GND)

Page 4770
Checking wiring
Final procedures


Page 897
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2792
Page 277
Solar Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6929
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7277
Torque Converter, Installing
‹› Depth gauge
- Slide converter hub through oil seal up to first stop.
- Turn torque converter while pushing in lightly until recesses in torque converter engage into drive
of pump and torque converter slips noticeably inward.
=> [ Torque Converter Installation Dimension, Checking ] See: Procedures/Torque Converter

Installation Dimension, Checking
Radiator Cooling Fan Temperature Sensor / Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7675
Differential: Tools and Equipment
Special Tools
‹› Magnetic plate 50 MM dia. (VW 385/17)
‹› Dial gauge holder (VW 387)
‹› Thrust pad (30 - 205)
‹› - 1 - Internal puller (Kukko 21/7 )
‹› - 4 - Support (Kukko 22/2 )

Ignition Coil: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4814
WHAT ARE TRACKS?
15-28, and so on).
Page 6015
WHAT ARE TRACKS?
15-28, and so on).
Page 4209
Part 1
Page 2478
Ground (GND)

Page 4658
Page 7842
Ground (GND)

Page 6178
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3228
- With engine running, install adapter for filling oil VAS 6262/2 hand-tight.
- Add 1 l of ATF.
- Pull off adapter for oil filling VAS 6262 at quick-release connection and check:
If ATF now flows out of hole in adapter:

Drain ATF until it drips.
If no ATF drips out: -
Add another liter.
CAUTION: An ATF level which is too low or too high will impair the function of the transmission. But
if the transmission was 2 liters low, it must be carefully inspected. There is probably a major leak.
Draining and Filling ATF
Draining and Filling ATF, 09G, 6 Speed A/T

Page 4864
Part 1
Page 4867
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Specifications
Brake Fluid: Specifications
Brake Fluid Type
Permissible specifications of brake fluid for vehicles up to model year 2005
Brake fluid corresponding to FMVSS 116. DOT 4
Permissible specifications of brake fluid for vehicles from model year 2006
Brake fluid corresponding to VW standard, VW 501 14

Page 4326
Part 2
Page 3746
Part 1
Page 5740
Part 1
Page 2668
Part 1
Page 6002
NOTE:
Page 7902
5 38
6 50
- End diagnosis.
Final procedures
End diagnosis.
Specifications
Timing Chain: Specifications
Timing Chain Tensioner Mounting Bolts ..............................................................................................
...................................................................... 10 Nm
Belt Pulley/Vibration Damper Bolts
Replace Strength category 12.9 ..........................................................................................................

................................................................................... 70 Nm Strength category 10.9
......................................................................................................................................... 50 Nm plus
Timing Cover Bolts
Please refer to Chain Compartment Cover See: Timing Cover/Service and Repair, and Control
Housing Cover See: Variable Valve Timing/Variable Valve Timing Cover / Housing/Service and
Repairfor bolt locations and tightening specifications.
Page 6044
- Operate the starter and test the activation of the Fuel Injector while engine is cranking.
LED should flicker.
If LED does not flicker:
- Remove the Fuel Pump Relay (J17).
- Connect a jumper between the Fuel pump relay terminals 30 and 87
- Using a test lamp connected to ground, check terminal 1 of the Fuel Injector to be tested. The
lamp should be ON.
- If the test lamp did not turn on, locate the open or high resistance in the voltage supply circuit.
Fuse S-229 is located between the fuel pump relay and the injectors.
If the voltage supply was OK:
- Using a multimeter, check the Fuel Injector electrical harness connector terminals to the Motronic
Engine Control Module (ECM) (J220) electrical harness connector T60 terminals for an open
circuit.
- Check the wiring for an open, high resistance or short to voltage or ground.
- If necessary, repair the faulty wiring.
If no malfunction is detected in the wiring and If the voltage supply was OK:
- Install the engine cover. Refer to the Repair Information.
Final procedures
Page 827
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1113
WHAT ARE TRACKS?
15-28, and so on).
Page 2405
Part 2
Page 432
Warranty

Page 7510
- Use centering mandrel (3190 A) to center clutch plate.

Page 3830
Engine Oil, Draining or Extracting
‹› Oil extractor (V.A.G 1782 )
‹› Oil absorbent towel (VAS 6204/1)
Perform the following work procedure:
‹› In engines with standing oil filter module, oil filter should be changed before changing engine oil.
Removing the filter element will open a valve
and oil in the filter housing will flow automatically into the crankshaft housing.
‹› If engine oil is drained and not extracted using old oil extraction unit, replace oil drain plug. This
prevents leaks.
‹› Observe waste disposal regulations!
- Extract engine oil using old oil collecting and extracting unit (V.A.G 1782).
Or
- Remove oil drain plug
- Let engine oil drain.

- Screw in new oil drain plug with sealing ring hand-tight.
Torque specifications for oil drain plug:
The torque specifications are dependent on engine code.
CAUTION! ‹› Torque settings must not be exceeded
‹› A torque figure that is too high may lead to leaks or even damage the oil pan.
- Fill up with engine oil, Note oil specification.
Oil Filter, Replacing
‹› Oil Filter, 2.5L, Replacing

Locations
Fluid Pressure Sensor/Switch: Locations
Automatic Transmission Hydraulic Pressure Sensor 1 G193 and Automatic Transmission Hydraulic
Pressure Sensor 2 G194, 09G, 6 Speed A/T
Component location: Sensors are located in valve body.
1. Automatic Transmission Hydraulic Pressure Sensor 1 G193 2. Automatic Transmission

Hydraulic Pressure Sensor 2 G194
Page 4834

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4655
Part 2
Page 5837
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6496
Ground (GND)

Page 2670
Part 3
Page 889
1 - Track Numbers

Page 7263
- Move selector lever/shift rod - 3 - at transmission in "P" position. Locking lever must engage in
parking lock gear, both front wheels are locked (cannot be turned together in one direction).
- Tighten bolt - 2 - (13 Nm).
- Check shift mechanism => [ Selector Mechanism, Checking ] See: Shifter A/T/Testing and
Inspection.
Page 1844
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6812
End diagnosis.
Page 5642


Page 4491
Final procedures

Page 6518
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1299
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6274
Ground (GND)

Page 789
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2076
Door Switch: Diagnostic Aids
Page 3107
Cabin Air Filter: Service and Repair Dust and Pollen Filter, Replacing Filter Element
Dust and Pollen Filter, Replacing Filter Element
The filter is located beneath the inner plenum chamber cover on the right side.
Remove inner plenum chamber cover, then the right end plate.
- Press retainers of filter housing - arrows - in direction of - arrow - and remove filter element with
frame upward - arrow A -.
- Remove filter element from frame.
- Guide left and right frame edge respectively into first fin - arrows - of new filter element.
Intake Air Temperature Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Service and Repair
Headlamp Dimmer Switch: Service and Repair
Headlamp Adjuster and Instrument Panel Illumination Dimmer Switch
The Headlamp Adjuster (E102)/ Instrument Panel Illumination Dimmer Switch (E20) are a single
unit and cannot be replaced separately.
Removing
- Carefully loosen the switch housing from the frame with a small screwdriver and remove it.
- Disconnect electrical connector.

Installing
Install in reverse order of removal.

Page 6644
1 - Track Numbers


Page 5598
1 - Track Numbers

Page 7569
Part 1
Page 3673
^ With position holder
9 - Sealing ring (transmission side)
10 - Control housing cover
11 - O-ring
^ Replace
12 - 25 Nm
13 - Fitting sleeves
14 - 5 Nm
15 - Engine speed (RPM) sensor G28
16 - Seal
^ Replace
Page 1296
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3528
nut - 5 -.
1 Wheel bearing
2 Thrust piece (E-13-1)
3 Hollow piston cylinder ( HKZ-15)
4 Thrust piece (E-10)
5 Special nut (E-8-214) and tie bolt
Wheel Hub, Installing
1 Wheel hub
- Tighten bolts for control arm and ball joint on to old marks.
Page 2870
Requirements:

Work procedure:
Page 6753
lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update
programming procedure first.
The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM
programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the
normal parameters and specifications approved by Volkswagen of America, Inc.
If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming"
(flashing) procedure:
^ Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to
have been tuned, and that any damage caused by the tuning of the ECM (including any adverse
emissions consequences) will not be covered by Volkswagen of America, Inc. warranties.
^ For any repair requested by the owner under warranty or outside warranty that requires update
programming, which will automatically wipe out the "Tuning" program, your Dealership should
advise the owner of the above and get Owner's written consent (see Control Module Tuning form)
to the update programming procedure.
‹› New Beetle
Specifications
Compression Check: Specifications
Compression Pressure (Positive)
Engine oil temperature must be at least 30° C (86° F) New ................................................................

............................................................................................................................................. 9.0 to
13.0 bar Wear limit ..............................................................................................................................
................................................................................. 8.0 bar Difference between cylinders (max.) .....
..............................................................................................................................................................
.... 3.0 bar
Page 6524
Page 549
Ground (GND)

Page 2761
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 829
Part 2
Page 7707
Gear Oil, Filling
Fill up gear oil in collect container to 1.7 liters.
- Remove backup light switch (F4) - arrow -.
- Connect hose (approximately 600 mm long, outside diameter 10 mm) to commercially available
funnel.
- Insert hose into mounting hole of backup light switch (second mechanic) and fill up gear oil.
- Install backup light switch (F4) - arrow - => [ (Item 2) ] See: Shifter M/T/Service and
Repair/Removal and Replacement/Shift Mechanism Assembly Overview.
- Check switching function.
- Install battery tray and battery.
- Install center section of noise insulation below engine/transmission.

Page 2607
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Locations

Page 1657
Page 637
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2685
Part 3
Page 442
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6357
Submit only one claim per case.

Page 3288
Engine Oil: Removal and Replacement
‹› Engine Oil, Draining or Extracting
‹› Oil Filter, Replacing
prevents leaks.
Or

Page 4815
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 868
New Beetle:
^ Plug pods connector end of VAS 6103/2 onto seat harness going to the PODS.
(A5) Jetta, Passat Sedan, GTII Rabbit and Eos:
^ Use adapter cable VAS 6103/2-1 and connect it to VAS 6103/2 cable as shown above.
^ Connect remaining end of VAS 6103/2-1 to seat harness going to the PODS.
New Beetle:
^ Move passenger seat height adjustment to fully upright position.
^ Identify 10 pin Seat Occupant Recognition Module connector (1) underthe right front edge of
seat.
TIP
^ Disconnect black Seat Occupant Recognition Module harness connector from bracket.
Page 3495
Ground (GND)

Page 1730
Part 1
Page 2418
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 228
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1484
Part 2
Page 6649
Part 1
Locations


Page 3770
Ag-Ig
Page 7094
- Check ATF level and top off => [ ATF Level ] See: Fluid - A/T/Testing and Inspection/ATF Level.
Page 2592
Seat Occupant Sensor: Service and Repair Passive Occupant Detection System (PODS) (USA)
Airbag
be scrapped.
Passive Occupant Detection System (PODS) (USA)
Removal
‹› All wires disconnected when removing the PODS must be reconnected correctly during
installation.
‹› Before beginning work on the PODS, note how all wires are connected and routed.

- Remove the front passenger seat (install the airbag adapter (VAS 5094)).
- Remove bolt on inside of seat - arrow -.
- Remove plastic rivet - 1 - at front part of seat.

Body - Sunroof Malfunctions or is Inoperative
Central Control Module: All Technical Service Bulletins Body - Sunroof Malfunctions or is
Inoperative
60 07 06
June 19, 2007

Page 529
Once adaptation is finished, allow 10 minutes before inspecting fuel gauge for a change.
Tip:
It is not necessary to have VAS 5051/5052 connected to vehicle during 10 minute waiting period.
Warranty
* Code per warranty vendor code policy.
No Special Parts required. Always see ETKA for the latest part(s) information.
Fuel Rail With Fuel Injectors, Assembly Overview
Fuel Injector: Locations Fuel Rail With Fuel Injectors, Assembly Overview
Fuel Rail With Fuel Injectors, Assembly Overview
1 - 3.5 Nm
2 - Fuel rail
3 - Fuel supply line
4 - O-ring -
Replace
- Moisten with clean engine oil
5 - Retaining clip -
Make sure clip is correctly seated on fuel injector and fuel distributor
6 - Fuel injector N30, N31, N32, N33, N83
7 - Intake manifold
8 - Protective cap
9 - Breather valve
Page 3208
these reasons, the cooling system must be filled with radiator freeze and corrosion protection fluid
all year round.
‹› Especially in countries with tropical climates or when vehicle is driven under heavy load, the
coolant improves the engine reliability by its
increased boiling point.
‹› The coolant concentration must not be reduced by adding water, even during the warmer
season. The coolant additive ratio must be at least 40%.
Freeze protection table
- Check freeze protection ratio once more after road test.

Page 300
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4924
WHAT ARE TRACKS?
15-28, and so on).
Variable Valve Timing Actuator: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 334
Vacuum Pump Relay: Diagnostic Aids
Page 4172
WHAT ARE TRACKS?
15-28, and so on).
Page 6068
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 806
If the motor did operate:
- Turn the Ignition switch ON.
- Connect an LED test lamp to battery ground.
- Connect the other end to relay connector terminal 4 (relay 85).
- Turn the Ignition switch OFF.
If the LED did Not turn ON:
- Locate the open, short or high resistance on the voltage supply circuit from the ECM relay,
through fuse S130 to the Secondary Air Injection (SAI) Pump Relay (-J299-) terminal 4 (relay 85).
If the LED did turn ON:
‹› The Secondary Air Injection system ONLY operates at initial start-up when the coolant
temperature is near ambient temperature. The pump will
operate for approximately 20 to 45 seconds and will NOT run again unless coolant temperature
and ambient temperature are within 3 °C of each other.
- Connect an LED test lamp to Battery Positive.
- Start the engine.
If the LED was ON:
- Replace the Secondary Air Injection (SAI) Pump Relay (-J299-).
If the LED was Not ON:
Checking wiring
- Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay (-J299-) electrical
harness connector terminal 3 (relay 86) to the Motronic Engine Control Module (ECM) ( J220)
electrical harness connector T121 terminal 46 for an open circuit or high resistance.
- Check the wiring for an open, high resistance or short to voltage.

Left Front Seat Belt Micro Switch F140
Left Front Seat Belt Micro Switch F140

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Air Injection Vacuum Control Solenoid Valve: Testing and Inspection
Secondary Air Injection Combination Valve, Checking
The following procedure is used to test all combination valves.
‹› Hand vacuum pump.
Test conditions
‹› Vacuum lines and hose connections free of leaks.
‹› Vacuum lines not kinked or plugged.
Test procedure
Start procedure
- Remove the vacuum hose from the Secondary Air Injection Combination Valve.
- Connect hand vacuum pump to combination valve vacuum connection.
- Remove the air duct hose from the Throttle Valve Control Module (J338) and position aside.
- Disconnect the Secondary Air Injection hose.
- Inject a light air pressure into the in Secondary Air Injection hose to close the combination valve.
(do not use compressed air).
The Secondary Air Injection Combination Valve should close and seal. Air should not be able to
pass through the valve.
- Operate the hand vacuum pump.
The Secondary Air Injection Combination Valve should open. Air should be able to pass through
the valve.
If combination valve does not open:
Replace the Secondary Air Injection Combination Valve
Final procedures


Page 6571
Control Module: Testing and Inspection Transmission Control Module (TCM) J217, Voltage Supply,
Checking
Transmission Control Module (TCM) J217, Voltage Supply, Checking
- Multimeter.
- Wiring diagram.
Requirements
- Fuse SA6 OK.
- Fuse SB28 OK.
- Fuse SC14 OK.
- The battery voltage must be at least 12.5 volts.
- The Ground (GND) connections at the transmission OK.
- The parking brake engaged.
- The selector lever of automatic transmission in position "P".
- All electrical consumers switched off.
- The ignition switched off.
Test procedure
Start diagnosis
Checking voltage
- Using a Multimeter, check the Transmission Control Module (TCM) J217 electrical harness
connector T52 terminals 27 and 28 to Ground (GND) for voltage.
Specified value: battery voltage.
- Check the wiring from the Transmission Control Module (TCM) J217 electrical harness connector
T52 terminals 27 and 28 to the Fuse (on fuse panel) S231 for an open circuit or a short circuit.
connector T52 terminal 3 to Ground (GND).
Specified value: battery voltage

- Check the wiring from the Battery to the Transmission Control Module (TCM) J217 electrical
harness connector T52 terminal 3 for an open circuit or a short circuit.
connector T52 terminals 1 and 2 to Ground (GND) connection on left headlight for resistance.
- Check the Transmission Control Module (TCM) J217 electrical harness connector T52 terminals 1
and 2 to Ground (GND) connection on left headlight for an open circuit or a short circuit.

Page 29
- Antenna cables - Touareg 2004 > 2006
Tip:
Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the
latest parts information.
Page 6206
1 - Track Numbers

Page 6853

Page 3250
funnel.

Page 7568
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2310

09.

Code.
Page 4544
Final procedures

Locations


Page 3156
Coolant Line/Hose: Testing and Inspection
Coolant Fan, Checking
‹› Connector test set (VAG 1594 A)
Prerequisites
‹› Main fuses must be OK.
‹› Coolant Fan Control (FC) Thermal Switch (F18) OK.
Sequence
- Disconnect the connector for the coolant FC thermal switch.
- Bridge terminals 1 and 2 of connector with adapter cables from (VAG 1594A).
Stage 1 of coolant fan (V7) must start up.
Stage 2 of coolant fan must start up.

If 1st or 2nd speeds of fans do not run:
- Locate and repair open circuit in wiring using wiring diagram.
If no fault is detected in the wiring:
- Replace the coolant fan.

Page 7318
1 - Track Numbers

Page 1907
Page 365
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7806
WHAT ARE TRACKS?
15-28, and so on).
Suspension Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4556
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1608
Ground (GND)

Page 4170
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 587
Part 1
Page 4440
- Then align the exhaust system free of tension. Refer to => [ Exhaust System, Installing ] See:
Service and Repair/Removal and Replacement/Exhaust System, Installing.
Page 5577
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Locations
2 - Air shroud

6 - 5 Nm
7 - Bolt
8 - Fan wheel
9 - Fan ring
10 - Cover
12 - 5 Nm
13 - Washer
14 - Bolt
15 - Connector
16 - 5 Nm
Page 5299
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6515
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1691
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4695
Page 7282
Transmission Cooler: Service and Repair ATF Cooler
ATF Cooler
‹› Hose Clamps Up To 25 mm Dia. (3094)
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
- Clamp off ATF cooler hoses using Hose Clamps Up to 25 mm dia. (3094) and disconnect from
ATF cooler.
Page 4106
Coolant Line/Hose: Testing and Inspection
Coolant Fan, Checking
‹› Connector test set (VAG 1594 A)
Prerequisites
‹› Main fuses must be OK.
‹› Coolant Fan Control (FC) Thermal Switch (F18) OK.
Sequence
- Disconnect the connector for the coolant FC thermal switch.
Stage 1 of coolant fan (V7) must start up.
Stage 2 of coolant fan must start up.

If 1st or 2nd speeds of fans do not run:
- Locate and repair open circuit in wiring using wiring diagram.
If no fault is detected in the wiring:
- Replace the coolant fan.

Page 3397
Fuse Block: Service and Repair Relay Panel and 13-Pin Relay Carrier
Connecting.
Connecting.
Removing
- Loosen both nuts - C - and all connectors - D -.
- Remove the relay panel - B - and relay carrier - A - downward.
Installing
- Tighten the nuts - C - to 3 Nm and the threaded connections - D - to 9 Nm.

Page 7596
Wheel Bearing, Installing
- Clean hole of wheel bearing housing.
- Coat entire surface with Molykote grease.
Molykote grease (G 052 723 A2)
- Put wheel bearing - 1 -, pressure piece - 2 - (put collar into bearing), and hollow piston cylinder - 3
- with tie bolt on wheel bearing housing.
Page 915
Battery Control Module: Diagnostic Aids
Page 6845
Page 4876

Page 951
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3997
Start in the area of the alignment bushings - arrows -.
‹› Make sure the sealing surfaces are not damaged.
- Drive out the seal with the control housing cover removed.
Installing
- Remove the remainder of the sealant from the cylinder block, upper oil pan and control housing
cover using a rotating plastic brush.
- Clean the sealing surfaces of the cylinder block, upper oil pan and control housing cover, they
must be free of oil and grease.
- Replace the seals - 1 and 2 -.

Page 1033
Module Components, Adapting ] See: Relays and Modules - Powertrain Management/Relays and
Modules - Computers and Control Systems/Body Control Module/Testing and Inspection.
Removing

Installing
[ Comfort System Central Control Module, Coding ] See: Relays and Modules - Powertrain
Management/Relays and Modules - Computers and Control Systems/Body Control Module/Testing
and Inspection.
Page 4492
Removing
spring clamp - 3 -.
Page 2821
Part 1
Engine Code BPS
‹› Observe safety precautions. Refer to => [ Safety Precautions ] See: Powertrain


replaced.
connection.
Locations
Page 7109
Transmission Input Speed Sensor
Transmission Speed Sensor: Service and Repair Transmission Input Speed Sensor
- Remove bolt - 1 - of Transmission Input Speed (RPM) Sensor (G182).
Installing

- Tighten bolt - 1 - of Transmission Input Speed (RPM) Sensor (G182) => [ (Item 15) Bolt, 6 Nm ]
Page 2255
09.

Code.
Page 4559
Part 3
Page 6289

Page 2461
1 - Track Numbers

Page 3383
Fuse: Application and ID Fuse Arrangements on Thirteen Position Auxiliary Relay Panel, Above
Relay Panel, From July 2005
Fuse Arrangements On Thirteen Position Auxiliary Relay Panel, Above Relay Panel, E-J
Page 1466
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7472
- Remove cable bracket from transmission - arrows -.
- Tie up shift cable and selector cable.
- Remove bracket - B - from transmission and disconnect it from hose/line assembly - A -.
- Remove transmission support - arrows A -.
- Lay lint-free cloth under slave cylinder.
- Pull clip for hose/line assembly out of slave cylinder until stop.
- Pull hose/line assembly out of slave cylinder and seal.
- Remove slave cylinder - arrows B -.
‹› Do not depress clutch pedal.
Installing
Locations
Page 2704
Acceleration Sensor: Diagnostic Aids
Page 6725
SVM can provide a response code with a repair suggestion or after a successful repair. The
response code will appear in the diagnostic log.
Warranty
Information only.
Checking for Internet Connectivity:

With the tester connected to the internet, go to Guided Functions >> All remaining vehicles >>
Immobilizer I & II >> Online System Test.
Technical Helpline Contact Requirements:
Contact the Technical Helpline via the Volkswagen Technical Assistance (VTA) system in ElsaWeb
or phone in cases where there is a clear technical issue with the vehicle or response from the SVM
system. Always include the following information in the VTA contact.
^ SVM Action Code attempted
^ Control Module(s), affected part numbers and software levels, Address word(s) that are in
question
^ The complete tester diagnostic log from the GFF session attached to the VTA helpline ticket
Further Tester Assistance:
Page 4468
Installing

Owner's Manual
General Information
Page 2867
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 6521
Part 3
Page 4158
Page 1573
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7149
Page 4799
Page 2223
1 - Track Numbers

Page 7176


Page 478
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5942
1318).
disconnected.
Check Valve, Checking ] See: Fuel Pump/Testing and Inspection/Fuel Pump Checking, Engine
Code BPS (Plastic Fuel Tank).
and Operation.
Procedures
Engine Oil: Procedures
Engine Oil, Checking Level
Please note the following:
- After stopping the engine, wait for at least 3 minutes for the oil to flow back into the oil pan.
- Pull out dipstick, wipe off with a clean cloth and re-insert dipstick again up to stop.
- Pull out dipstick again and read oil level.
If the dipstick appears as illustrated:
If oil level is above area - A -, the catalytic converter can be damaged.
- When oil level is below marking - C -, top off with oil to marking - A -. Note oil specification.
Page 6098
9 Breather Valve
Page 6481
- Install selector mechanism cover and circuit board => [ Selector Mechanism Cover and Circuit
Board ] See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service
and Repair/Removal and Replacement/Selector Mechanism Cover and Circuit Board.
- Install center console
- Install selector lever handle => [ Selector Lever Handle ] See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Removal and
Replacement/Selector Lever Handle.
- Check selector mechanism => [ Selector Mechanism, Checking ] See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Testing and Inspection.

Page 1012
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3048
3 Fuel Supply Line
‹› Black
4 Fuel Return Line
‹› Blue
‹› 4 bar
6 Gasket
‹› Replace
7 O-ring
‹› Replace
8 Fuel Supply Line
‹› Black
9 Bolt, 3 Nm
10 Bracket

Page 4742
1 - Track Numbers

ABS Control Module J104
ABS Control Module J104


Locations


Page 5926
Ground (GND)

Page 7857
strip - 2 -.
Page 1903
Part 1
Hose/Line HVAC: Description and Operation
A/C Refrigerant System Component Description
A/C System Hoses and Lines
The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for
example, copper) and breaks down certain hose material. Use only hoses and lines that are
identified with a green mark (stripe) or the lettering "R-134a".
Hoses and lines are fastened together with threaded couplings/fittings and are retained (to
bodywork or components) with specially isolated hose clamps.
‹› During servicing, all couplings, fittings and related fasteners must be torqued to specifications =>
[ A/C Refrigerant System Component Overview
] See: Heating and Air Conditioning/Service and Repair/Removal and Replacement/A/C Refrigerant
System Component Overview.
‹› Ensure that only special tools (as specified) are used while servicing.
Page 3905
7 Drive Plate/Flywheel
‹› To remove, secure the crankshaft using the locking pin (T40069).
‹› Drive plate, removal and installation. Refer to => [ Drive Plate ] See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Drive Plate.
8 Sensor Wheel
‹› For the engine speed (RPM) sensor (G28).
‹› With position holder.
9 Crankshaft Seal, Transmission Side
‹› Removal and installation, refer to => [ Crankshaft Seal, Transmission Side ] See: Crankshaft
Seal, Transmission Side.
10 Control Housing Cover
‹› Removal and installation, refer to => [ Control Housing Cover ] See: Camshaft, Lifters and Push
Rods/Variable Valve Timing Cover /
Housing/Service and Repair.
11 O-ring
‹› Replace
12 Bolt, 25 Nm
13 Alignment Bushings
14 Bolt, 5 Nm
15 Engine Speed (RPM) Sensor (G28)
16 Seal
‹› Replace
Page 1749
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4726
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7237
End diagnosis.
Page 3088
19 Coolant Pump
‹› In the cylinder block.
‹› Removal and installation, refer to => [ Coolant Pump ] See: Engine, Cooling and Exhaust/Cooling
System/Water Pump/Service and Repair.
20 Ribbed Belt Tensioner, for the A/C Compressor Belt, 35 Nm
21 Ribbed Belt Tensioner, for the Generator, Power Steering Pump and Coolant Pump Belt, 35 Nm

‹› Replace
23 Bolt, 25 Nm
24 Bushing
‹› Quantity: 2
25 Engine Mount
Ribbed Belt Routing
1. Power steering pump
2. Generator pulley
3. Lower idler pulley
4. Ribbed belt, for the generator, power steering pump and coolant pump
5. A/C compressor pulley

Page 2329
Oxygen Sensor: Testing and Inspection Oxygen Sensor After Catalytic Converter, Checking Heater
Oxygen Sensor after Catalytic Converter, Checking Heater
‹› Vehicle must be raised before electrical harness connector for the Oxygen Sensor (O2S) Behind
Three Way Catalytic Converter (TWC) (G130) is
accessible.
‹› When servicing terminals in harness connector of Oxygen Sensor (O2S) Behind Three Way
Catalytic Converter (TWC) (G130), use only
gold-plated terminals.
‹› Multimeter.
Test requirements
‹› The Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) (G130) fuse 15 in Fuse
box B is OK.
Test procedure
Start diagnosis
- Remove the black plastic cover (right side) underneath the vehicle to access the O2S connector..
- Disconnect the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) (G130)
(TWC) (G130) electrical harness connector terminals 1 to 2 for resistance.
- Replace the Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) ( G130)
- Turn the ignition switch ON
(TWC) ( G130) electrical harness connector terminal 1 to engine ground.
Page 1524
Acceleration/Deceleration Sensor: Diagnostic Aids
Page 5570
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3742
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3544
1 Phillips-head screw
2 Brake disc
3 Dust cap
An appropriate seal can only be achieved with a new dust cap.
Only then can an optimal function and long service life be guaranteed
‹› Pressing off and driving in => [ Wheel Bearing and Hub Unit ] See: Wheel Bearing and Hub Unit.
4 Self-locking 12 point nut
‹› M20 x 1.5
‹› Tightening specification => [ Rear Axle ] See: Specifications/Mechanical Specifications/Steering

and Suspension/Suspension/System
Wheel bearing, wheel hub and rotor are installed together in one housing.
This wheel bearing/wheel hub unit is maintenance-free and adjustment free. It is not possible to
adjust or service the unit.
6 Axle beam
Service and Repair
Evaporative Emission Control Canister: Service and Repair
EVAP Canister and Leak Detection Pump
Removing
- Remove the rear right wheel housing liner.
- Disconnect the vent lines - 1 and 2 -.
Press in the securing ring - A - to disengage the lines.
- Disconnect the connector - 3 -.
‹› Illustration shows a metal fuel tank. Steps for the plastic fuel tank are similar.
- Disconnect the vacuum line - 3 -.
- Remove the right rear side turn signals.

Page 893
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6896
Page 7214
Installing

Page 2973
Part 2
Page 2620
1. Lock Cylinder
3. Securing lever
Installing
Page 6089
Fuel Pump Relay: Locations Relay and Fuse Arrangements on Relay Panel, From July 2005
Page 4882
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6545
Tip:
Page 1543
- Remove bolt - 2 - from stub axle.
- Pull ABS wheel speed sensor out of stub axle.
Installing
- Before inserting wheel speed sensor, clean inner surface of hole and coat sensor completely with
securing grease (G 000 650 ).
- Insert wheel speed sensor in hole of stub axle and tighten bolt to 8 Nm.
- Connect wheel speed sensor and sensor wire.

Page 7302
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2684
Part 2
Page 4691
Part 1
Page 6655
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 7334
- Remove nut - 1 -.
Locations
Oil Filter: Locations
1.8L - 2.0L
- Loosen oil filter -arrow-
TDI - Diesel engines:
- sealing cap -1-
- O-rings -2- and -3-
- oil filter element -4-.
2.5L
- oil filter housing stop -1-

Page 2858
Ground (GND)

Page 1132
Part 2
Page 2652
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5958
Part 1
Page 6597
Transmission Position Relay: Diagnostic Aids
Page 6333
- Check the wiring connection for an open circuit, short circuit to Battery (+) or Ground.
- Replace the Camshaft Position (CMP) Sensor (G40 ).
If no malfunction is found in the wiring and voltage supply was not OK:
Final procedures
1. Check the DTC memory => [ Diagnostic Mode 03 - Read DTC Memory ] See: Computers and
Control Systems/Testing and Inspection/Scan Tool
Testing and Procedures/Diagnostic Modes 01 - 09.
2. If necessary, erase the DTC memory => [ Diagnostic Mode 04 - Erase DTC Memory ] See:
3. If the DTC memory was erased, generate readiness code => [ Readiness Code ] See:

Page 2838
Ground (GND)

Page 983
Steering Mounted Controls Communication Module: Diagnostic Aids
Page 3372
Part 2
Page 4490
Checking wiring

Page 7101
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2920
Part 1
Page 7499
Pressure Plate: Specifications Specifications - Clutch Pressure Plate Bolts
Sachs
Clutch, Pressure Plate Bolts, Sachs (M7)
First pass: Hand-tighten all bolts evenly by hand until bolt head makes contact on pressure plate
Final pass
................................................................................................................................................ 20 Nm
in diagonal sequence and in small stages
LuK
Clutch Pressure Plate Bolts, LuK (M6)
First pass: Hand-tighten all bolts evenly until bolt head makes contact on pressure plate Final pass
................................................................................................................................................ 13 Nm
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2590
Seat Occupant Sensor: Service and Repair Passive Occupant Detection System (PODS) Top Side
Assembly Overview, USA
Airbag
Passive Occupant Detection System (PODS) Top Side Assembly Overview, USA
1 - Seat Frame
2 - Pressure Transfer Hose
3 - Sensor Mat
‹› The sensor mat and seat cushion are one unit and may not be separated.
4 - Front Clip
‹› Quantity: 2
‹› Replace the clips with the clips from the replacement kit
5 - Rear Clip
‹› Quantity: 2
‹› Replace the clips with the clips from the replacement kit
6 - Seat Cushion
Page 4456
Page 2868
fuse/relay panel) S7 for an open circuit, short to ground (GND) or a short to Battery (+).
Checking wiring
- Install the test box. Install the Adapter F/VAG1598 (68 Pin) VAG1598/22.
connector T52 terminals for an open circuit.
Multi-Function Transmission Transmission Control Module (TCM)
Range (TR) Switch F125 J217 electrical connector T52
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- Replace the Multi-Function Transmission Range (TR) Switch F125.
- End diagnosis.
Final procedures
Page 7542
Page 3133
Note: When screwing in oil drain adapter T40057 , a valve in the oil filter housing is opened. If oil
drain adapter T40057 is unscrewed again, the valve closes automatically again.
- Unscrew dust cap -arrow- from oil filter housing.
- Screw oil drain adapter T40057 into oil filter housing and hold hose into an oil collecting pan.
- Allow engine oil to drain.
- Unscrew oil drain adapter T40057 again.
The drain valve -1- should seal flush with the under side of the oil filter housing -2-.
- Oil filter housing can now be removed using Oil Filter Wrench VAS 3417.
Page 3987
Part 2
Page 2228
Part 1
Page 6794
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1963
WHAT ARE TRACKS?
15-28, and so on).
Transmission Control Module (TCM) J217 CAN-Bus
Terminal Resistance, Checking
Control Module: Testing and Inspection Transmission Control Module (TCM) J217 CAN-Bus
Transmission Control Module (TCM) J217 CAN-Bus Terminal Resistance, Checking
The Motronic Engine Control Module (ECM) J220 communicates with all databus capable control
modules via a CAN databus.
These databus capable control modules are connected via two data bus wires which are twisted
together (CAN_High and CAN_Low), and exchange information (messages). Missing information
on the databus is recognized as a malfunction and stored.
Trouble-free operation of the CAN-bus requires that it have a terminal resistance. The central
terminal resistor is located in the Engine Control Module (ECM) J220.
- Multimeter.
- Wiring diagram.
Test requirement
- A CAN-Bus malfunction was recognized.
- The Transmission Control Module (TCM) J217 fuses OK.
- The Motronic Engine Control Module (ECM) J220 fuses OK.
- Battery voltage at least 12.5 V.
Test procedure
Procedure
- Disconnect the Data Bus On Board Diagnostic Interface J533 electrical harness connector.
NOTE: The Transmission Control Module (TCM) J217 must remain connected for the following
step.
- Using a Multimeter, check the Data Bus On Board Diagnostic Interface J533 electrical harness
connector terminals 6 to 16 for resistance.
Specified value: 60 to 72 Ohms (at approx. 20 degrees C)
Checking wiring
connector to the Transmission Control Module (TCM) J217 electrical harness connector T52 for
resistance.
Data Bus On Board Transmission Control Module (TCM)
Diagnostic Interface J533 J217 electrical harness connector T52
electrical harness connector terminals or test box
terminals terminals
6 (Can_Bus Low) 34

Page 4310
Part 1
Page 7330
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 6073
Page 1760
WHAT ARE TRACKS?
15-28, and so on).
Page 2140
Part 3
Page 7518
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6966
- Replace drain plug seal.
- Install drain plug - B - => [ (Item 27) ATF drain plug, 40 Nm ] See: Valve Body/Service and
- Instal overflow tube - C - => [ (Item 3) Overflow tube, 2 Nm ] See: Valve Body/Service and
Page 132
Part 3
Page 6522
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3793
‹› When screwing in oil drain adapter (T40057 ), a valve in the oil filter housing is opened.
‹› If oil drain adapter (T40057) is unscrewed again, the valve closes automatically again.
- Unscrew dust cap - arrow - from oil filter housing.
- Screw oil drain adapter (T40057) into oil filter housing and hold hose into an oil collecting pan.
- Unscrew oil drain adapter (T40057 ) again.
The drain valve - 1 - should seal flush with the under side of the oil filter housing - 2 -.
Page 3747
Part 2
Page 2224
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7977
Part 3
Page 949
Part 2
Page 3777
Ch-Fu
Page 2273
1 - Track Numbers

Page 607
Page 4971
cylinder.
Page 6149
WHAT ARE TRACKS?
15-28, and so on).
Page 1195
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 943
1 - Track Numbers

Page 6538
plan)
TCM.
Warranty
Information only.
Page 4428
- Pull off front exhaust pipe - 2 - from double clamp and from manifold.
‹› The flex joint in the front exhaust pipe must not be bent more than 10 degrees, otherwise it may
be damaged.
Installing
‹› Replace gaskets and self locking nuts.
‹› Install the exhaust system free of stress. Refer to => [ Exhaust System, Installing ] See: Service
and Repair/Removal and Replacement/Exhaust
System, Installing.
‹› 1 Coat stud bolts on the exhaust manifold with hot bolt paste (G 052 118 A3)
Page 1418
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2482
Part 2
Page 896
Part 3
Page 6989
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1319
After rotary position has been verified:
1. Check coding of comfort module.
After coding of comfort module has been verified:
1. Check wiring between door control module and lock before replacing any components.
To Check Door Ajar Switch (all vehicles):
2. Open Door, instrument cluster should display open door.
3. Manually position door latch to closed position
4. Wait for instrument cluster open door display to turn OFF.
5. Move door back and forth and observe the open door display in instrument cluster.
The state of the door ajar should not change while performing this test.
If the state of the door ajar does change:
1. Verify mechanical adjustments and check wiring between door control module and lock before
replacing any components.
Warranty
Information Only.
removal.
Page 6487
circuit.
- End diagnosis.
Final procedures
Page 4657
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6374
Vehicle Information
Condition
Campaign
Note:
Symptoms:
^ MIL ON.
^ Rough idle.
Production Solution

Service
Page 2469
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3691
‹› Internal dial gauge 50 to 100 mm
- Measure diagonally at 3 positions transversely - A - and longitudinally - B -.
Deviation from nominal size: Max. 0.08 mm.
‹› Cylinder bore must not be measured if the cylinder block is secured to the engine stand with the
engine lateral bracket (T03001), or else the results
may be incorrect.
Door Sensor/Switch (For Alarm): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6818
1 - Track Numbers

Page 1534
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7610
- Remove bolts - A - from brake caliper.
- Remove brake caliper and hang on body.
- Remove Phillips-head screw for brake disc and remove brake disc.
- Pull off wheel hub/wheel bearing unit from stub axle.
A Puller, e.g. (Kukko 20/2)

Page 7600
- Press out drive axle.
Note: ^
Be sure there is sufficient room when pulling out drive axle.
- Pull out wheel bearing housing with ball joint from control arm.
- Take drive axle out of wheel bearing housing and tie up.
Drive axle must not hang down!
Otherwise inner joint is damaged by excessive bending.
- Remove cover plate.
- Remove coupling rod from control arm.
- Detach wire for speed sensor from suspension strut.
CAUTION: Place engine/transmission jack V.A.G 1383 A underneath (danger of accident if parts
fall off when ejecting wheel hub and wheel bearing).
Pulling out wheel hub
- Insert pressure bolts - 1 - into wheel bearing housing.
- Assemble bell - 2 -, hollow piston cylinder - 3 - with tie bolt and special nut - 4 -.
- Pull out wheel hub while holding device securely.
1. Pressure bolt E-15 2. Bell E-40 3. Hollow piston cylinder HKZ-15 4. Special nut E-8-214 and tie
bolt 5. High pressure hose with quick-release
Pulling out wheel bearing
- Remove securing ring.

Door Control Module, Driver Side J386
Door Control Module, Driver Side J386

Page 4207
WHAT ARE TRACKS?
15-28, and so on).
Page 7812
Page 5343
Ground (GND)

Page 5855
- Check the wiring for high resistance or an open circuit.
If no malfunction is detected in the wiring or if the voltage supply was OK:
Checking wiring
- Using a multimeter, check the Leak Detection Pump (LDP) (-V144-) electrical connector terminal
1 to Motronic Engine Control Module (ECM) (J220) electrical connector T121 terminal 80 for an
open circuit or high resistance.
- Using a multimeter, check the Leak Detection Pump (LDP) (-V144-) electrical connector terminal
2 to Motronic Engine Control Module (ECM) (J220) electrical connector T121 terminal 25 for an
open circuit or high resistance.

- Check the wiring for high resistance, a short circuit to Battery positive (+) or an open circuit.
If no malfunction is found in wiring:
Assembly is performed in the reverse order of the removal, note the following:
- Install the right rear wheel housing liner. Refer to the Repair Information.
Final procedures
Page 5840
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 854
- Press -Q- button to confirm input.
2000 > MY Coding
Page 7887
Warranty

Page 2871
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 4252
Part 1
Page 774
Engine Control Module: Component Tests and General Diagnostics
CAN-BUS Terminal Resistance, Checking
CAN-Bus Terminal Resistance, Checking
- Multimeter.
- Wiring diagram.
Test requirement
- Battery voltage at least 12.5 volts.
- All electrical consumers such as, lights and rear window defroster, switched off.
- Vehicles with automatic transmission, shift selector lever into position "P" or "N".
- A/C switched off.
- Ground (GND) connections between engine/transmission/chassis OK.
Test procedure
Function
The Motronic Engine Control Module (ECM) J220 communicates with other CAN-Bus capable
control modules.
The control modules are connected by two data bus wires which are twisted together (CAN_High
and CAN_Low), and exchange information (messages). Missing information on the CAN-bus is
recognized as a malfunction by the Motronic Engine Control Module (ECM) J220 and the other
control modules connected to the CAN-bus.
Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central
terminal resistance is located in the Motronic Engine Control Module (ECM) J220.
Start diagnosis
NOTE: The Motronic Engine Control Module (ECM) J220 must remain connected for the following
step.
Checking wiring
- Install the Adapter Cable (121-pin) VAG1598/31.
connector to the Motronic Engine Control Module (ECM) J220 electrical harness connector T121
for resistance.
Data Bus On Board Diagnostic Motronic Engine Control Module (ECM)

Page 4782
Ground (GND)

Page 1214
1 - Track Numbers

Page 5606
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2409
Page 2775
Part 3
Page 3611
‹› If the sealing plug was pressed in too far, it must be pressed through and pressed in again up to
the mark.
following:
‹› Remove the (T40069) from the cylinder block and install the locking bolt (30 Nm).
Page 5509

Page 3594
Variable Valve Timing Actuator: Diagnostic Aids
Seat Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5664
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2214
Page 7556
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6290
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 7807
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5026
Spark Plug Pliers
AST tool# H 1849
- Spark Plug Pliers

Engine Controls - DTC's 00545/00638 Stored
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - DTC's
00545/00638 Stored
Condition
DTC's 00545 and 00638 Stored in DTC Memory

01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated
May 23, 1997 due to inclusion into ElsaWeb.
May be caused by:
- Incorrect Engine Control Module (ECM) coding (codeable ECM only).
- Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.-
Malfunctioning ECM.
- Intermittent continuity in engine harness.
- Poor engine compartment ground (GND).
Production Solution
Not Applicable.
Service
If vehicle exhibits this condition use the following table as a guide for repairs:
- Erase DTC memory, road test vehicle and recheck for any stored DTC's.
Warranty
Information only.
Page 2027
Brake Light Switch, Through 11.06
Brake Light Switch: Service and Repair Brake Light Switch, Through 11.06
Brake Light Switch, through 11.06
‹› When one of the two old 4 pin brake light switches (to 11.06) is removed, it must be renewed
with a new 4 pin brake light switch (from 11.06).
‹› Exception: If a 2 pin brake light switch was fitted, it can be renewed only with the same type of 2
pin brake light switch.
‹› For distinguishing features see => [ The most visible distinguishing feature is
the new lighter colored end of the push rod head ] See: Brake Light Switch, From 12.06.
Removing
- Remove trim on driver's side.
- If necessary remove footwell vent.
- Pull connector off brake light switch.
The brake light switch may be removed only while operating rod is pressed in (brake pedal is not
operated), or the locking mechanism of the brake light switch will be damaged.
- Remove brake light switch by rotating 90 or 45 degrees toward left.
Installing, adjusting and locking
Because old brake light switches (to 11.06 with the exception of 2 pin brake light switches) may no
longer be used, the description has been omitted.
Page 3207
‹› Freeze protection must be guaranteed to approximately -25 °C (approximately -35 °C in
countries with an arctic climate).
‹› If climate conditions make greater freeze protection necessary, the amount of G 12 can be
increased up to 60% (Freeze protection to
approximately -40 °C). Adding more coolant reduces the freeze protection and reduces the cooling
efficiency.
- If freeze protection is insufficient, drain off required quantity shown in freeze protection table and
add coolant additive -G 12- which corresponds to TL VW 774 F.
Coolant Level, Checking and Filling
- Check the coolant level in the coolant reservoir with the engine cold.
‹› Delivery inspection: coolant level at max. marking - arrow -
‹› Inspection service: coolant level between the min. and max. marks.
- If coolant level is too low, fill with coolant mixture.
‹› If fluid losses are greater than can be reasonably expected, rectify malfunctions.
Mixture Ratio
‹› Coolant additive -G 12- according to TL VW 774 F prevents freezing and corrosion damage,
scaling and also raises boiling point of coolant. For
Page 5617
- Using a multimeter, Check the Knock Sensor electrical harness connector to the Motronic Engine
Control Module (ECM) (J220) electrical harness connector T121 for an open circuit.
Ground.
If no malfunction is found in the wiring and the resistance was OK:
Final procedures


Page 2711
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5845
Entertainment System Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Engine Oil: Capacity Specifications
Engine Oil
Filling quantities With filter ...................................................................................................................

................................................................................ 6.0 liters (6.3 qts)
Page 6207
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 965
Part 3
Page 5147
Data Link Connector: Electrical Diagrams
Diagram 54\2 (Track 1-14)
IMPORTANT NOTE:
This manufacturer uses "Track" style wiring diagrams. For information on how to use these
diagrams effectively, please refer to Diagram Information and Instructions. See: Diagrams/Diagram
Information and Instructions
Diagram 54/2 (Track 1-14)
Master Diagram Index: To locate diagrams by component name, please refer to the Master
Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index
Fuse Identification: Starting with fuse 23, fuses in the fuse holder are identified with an additional
numeral 2 added to the number when shown in the wiring diagram (i.e. fuse 23 in the vehicle
becomes 223 in the diagrams, fuse 24 becomes 224, and so on).
IMPORTANT NOTE:
Headlamp Washer Motor Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Power Trunk / Liftgate Lock Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3678
- Use the (3409) to support the screwdriver in order to prevent damage to the sealing flange of the
cylinder block.
Sealing flange is damaged while removing.
- Pry off the sealing flange completely.
‹› After removing the sealing flange, clean the (3409) which is intended for the removal of interior
parts.
Installing
- Remove the remainder of sealant from the cylinder block using a rotating plastic brush.
- Clean the sealing surface of the cylinder block and crankshaft journals; they must be free of oil
and grease.
‹› Do not additionally oil or grease the sealing lip of the sealing flange!
‹› The following steps must be followed so that the sealing lip of the sealing flange does not roll
itself up when installing.
- Widen the sealing lip of the new sealing flange as shown using (T03004).
The surface - A - is the outer side.
- After a short time, remove the (T03004) and slide it rotated 180° into the seal.
Page 5008
Fuel Filter
Removing
‹› Observe the safety precautions. Refer to => [ Safety Precautions ] See: Fuel Delivery and Air
Induction/Fuel Tank/Description and Operation.
‹› Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] See: Fuel Delivery
and Air Induction/Fuel Tank/Description and
Operation.
connection.
Installing
- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] See: Fuel Delivery and Air

Service and Repair
Variable Valve Timing Cover / Housing: Service and Repair
Control Housing Cover

Removing
‹› Engine removed, transmission disconnected from flange.
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] See: Timing
Cover/Service and Repair.
- Remove the flywheel or drive plate and remove the sensor wheel for the engine speed (RPM)
sensor (G28) from the crankshaft.
- Remove the cylinder head. Refer to => [ Cylinder Head ] See: Cylinder Head Assembly/Service
and Repair/Removal and Replacement/Cylinder Head.
- Disengage the wiring harness - arrow - and remove the engine speed (RPM) sensor (G28) - 1 -
and vacuum pump - 2 -.
- Pry off the control housing cover - 1 - from the cylinder block - 2 - or from the upper oil pan - 3 - at
the positions designated at the top and bottom using a suitable screwdriver - A -.
Page 7493
‹› Remove and install along with release bearing => [ Release Bearing, Removing and Installing ]
See: Clutch Release Mechanism
‹› Lubricate contact area at ball stud with MoS2 grease
8 Release bearing
‹› Do not wash bearing, only wipe off
‹› Replace noisy bearings
‹› Removing from clutch release lever and inserting into clutch release lever => [ Release Bearing,
Removing and Installing ] See: Clutch
Release Mechanism
‹› Lubricate contact area at release lever with MoS2 grease
9 Bolt with collar, 20 Nm
10 Clutch slave cylinder
‹› Removing and installing => [ Slave Cylinder ] See: Clutch Hydraulic System/Clutch Slave
Cylinder/Service and Repair.
11 Plunger
‹› Lubricate end of plunger with MoS2 grease
12 Assembly bolt
‹› Secures clutch release lever when installing transmission
‹› Remove after transmission is installed
‹› If assembly bolt => [ (Item 12) Assembly bolt ] is not present, M8 x 35 bolt can be used.
Page 4294
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1376
Part 1
Page 1692
Ground (GND)

Page 2279
Part 2
Page 3542
- Pull off bearing inner race from stub axle.
Only use puller - A - with tension bracket, e.g. (Kukko 204-2) (commercial type)..
Installing
- Push wheel bearing/wheel hub unit onto stub axle as far as it will go.
- Install on installation sleeve wheel brg. (3420 ) and pull on wheel bearing/wheel hub unit until it
stops.
Make sure that wheel hub/wheel bearing unit is not tilted!
- Remove installation sleeve wheel brg. (3420).
- Use a new 12 point nut - A - and tighten, tightening specification => [ Rear Axle ] See:
Specifications/Mechanical Specifications/Steering and Suspension/Suspension/System
Page 1116
Part 2
Page 4852
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 331
Part 3
Page 667
Page 2394
Final procedures

09.

Code.
Page 169
WHAT ARE TRACKS?
15-28, and so on).
Page 5653
If no malfunction is found in the wiring and the voltage was Not OK:
Final procedures


Page 136
Global Positioning System Module: Connector Views
Telematics Control Module -J499- Multi-pin Connector Assignments
42 pin multi-connector -T42-
1 - Signal activation - Dual Horn Auxiliary Relay
2 - Signal activation - "lock vehicle"
3 - Cellular telephone connection -Audio in (not used)
4 - Cellular telephone connection - Battery Feedback (not used)
5 - Cellular telephone connection - Ground (GND)
6 - Cellular telephone connection - TXD-transfer (not used)
7 - Cellular telephone connection - RTS (not used)
8 - Cellular telephone connection - shielding Ground (GND) (not used)
9 - not used
10 - Line (+) Output to radio
11 - Auxiliary speaker (+) (not used)
12 - Telephone microphone (+)
13 - K-wire, Data Link Connector (DLC)
14 - Power supply - Terminal 15
15 - Telematics indicator LED "red" (in Telematics Control Head)

16 - Telematics indicator LED "green" (in Telematics Control Head)
17 - not used
18 - Ground (GND) (Terminal 31)
19 - Ground (GND) (Terminal 31)
20 - not used
21 - not used
22 - Signal activation - Auxiliary Emergency Flasher Relay
23 - Signal activation - "unlock vehicle"
24 - Cellular telephone connection - Audio out (not used)
25 - Cellular telephone connection - Audio Ground (GND) (not used)
26 - Cellular telephone connection - power supply (not used)
27 - Cellular telephone connection - RXD (not used)
28 - Cellular telephone connection - RTS (not used)
29 - Signal status - Telephone (not used)
30 - not used
31 - Line (-) Output to radio
32 - Auxiliary speaker (-) (not used)
33 - Telephone microphone (-)
34 - Mute - Radio
35 - Input "SOS" from Telematic control head
36 - Input "Power" from Telematic control head
37 - not used
38 - Crash-Signal from airbag control module
39 - Terminal 30 (B+)
40 - Terminal 30 (B+)
41 - Emergency (backup) battery (+) (not used)
42 - Emergency (backup) battery (-) (not used)

Page 4984
1318).
Checking Injection Quantity and for Leaks ] See: Fuel Delivery and Air Induction/Fuel
Injector/Testing and Inspection/Fuel Injectors, Checking Injection Quantity and For Leaks.
disconnected.
Check Valve, Checking ] See: Fuel Delivery and Air Induction/Fuel Pump/Testing and
Inspection/Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank).
Regulator ] See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and
Replacement.
Page 4908
Ground (GND)

Page 7736
- Apply a small quantity of grease ( G 000 450 02 ) on pin - arrows - of transmission shift lever - 1 -
and of relay lever - 2 -.
- Replace lock washers - 3 - and - 4 - after every disassembly.
- Secure shift cable with locking washer - 3 - and shift lever cable with lock washer - 4 -.
- Align shift mechanism housing parallel to chassis.
‹› Distance to chassis must be equal on both sides.
- Replace clamp - arrow -.
- Install front heat shield.
- Install exhaust system free of stress and install cross member.
- Adjust shift mechanism => [ Shift Mechanism, Adjusting ] See: Adjustments.
- Connect battery and note steps after connecting battery.
Auxiliary Cabin Heater Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2157
Page 967
Page 7431
‹› If a harness connector is damaged, wiring harness or valve body must be replaced together with
solenoid valves.
- Disconnect connector - 2 - from transmission connector.
- Remove bolt of 14-pin transmission connector.
- Disconnect connector and wiring harness outward from transmission housing.
Installing

Page 855
Additional code numbers New Beetle convertible (Airbag Control Module -J234- version VW7)
- Confirm entry with -Q- button.
GO0909G05E 04 AIRBAG VW7 0518 -> Coding 0012340 WSC12345
Control module identification number with relevant letter index, code number and workshop code
will be displayed on the scan tool V.A.G 1551.
If the contents of the display are as shown then the coding is successful.
If the code number entered, is not accepted by the control module, the following will be displayed:
FAULT -> Coding 00085 not accepted
Indicated on display
In this case the control module has not been programmed with the relevant data for the vehicle
Coding is then not possible.
The airbag Airbag Malfunction Indicator Lamp (MIL) -K75- will not extinguish and lights up
continuously.
A check must then be completed to see if the correct control module for the vehicle has been
installed (compare Part No. and letter index), or whether an incorrect code number has been
entered.
Ending function:
- -> Press button

Page 6897
Page 2679
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1307
Ultrasonic Sensor: Service and Repair
Anti-Theft Alarm System and Interior Monitoring
Passenger Compartment Monitoring Switch
The Passenger Compartment Monitoring Switch (E183 ) Is Installed Inside The Left Trim Panel.
Removing
- Carefully pry out the Passenger Compartment Monitoring Switch (E183) with a screwdriver.
Installing
Install in reverse order.

Page 4288
WHAT ARE TRACKS?
15-28, and so on).
Exhaust System - Heat Shield Replacement Guidelines
Heat Shield: Technical Service Bulletins Exhaust System - Heat Shield Replacement Guidelines
26 08 02
Aug. 28, 2008
2015831 Supersedes T.B. Group 26 Number 07 - 07 Dated October 2, 2007 Due to removal of
Routan applicability.
Vehicle Information
Condition
Exhaust Heat Shield, Replacement Guidelines
Underbody heat shields are important for proper vehicle performance. Heat Shields are to be
inspected after completion of any type of repair to the underbody (exhaust system, transmission,
etc.), and if damaged, replaced
Damaged heat shields may exhibit the following symptoms:
^ Bent / Moved out of tolerance heat shield material
^ Lack of sufficient clearance
^ Torn / Damaged heat shield material
^ Contaminated (fluid saturation) heat shield material
^ Peeling / Separating heat shield material resulting from damage
Production Solution

Page 6158
terminals.
Checking activation
Final procedures


Page 2845
Page 1249
Ground (GND)

Page 6155
Page 2968
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2048
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1861
WHAT ARE TRACKS?
15-28, and so on).
Page 5550
Ground (GND)

Page 7236
circuit.
- End diagnosis.
Final procedures
Page 4389
Ground (GND)

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 261
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Shift Cable: Testing and Inspection
Selector Lever Cable, Checking and Adjusting
Checking
- Move selector lever to position "P".
wrench - 2 -.
- Press locking devices on selector lever cable support bracket together - arrows - and pull selector
lever cable out of transmission support mounting.
- Set down selector lever cable so that the end can move freely.
‹› Do not bend or kink selector lever cable.
- Shift selector lever from "P" to "S".
- Check protective boot on selector lever cable for damage, replace cable if necessary.
- Move selector lever in position "P".
‹› Selector mechanism and selector lever cable must move freely when shifting, if necessary,
replace selector lever cable (=> [ Selector Lever Cable ]
See: Service and Repair) or service selector mechanism.

- Press selector lever cable carefully onto selector shaft lever and then into transmission support
mounting.
Locking mechanism of selector lever cable must engage in support mounting.
Adjusting
- Move selector lever to position "P".
- Loosen bolt - 2 - on front ball socket of selector lever cable - 1 -.

Page 94
1 - Track Numbers

Page 6626
Ground (GND)

Page 3774
Va-To
Warranty
Information only.

Page 6301
Ground (GND)

Page 2486
Page 7306
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 327
WHAT ARE TRACKS?
15-28, and so on).
Page 6706
WHAT ARE TRACKS?
15-28, and so on).
Specifications
Fuel Pressure: Specifications
Fuel Pressure
At idle speed ........................................................................................................................................

............................................ approximately 4.0 bar Ignition Off, after 10 minutes ...............................
....................................................................................................................................... at least 3.0
bar
Page 4915
Page 1465
Ground (GND)

Page 1254
Part 3
Page 2245
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1744
WHAT ARE TRACKS?
15-28, and so on).
Page 6981
1 - Track Numbers

Page 1863
Part 1
Ventilation Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3064

Service and Repair
Timing Belt: Service and Repair
Camshaft Drive Toothed Belt, Checking
Toothed Belt, Checking Condition
- Open fasteners of upper toothed belt cover and remove cover.
- Check condition of toothed belt for:
‹› Cracks, cross-sectional breaks
‹› Separation (cover layer, belt cords)
‹› Wear-through on cover layer
‹› Fraying of cords
‹› Surface cracks (plastic shroud)
‹› Oil or grease contamination
‹› It is essential to replace toothed belt if malfunctions are found. By replacing, failures and/or
disturbances can be avoided. Replacing the belt is a
repair procedure.
While checking the condition, take notice of the following defects:
A - Tears (cover side)
B - Lateral movement
C - Fraying
D - Tears (in teeth)

Page 5457
Page 398
Auxiliary Heater Element Relay: Diagnostic Aids
Accelerator Pedal Position Sensor: Testing and Inspection
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 5324
1 - Track Numbers

Page 2635
WHAT ARE TRACKS?
15-28, and so on).
Page 4866
Part 3
Page 2857
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2008
Part 1
Superheat Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7564
1 - Track Numbers

Page 3430
Adapting maximum distance driven up to next service event:
- Using the number pad on the display - arrow - press buttons 4 and 3.
Adaptation channel 43 adapts the maximum distance to the next service interval.
- Confirm entry by pressing "Q" button on display number block.
Page 6547
Warranty
Information only.
removal.
Telematics Indicator Lamp (K186), Malfunction
Recognition
Global Positioning System Module: Testing and Inspection Telematics Indicator Lamp (K186),
Malfunction Recognition
Telematics
Telematics Indicator Lamp (K186), Malfunction Recognition
The following descriptions are for initial malfunction recognition with the OnStar Telematics
indicator lamp.
Detailed fault finding is only possible using the Vehicle Diagnosis, Testing and Information System
(VAS 5051B ) in the "Guided Fault Finding" mode.
A Telematics indicator lamp in the form of an LED is installed in the Telematics Control Head
(E264). LED indications are red or green, blinking quickly or slowly.
Depending on the status of the Telematics system, activation of the Telematics indicator lamp with
the ignition switched on corresponds to the following table:
Further Information
‹› If the ignition is off, the Telematics indicator lamp is also off.
‹› After ignition is switched on, self-check routine is performed in Telematics system. The green
LED illuminates after approximately 15 seconds if
no malfunctions are identified. System is now ready to send or receive calls. The green LED
continues to illuminate if no reception is possible in certain areas.
‹› If the green LED flashes slowly, a communication request has been initiated and the system is in
the process of establishing a connection.
‹› If the LED illuminates red, a malfunction was found during the self-check or the system
performed a faulty function.
‹› After the OnStar or Emergency button is pushed, the message: "connecting to OnStar" is issued,
followed by a sequence of tones. Normal
connection time is 10 to 15 seconds. However, connection time can be up to three minutes,
depending on reception conditions. Be patient.
The Telematics indicator lamp illuminates green and the following message can be heard:
‹› Message Unable to contact OnStar, connection is interrupted.
‹› Message OnStar request ended
‹› Cellular network message is heard
‹› nothing happens
All previous points indicate an issue with cellular reception.
Proceed as follows: Drive vehicle to more elevated or open area repeat connection attempt.
Depending on local conditions, it is possible - and normal - that several connection attempts are
necessary.
Malfunctioning antenna system of vehicle also affects connectivity. If necessary conduct fault
finding for the antenna system with the Vehicle Diagnosis, Testing, And Information System (VAS
5051B) in the "Guided Fault Finding" mode.
If there is still no connection, write down the VIN and customer data. Call OnStar service at:
1-888-390-4050. Identify yourself to OnStar Service as a Volkswagen technician. OnStar Service
will check and confirm that the customer account is active. Further troubleshooting assistance may
be given.
Page 7604
Removing securing ring
Pressing out wheel bearing from wheel bearing housing
Coat entire surface with Molykote grease

Page 2669
Part 2
Page 910
Part 1
Page 3690
‹› Feeler gauge
- Before measuring, clean the ring groove.
Pistons, Checking
‹› External micrometer 75 to 100 mm
- Take the measurement approximately 10 millimeter (mm) from the lower edge of the piston skirt
and offset 90° to the piston axis.
Deviations from nominal dimension: Max. 0.04 mm
Cylinder Bore, Checking

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3916
- Install the (VAS 5161/6) with the (VAS 5161/5) into the (VAS 5161/19B).
- Insert the (VAS 5161/8) into the (VAS 5161/19B).
- Engage the (VAS 5161/2) on the (VAS 5161/6).
‹› On the exhaust side, (VAS 5161/2) must be engaged as shown.
- Press down the (VAS 5161/8). At the same time, turn the knurled bolt for the (VAS 5161/8)
clockwise until the points engage in the valve keepers.
Page 2666
WHAT ARE TRACKS?
15-28, and so on).
Page 1893
Refrigerant Temperature Sensor: Diagnostic Aids
Page 231
Power Door Lock Control Module: Diagnostic Aids
Page 2655
Part 3
Page 592
Headlamp Alignment Control Module: Diagnostic Aids
Page 2699
Part 1
Page 5347
Part 2
Page 5873
Page 5050
Final procedures


Page 2492

Page 3081
Drive Belt: Testing and Inspection
Ribbed Belt, Checking
- Lift vehicle.
- Remove engine compartment cover, engine side

- Remove bolt/screw - 1 -.
- Release clips - 2 -.
- Take cover out of retainers - 3 -.
NOTE: Do not reuse the clips, renew clips each time cover is removed.
- Crank engine by hand at vibration dampener/pulley - arrow -. Check ribbed belt for: -
Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
- Layer separation (top layer, cord strands)
- Base break-up
- Fraying of cord strands
- Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks)
- Traces of oil and grease

Page 792
Part 3
Page 5173

Power Door Lock Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1662
Wheel Speed Sensor: Service and Repair Rear Axle
ABS Component Overview

1 Right rear ABS wheel speed sensor (G44)/left rear ABS wheel speed sensor (G46)
2 Socket head bolt, 8 Nm
3 Stub axle
4 Cover plate
5 Hex bolt, 60 Nm
‹› With dished washer
7 Brake disc
8 Cap
9 Self-locking 12 point nut (175 Nm)

Page 2155
Part 3
Page 3459
1 - Track Numbers

Page 909
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1165
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1255
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7227
Part 3
Page 3242
funnel.

Page 390
Ground (GND)

Page 923
WHAT ARE TRACKS?
15-28, and so on).
Page 6479

Page 6955
Fluid - A/T: Service and Repair 09G Transmission
ATF, Filling
ATF, Filling
‹› Used oil collection and extraction unit (V.A.G 1782 )
‹› Vehicle diagnosis, testing and information system ( VAS 5051)
‹› Drip tray for workshop hoist (VAS 6208)
‹› Adapter for filling oil (VAS 6262)
‹› Adapter (VAS 6262/2)
- With engine "running", install adapter for filling oil (VAS 6262/2) hand-tight.
- Add 1 l of ATF.
- Pull off adapter for oil filling (VAS 6262) at quick-release connection and check:

Page 5566
1 - Track Numbers

Page 5721

Page 405
Ground (GND)

Page 1557
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6282
Turbo Boost Sensor: Diagnostic Aids
Page 3545
7 Brake caliper
8 Stub axle
‹› Straightening work prohibited.
‹› Do not re-cut threads.

Relay and Fuse Arrangements, Overview, From July 2005
Relay And Fuse Arrangements From July 2005
09G, 6 Speed A/T
Data Link Connector: Locations 09G, 6 Speed A/T
Data Link Connector (DLC), 09G, 6 Speed A/T
Component location: Data Link Connector (DLC) - arrow - is located on left side under driver-side
storage compartment.
Page 5602
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 575
Page 4096
Coolant: Service and Repair
Cooling System, Checking Freeze Protection and Coolant Level
‹› Only G12 conforming to TL VW 774 F my be used as an additive. It can be recognized by the

purple color.
‹› G 12 purple (according to TL VW 774 F) can be mixed with the previous coolant additives G 11
and G 12 (red).
‹› G 12 purple (according to TL VW 774 F) may be mixed with previous coolant additive G 12 red.
G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent freezing and
corrosion damage, scaling and also raise the boiling point of the coolant. For these reasons, the
cooling system must be filled with radiator freeze and corrosion protection fluid all year round.
Checking freeze protection and adding coolant additive if necessary.
‹› Coolant Level, Checking and Filling
Freeze Protection, Checking and Adding Coolant Additive
‹› Refractometer (T10007)
‹› Read the bright/ark boundary to obtain an accurate reading for the following tests. Place a drop
of water on the glass to improve the readability of
the bright/dark boundary. The bright/dark boundary can be clearly recognized on the
"WATERLINE".
- Check the concentration of the coolant additive using refractometer (T10007) (operating
instructions).
The scale - 1 - of the refractometer is designed for coolant additives -G 12- and -G 11-.
Page 5899
Final procedures

Page 5196

Page 5623
legend.
wiring diagram.
harness.


question.)
19 - Legend




F125

Page 4608
Final procedures

Page 2806
Part 3
Page 273
Part 1
Page 6653
Page 2326
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 6898
Tip:
Page 1876
High Pressure Sensor / Switch: Testing and Inspection High Pressure Sensor, Multi-Pin Connector
Assignments
High Pressure Sensor, Multi-Pin Connector Assignments
‹› Contact 1: Ground (GND)
‹› Contact 2: Square wave signal (output) to Coolant Fan Control (FC) Module (J293) and Motronic
Engine Control Module (ECM) (J220)
‹› Contact 3: Terminal 15 (ignition on)
‹› A/C Clutch (N25) is switched off when connector - B - is disconnected

Page 7804
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7582
Constant Velocity Joint: Service and Repair Inner CV Joint
Inner CV Joint
In order to replace the grease in case of strong contamination, joint must be disassembled and if
the journal surfaces and balls must be checked for wear and damage.
Removing
- Swing ball hub and ball cage.
- Press joint piece out in direction of arrow.
- Press balls out from cage.
‹› Ball hub and joint piece are paired. Do not interchange.
- Flip out ball hub from ball cage via the running path of the ball - arrows -.
- Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting buildup)
and chafing.
Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be
replaced in such cases. Flattening and running marks of the balls are no reason to replace the
joint.
Installing
- Insert ball hub into the ball cage via the two chamfers. The installation position is at random.
Press balls into the cage.
- Insert hub with cage and balls upright into joint piece.
‹› When inserting, make sure that in each case the wide gap - a - at joint piece contacts narrow gap
- b - at hub after swinging in.
Page 278
Trunk / Liftgate Relay: Diagnostic Aids
Page 1556
Part 3
Page 2011
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 898
Specifications
Fuel Injector: Specifications
Using a multimeter, check the Fuel Injector electrical terminals 1 to 2 for resistance.
Specified value: 12.0 to 20.0 Ohms (at approx. 20 degrees C)

Page 7026
Page 1379
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 444
WHAT ARE TRACKS?
15-28, and so on).
Page 1078
Checking
- Multimeter.
- Wiring diagram.
Requirements
- Fuse SA6 OK.
- Fuse SB28 OK.
- Fuse SC14 OK.
Test procedure
Start diagnosis
Checking voltage


Page 6520
Part 2
Page 4360
- Remove the nut - 1 - from the bracket. To do so, remove the right main head lamp.
- Disconnect the intake line from the power steering pump. Seal the pump and line with clean
plugs.
- Remove the nut - arrow - for the intake line - A - at the engine mount. Remove the intake line.
- Only slightly loosen the bolts for the engine and transmission mounts at the subframe (less than 1
rotation).
- Install the (T03000) as follows:

Page 5533
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2243
Ground (GND)

Page 5102
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Antitheft Mode Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4686
1 - Track Numbers

Page 4801

Page 7040
Page 2777
Page 3593
Page 2033
STACK:
Page 5746
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Solar Cell Isolation Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2238
Electronic Throttle Actuator Position Sensor: Locations Accelerator Pedal Module Assembly
Overview
1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
5 Bracket

Page 2757
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6048
- Connect the second terminal of the injector with the adapter cable to the (VAG 1348/3A) using
(VAG 1348/3-2).
- Connect the alligator clip to the battery positive (+).
- Operate the (VAG 1348/3A) for 30 seconds.
- Repeat the check on the other injectors. Use new graduated measuring glasses for this.
- After all fuel injectors have been activated, place the graduated measuring glasses on a level
surface and compare the quantity of fuel.
‹› Specified value: 85 to 105 ml per injector
While checking the injection quantity, the spray pattern should also be checked. Spray pattern must
be the same for all injectors.
If the measured value of one or more injectors is below or above the indicated specified value:
- Replace the faulty injector. Refer to => [ Fuel Injectors ] See: Service and Repair/Fuel Injectors.
Page 1648
1 - Track Numbers

Procedures
Connecting Rod: Procedures
New Connecting Rod, Separating
New connecting rods may not be separated at the location where they should be. If the connecting
rod bearing cap cannot be removed by hand, proceed as follows:
- Mark which cylinder the connecting rod belongs to, see - item 6 - in => [ Connecting Rod ] See:
Piston/Service and Repair.
- Lightly clamp the connecting rod in a vise equipped with aluminum protective pads.
‹› Only clamp the connecting rod lightly to avoid damaging it.
‹› Clamp the connecting rod below the dotted line.
- Loosen both bolts - arrows - about five turns.
- Carefully tap against the connecting rod bearing cap in the direction of the - arrow - with a plastic
hammer until the cap is loose.
Page 5999
- For fuel filter
- Secured to fuel tank
Page 6967
- Replace check plug seal - B -.
- Install check plug - A - with new seal - B - hand-tight only.
Page 2419
Part 1
Page 5020
Spark Plug: Application and ID

Page 5214
Part 2
Page 5932
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4467
Control Modules

Removing

Page 5486
WHAT ARE TRACKS?
15-28, and so on).
Page 1983
Part 3
Page 4875
Final procedures

Page 5025
- Remove spark plugs with spark plug removal tool ( 3122 B).
Installing
- Install new spark plugs using the spark plug removal tool (3122 B) and tighten to 20 Nm.
- Guide ignition coils with power output stages into cylinder head and align ignition coils to
designated recesses of cylinder head cover.
- Press ignition coils with power output stages on to spark plugs up to stop, they must engage
audibly.
‹› Make sure that wiring of ignition coils with power output stages is routed properly.
- Install engine cover.

Page 3486
Tire Pressure Module: Service and Repair
Control Modules

Removing

Page 1250
WHAT ARE TRACKS?
15-28, and so on).
Page 5867
WHAT ARE TRACKS?
15-28, and so on).
Locations
Sealing Flange, Engine Front: Locations
Sealing flange, assembly overview
1 - Belt pulley/vibration damper
2 - Bolts
^ 5 pieces
^ Replace
^ Tightening torque
Strength category 12.9:
- 70 Nm
Strength category 10.9:
- 50 Nm plus an additional 1/4 turn (90°)
3 - 10 Nm
4 - Sealing flange on belt pulley side
^ With integrated sealing ring
^ Removing and installing Sealing flange for crankshaft (ribbed belt side), replacing
5 - Cylinder block
6 - 60 Nm plus an additional 1/4 turn (90°)
^ Replace
7 - Drive plate/flywheel
^ To remove, secure crankshaft using locking pin T40069.
8 - Sensor wheel
^ For Engine Speed (RPM) Sensor G28

Page 3963
Timing Chain: Tools and Equipment
Bracket for Chain Adjuster
AST tool# 3366
Used when removing and installing the timing chain adjuster. VW and Audi 4, 6 and 8 cylinder
engines with 5 valves per cylinder.
- Used for R and R of the Timing Chain Adjuster
- Applicable to Many VW and Audi Models
Additional Tools Possibly Required:
3242 - Locking Pin

Page 2718
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4406
WHAT ARE TRACKS?
15-28, and so on).
Page 4785
Part 1
Control (EPC)) G188

Page 2119
6 Hex bolt
‹› M8 x 12
‹› Tightening specification => See: Specifications/Mechanical Specifications/Steering and

Suspension/Suspension/System Specifications/Rear
Suspension/Rear Axle Component Tightening Specifications.
7 Hex bolt
‹› M8 x 12

8 Heat shield
Page 2143
Horn Switch: Diagnostic Aids
Page 1814
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5815
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4320
1 - Track Numbers

Page 292
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5767
Page 1435
Ground (GND)

Page 3575
Part 2
Locations
Central Control Module For Comfort System J393

Page 7726
- Install rubber sound insulation.
- Install cover in upper part of center console.
Function
‹› Shift lever must rest in 3rd/4th shift gate when transmission is in neutral.
- Operate clutch.
- Shift through all gears several times. Pay particular attention to function of reverse gear lock.
Should a gear fail to engage smoothly after repeated selection, shift rod play (lift) should be
checked as follows:
- Select 1st gear.
- Push shift lever toward left until stop and release.
- Simultaneously (2nd technician), observe shift rod on transmission.
- When moving shift lever, shift rod must move approximately 1 mm in direction of - arrow -.
- If this is not the case, adjust shift mechanism => [ Shift Mechanism, Adjusting ] See: Adjustments.
Page 171
Part 1
Page 5556
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5665
Part 1
Page 39
- Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM).
^ Screen indicates number of stations broadcasting close to frequency band of selected station.
^ As the number increases for [mp] and (adj], static and signal crossing will increase.
To exit service mode:
- Depress and hold the mix button or switch radio OFF then back ON
Navigation units
^ No internal diagnosis functions. Continue to antenna lead diagnosis.
Section 3 - Antenna Lead Diagnosis
After initial radio diagnosis using internal service functions, use the following procedures:
- Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base.
- Check for proper connection. (follow steps for your type of system).
- For all systems, locate cable end-point at either diversity box or antenna mast base.
- Disconnect cable from either diversity box or antenna mast base.
- Carefully ground center wire in cable to chassis.
^ Cable and radio are ok.

Locations

Page 7474
- Hand-tighten all bolts.
- Tighten bolts to tightening specification.

Page 2026
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 201
Door Control Module, Passenger Side J387

Page 463
Part 3
Page 7897

Page 5967
Page 4289
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 460
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2330
wiring diagram.
Final procedures

09.

Code.
Page 7151
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 3226
- If ATF level is checked, oil seal - arrow - on ATF inspection plug must always be replaced.
ATF Level, Checking

ATF Level, Checking
The ATF temperature should not be more than approximately 30°C at start of test. ^
Transmission not in emergency running mode; ATF temperature not above approximately 30°C
^ Vehicle must be standing level
^ Selector lever in "P".
- Connect tester and continue switching until it is ready for operation Vehicle Diagnosis, Testing
and Information System VAS 5051, Connecting and Selecting Functions.
- Press right Guided Functions.
- Then select vehicle, the transmission and Check ATF Level.
- Press ->.
- Start engine.
- Raise vehicle.
- Place drip tray under transmission.
- Press.
If a test temperature between 35°C and 45°C is displayed:

Page 7298
1 - Track Numbers

Page 1300
Part 1
Page 3271
Va-To
Warranty
Information only.

Page 591
Page 5669
Page 7732
- Open clamp - arrow - and pull off shift knob together with boot.
- Pull rubber sound insulation off shift lever.
- Remove front securing nuts for shift mechanism housing - arrows -.

Page 1554
Part 1
Page 4336
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4526
Page 4241
Vehicles with A/C
- Remove the bolts - arrows - for the condenser on the left and right sides of the radiator.
- To remove the radiator, secure the condenser to the lock carrier.
- Remove the radiator downward.
Installing
Installation is performed in the reverse order of removal, noting the following:
- The coolant must be replaced if a new radiator was installed.
- Fill with coolant. Refer to => [ Draining and Filling ] See: Service and Repair/Procedures/Draining
and Filling.
A/T Gear Indicator Flashes/Engine RPM Fluctuation
A/T Shift Indicator Module: Technical Service Bulletins A/T Gear Indicator Flashes/Engine RPM
Fluctuation
Condition
Customer States Gear Selection Indicator in Instrument Cluster Flashes
After selecting "D" "R" or "S" from park position, the gear selection indicator in the instrument
cluster flashes and the engine RPM may fluctuate without any gear engagement.
34 06 04 Aug. 17, 2006 2011888 Supersedes T.B. Group 34 number 06-03 dated Jul. 5, 2006 due
to the inclusion of EOS.
This may occur if the customer starts the engine, depresses the brake pedal, moves the gear
selector from Park position, and releases the brake pedal before the desired gear is selected.
Production Solution
Service
No repairs required. This is a vehicle function that will not allow the transmission to engage unless
the driver has
the brake pedal depressed.
Advise driver that the brake pedal must remain depressed when selecting desired gear from Park
position.
Depress brake pedal and the selected gear will engage. After this action the gear position indicator
will return to normal.
Warranty
Information only.
No Special Parts required, always see ETKA for the latest parts information. No special tools
required.
Locations
Clutch Vacuum Vent Valve Switch F36

Page 7467
It must not be covered in upper area of bearing for over-center spring - arrow 2 -.
- Then swing it in direction of - arrow 3 - out of bracket.
Installing
- Mount - A - must be located on operating rod - B - of master cylinder.
- Pull piston rod slightly out of master cylinder and hold in place using pliers.
- At the same time, press clutch pedal in direction of - arrow - to engage, while doing so ensure
correct engaging.
- Reinsert stop - A - for clutch pedal.

Page 4062
Water Pump: Specifications
Coolant Pump to Cylinder Block Bolts .................................................................................................
...................................................................... 10 Nm
Page 1946
Ground (GND)

Page 1229
1 - Track Numbers

Page 5960
Part 3
Specifications

............................................................................................................................................. 9.0 to
13.0 bar Wear limit ..............................................................................................................................
..............................................................................................................................................................
.... 3.0 bar
Fuel Filter With Attachments, Assembly Overview
Fuel Filter: Locations Fuel Filter With Attachments, Assembly Overview
1 - Fuel filter -
Direction of flow is marked with arrows
- Do not interchange connections
- Installed location: Pin on filter housing must engage in recess of guide on filter bracket
For fuel pressure regulator
3 - Fuel supply line -
Black
- From fuel tank
- Press in securing ring to disengage lines.
4 - Fuel return line -
Blue
- To fuel tank
5 - Fuel pressure regulator -
4 bar
6 - Gasket
Replace
7 - O-ring
Replace
Black
- To engine
9 - 3 Nm
10 - Bracket
Page 7927
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 374
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1734
Page 5123
Page 4949
Ground (GND)

Page 2210
Part 2
Page 5493
Transmission Input Speed (RPM) Sensor -G182- and
Transmission Output Speed (RPM) Sensor -G195-
Transmission Input Speed (RPM) Sensor -G182- And Transmission Output Speed (RPM) Sensor
-G195-
Page 4818
Part 3
Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley/Vibration Damper Bolts

........................................................................................... 50 Nm Final pass .....................................
................................................................................................................................... Tighten 90°
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5365
Final procedures

Page 7042
Tip:
Page 6645
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1408
Part 2
Page 4237
Temperature Gauge: Diagnostic Aids
Page 4965
Final procedures

Page 7676
‹› Assembly tool (3253/2)

‹› Drip tray for shop crane (VAS 6208)

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 394
Part 2
Page 5604
Part 2
Page 4800
Final procedures

Page 7674
- Insert thrust washer union with gear oil.
- Insert both large differential bevel gears and secure (e.g. with flange shaft).
- Install small differential bevel gears at 180 degrees from their final position and rotate into place.
- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.
- Insert threaded pieces - arrows B - into large differential planetary gears.
Installation position: Step facing toward differential planetary gear.
- Drive differential planetary gear axle into final position and secure with spring pin.
Installation position of thrust washer for tapered ring - 1 -
Collar - arrow - faces compression spring - B -.
Some transmissions are equipped with ridges - A -.
Ridges - A - face tapered ring - 1 -.

Page 4744
Ground (GND)

Page 340
1 - Track Numbers

Page 4790
Power Steering Pressure Switch: Diagnostic Aids
Page 3909
Driving in seal
- Support chain case cover with supports - arrows - on a firm surface and press in new sealing ring
until it stops.
Page 3347
Page 6712
Page 5039
Final procedures

Page 1390
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6346
Note
The misfire condition may be caused by a malfunctioning ignition coil.
The following vehicles and VIN ranges are affected by this condition:
Production Solution
Service
Procedure
Note
^ Check for Campaign Completion Label.
^ Verify whether a Campaign Completion Label with SAGA code 28F3 is affixed next to the vehicle
emission control label under the hood. If label is present, DO NOT proceed with this technical
bulletin.
^ Address misfire DTCs stored in the ECM fault memory.
^ Replace all ignition coils that have Misfire DTCs associated to them.
^ Inspect and if necessary replace all other ignition coils (even from cylinders without misfire) as
listed in the table below.
Page 2842
Part 2
Engine Controls - Wrong Cylinder Defined For Misfire
DTC
Engine Control Module: All Technical Service Bulletins Engine Controls - Wrong Cylinder Defined
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Subject: Incorrect Cylinder Assigned When Viewing Measuring Value Block with VAS 5051/5052 in
Self Diagnosis
Model(s): New Jetta, w/2.5L (Eng. code BGP, BGQ)
2005 --> 2006
New Beetle with 2.5L (Eng. code BPR, BPS) 2006
Condition
When using Self Diagnosis in the VAS 5051 / VAS 5052 Diagnostic testers, for cylinders 3, 4, 5,
the wrong measuring value blocks were assigned for displaying misfire count.
Service
DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 1696
Part 2
Page 1374
WHAT ARE TRACKS?
15-28, and so on).
Page 5286
Fuel Level Sensor: Service Precautions
Safety Precautions
connection.
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system,
always observe the following:
‹› Do not touch or remove the ignition wires when the engine is running or turning at starter speed.
‹› Only disconnect and reconnect wires for the injection and ignition system, including test leads, if
the ignition is turned off.
‹› Fuel pump is activated with switching on the ignition and by the door contact switch in the driver's
door. Therefore for reasons of safety, the
electrical connector - arrow - must be disconnected from the fuel delivery unit before opening the
fuel supply system, if the battery is not disconnected.
If the engine is to be cranked at starting RPM without starting:

- Disconnect the electrical connectors from all the fuel injectors.
components.
If special testing equipment is required during a road test, note the following:
‹› Test and measuring instruments must be secured to the rear seat and operated by a second
person from this location.
If test and measuring instruments are operated from the front passenger seat and the vehicle is
involved in an accident, there is a possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
Module (ECM) since malfunctions were stored by removing the fuse. Refer to => [ Engine Control
Module DTC Memory, Checking and Erasing ] See: Engine Control Module/Testing and
Inspection/Reading and Clearing Diagnostic Trouble Codes.
Page 7079
Page 5420
stop:
Checking resistance
Page 4662
Checking wiring


Page 3399
Fuse Block: Service and Repair A-Pillar Connector Station
Connecting.
Driver Side
The connector station is located in the left front footwell behind the footwell trim panel.
1. Central locking
2. Power window regulator, red
3. Power mirror adjustment, blue
The connector station on the driver side A-pillar is identical.

Page 3823
Note: When screwing in oil drain adapter T40057 , a valve in the oil filter housing is opened. If oil
drain adapter T40057 is unscrewed again, the valve closes automatically again.
- Unscrew dust cap -arrow- from oil filter housing.
- Screw oil drain adapter T40057 into oil filter housing and hold hose into an oil collecting pan.
- Unscrew oil drain adapter T40057 again.
The drain valve -1- should seal flush with the under side of the oil filter housing -2-.
- Oil filter housing can now be removed using Oil Filter Wrench VAS 3417.
Page 1615
Page 2789
Part 2
Restraints - Air Bag Lamp ON/DTC 02511 014 Stored
Seat Occupant Classification Module - Air Bag: Customer Interest Restraints - Air Bag Lamp
ON/DTC 02511 014 Stored
69 11 01
February 17, 2011
2010347 Supersedes T.B. V010807 dated January 29, 2008 to update scan tool applicability used
during procedure.
Vehicle Information
Condition
Airbag Monitoring Light ON, Passenger Occupant Detection System, DTC 02511 014 Stored in
Memory
Note
The passenger airbag system operates according to manufacturer specifications during the
following key-ON cycles, however, the Airbag Monitoring" indicator light in the instrument cluster
remains illuminated indicating a DTC stored in DTC memory.
"PASSENGER AIRBAG OFF" indicator light, in the center of the instrument panel, will stay
illuminated during the first key-ON cycle.
Airbag control module will disable the passenger airbag module during the first key-ON cycle when
this DTC is stored to memory, and the "PASSENGER AIRBAG OFF" indicator will alert occupants
that the airbag has been disabled.
Page 5807
- Start the engine.
If the LED was ON:
Checking wiring

Page 5616
Knock Sensor: Testing and Inspection
Knock Sensor, Checking
The following procedure is used to diagnose all Knock Sensors.
‹› Multimeter.
Test requirements
‹› The mounting bolt of Knock Sensor (KS) 1 (G61)/Knock Sensor (KS) 2 (G66) tightened to 20
Nm.
Test procedure
Start diagnosis
‹› Before disconnecting the Knock Sensor electrical harness connectors, mark the connectors if the
same color connectors are used.
- Disconnect the Knock Sensor (KS) 1 (G61) electrical harness connector or the Knock Sensor
(KS) 2 (G66) electrical harness connector.
‹› Correct ohm meter polarity MUST be followed or the results will be in error,
- Using a multimeter, check the Knock Sensor terminals 1 to 2 for resistance.
Specified value: near 4.85 M ohms
Specified value: OL or no continuity
If any of the specified values were Not obtained:
- Replace the faulty Knock Sensor (KS) 1 (G61)/Knock Sensor (KS) 2 (G66).
If the specified values were obtained:
Checking wiring
Locations
Coolant Fan Control (FC) Thermal Switch F18

Page 2542
Part 1
Page 3027
Final procedures

09.

Code.
Page 6470
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6216
Accelerator Pedal Switch: Diagnostic Aids
Locations
Trunk Lock Alarm / Central locking Switch F124

Fluctuation
Condition
Production Solution
Service
the driver has
position.
Warranty
Information only.
required.
Page 6841
Part 1

Suspension Fluid Temperature Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5179
Overview
1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
5 Bracket

Page 717
Part 3
Page 161
Navigation Module: Diagnostic Aids
Page 2068
Ground (GND)

Page 341
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3782
Sh-SW
Page 7077
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7552
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3398
Current relay assignments.

Page 7506
‹› Marking "Getriebeseite" (transmission side) faces transmission.
Checking Ends of Diaphragm Spring
Check Spring Connections and Rivets
- Check spring connections between pressure plate and cover for cracks and rivets for secure fit.
‹› A pressure plate with damaged spring connections or loose rivets - arrows - must be replaced.
Page 7058
Control Module: Service and Repair O9G, 6 Speed A/T
Transmission Control Module (TCM) J217, Removing and Installing, 09G, 6 Speed A/T
Removing
Note: ^
Harness connector of control module may only be disconnected or connected 30 seconds after
arrow 2 -.
Note: ^
Separating the connector automatically resets the adaptation values of the transmission. The
control module must relearn the values once the transmission is operational again. The quality of
the gear changes may deteriorate during the "learning" process.
Installing
(TCM) J217 - arrow 1 - and then engage multi-pin harness connector - arrow 2
- Connect diagnostic operation system VAS 5051 and advance program until "function/component
selection" is displayed.
- Then press "Powertrain (Repair Group 01; 10 to 26; 28 to 39)".

Page 1636
Page 5743
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6689
Removing
Installing
Page 5854
If any of the specifications are Not obtained:
- Replace the Leak Detection Pump (LDP) (-V144- ). Refer to the Repair Information.
- Check the Leak Detection Pump (LDP) (-V144-) for voltage.
- Using a multimeter, check the Leak Detection Pump (LDP) (-V144-)electrical harness connector
terminal 3 for voltage. Connect the negative multimeter lead to engine ground.
- Start the engine.
- Remove fuse S-243. Using a multimeter, check the Leak Detection Pump (LDP) (-V144-)wiring
from terminal 3 to fuse S-243.
Specified value: 1.5 ohms max

Page 5328
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 482
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4228
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7706
- While pressing down shift rod, rotate bracket - A - upward in - direction of arrow 2 - and
Gear Oil, Draining
Use a clean container (3.0 liters capacity) with scale to collect gear oil.
‹› Shift rod is secured.
- Drain gear oil by removing oil drain plug - arrow 1 - and then removing journal - arrow 2 -.
- Install journal - arrow 2 - with new O-ring => [ (Item 7) Bolt, 25 Nm ] See: Service and
Repair/Removal and Replacement/Transmission Housing and Shift Mechanism Assembly
Overview.
- Install oil drain plug - arrow 1 - => [ (Item 17) Oil drain plug, 30 Nm ] See: Service and
Repair/Removal and Replacement/Transmission and Clutch Housing Assembly Overview.
- Now rotate angle - A - back into initial position - direction of arrow - to let shift rod move freely
again.
Page 2861
Part 1
Page 6629
Part 1
Page 2723
6 Hex bolt
‹› Tightening specification => [ Stabilizer Bar ] See: Steering and
Suspension/Suspension/Specifications/Front Suspension.
7 Coupling link
‹› Various versions
8 Hex nut
‹› Tightening specification => [ Drive Axle ] See: Steering and

9 Bracket
10 Stabilizer bar
11 Connector
12 Longitudinal member
13 Pop rivet bolt
Pop rivet bolt can be pulled in using pop rivet tongs (V.A.G 1765 B).
Page 188
Part 2
Page 1710
1 - Track Numbers

Page 813
Page 5766
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Specifications - Clutch
Pressure Plate: Specifications Specifications - Clutch
Fastener Tightening Specifications
‹› 1 Always replace
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5120
Part 2
Page 642
Clutch Disc: Service and Repair Clutch Assembly Overview, Sachs

‹› If centering sleeves are not present, problems with shifting, changing gears and possibly a noisy
transmission (idler rattling) may occur.
2 Clutch plate
‹› Only replace together with pressure plate
‹› Installed position => [ Installation Position of Clutch Plate ] See: Service and Repair/Clutch,
Sachs
3 Pressure plate
‹› With adjustment mechanism
Page 3889
Intake Manifold: Locations
Intake Manifold With Attachments, Assembly Overview
1 - Hose for crankcase ventilation -
From cylinder head cover

2 - Ventilation hose
3 - Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
4 - Line
5 - Vacuum hose -
From Leak Detection Pump (LDP) V144
6 - 9 Nm
7 - Bracket
8 - Fuel rail -
Assembly overview
9 - Fuel supply line
10 - Gasket -
Replace
- Note installation position:
- Casting mark points upward.
11 - Intake manifold
12 - O-ring -
Replace if damaged
13 - Manifold Absolute Pressure (MAP) Sensor G71
14 - 3.5 Nm
15 - Coolant connections -
Only for Throttle Valve Control Module J338 heated by coolant
16 - 6.5 Nm
17 - Throttle valve control module J338 -
With Throttle Drive (for Electronic Power Control (EPC)) G186, Throttle Drive Angle Sensor 1 (for
Electronic Power Control (EPC)) G187 and Throttle Drive Angle Sensor 2 (for Electronic Power
Control (EPC)) G188
- During replacement, erase adaptation values and adapt Engine Control Module (ECM) to throttle
valve control module Vehicle Diagnosis,
Page 873
Warranty
No Special Parts Required
Page 6792
Part 2
Page 1950
Part 2
Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 4480
WHAT ARE TRACKS?
15-28, and so on).

Page 5806
Air Injection Pump Relay: Testing and Inspection
Secondary Air Injection Pump Relay, Checking
‹› Multimeter.
‹› LED Test Lamp
Test requirements
‹› Secondary Air Injection (SAI) Pump Relay (-J299- ) fuse OK.
‹› Motronic Engine Control Module (ECM) Power Supply Relay (J271) fuse OK.
‹› Battery voltage at least 12.5 V.
‹› All electrical consumers switched off.
Test procedure
Start diagnosis
- Remove the Secondary Air Injection (SAI) Pump Relay (-J299-).
Checking voltage
- Using a multimeter, check the Secondary Air Injection (SAI) Pump Relay (-J299-) socket 1 (relay
30) to Ground.
- Check the wiring connection from the Secondary Air Injection (SAI) Pump Relay (-J299-) socket 1
(relay 30) to the Battery Positive terminal for an open circuit or high resistance.
- Check the wiring connections for damage, corrosion, loose or broken terminals.
- Install a jumper between relay connector terminal 1 (relay 30) and 2 (relay 87).
- The Secondary Air Injection (SAI) Pump Motor ( -V101-) should turn ON.
If the motor did Not operate:
- Perform the Secondary Air Injection Pump Motor test.

Page 6932
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1071
STACK:
Page 4273
Page 4899
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 3831
‹› Oil Filter, TDI PD, Replacing
‹› Engine Oil, Filling
Oil Filter, 2.5L, Replacing
‹› Oil drain adapter (T40057)
‹› Oil filter wrench (VAS 3417)
‹› Torque wrench (V.A.G 1331/)
‹› Needle-nose pliers
Oil filter housing, emptying
CAUTION! ‹› Oil filter housing must be drained before it is removed.

Page 4923
Ground (GND)

Page 3461
Ground (GND)

Page 3986
Part 1
Page 3206
Coolant: Service and Repair
Cooling System, Checking Freeze Protection and Coolant Level
‹› Only G12 conforming to TL VW 774 F my be used as an additive. It can be recognized by the

purple color.
‹› G 12 purple (according to TL VW 774 F) can be mixed with the previous coolant additives G 11
and G 12 (red).
‹› G 12 purple (according to TL VW 774 F) may be mixed with previous coolant additive G 12 red.
G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent freezing and
corrosion damage, scaling and also raise the boiling point of the coolant. For these reasons, the
cooling system must be filled with radiator freeze and corrosion protection fluid all year round.
Checking freeze protection and adding coolant additive if necessary.
‹› Coolant Level, Checking and Filling
Freeze Protection, Checking and Adding Coolant Additive
‹› Read the bright/ark boundary to obtain an accurate reading for the following tests. Place a drop
of water on the glass to improve the readability of
the bright/dark boundary. The bright/dark boundary can be clearly recognized on the
"WATERLINE".
- Check the concentration of the coolant additive using refractometer (T10007) (operating
instructions).
The scale - 1 - of the refractometer is designed for coolant additives -G 12- and -G 11-.
Page 2584
Page 4345
Temperature Gauge: Diagnostic Aids
Page 4045
‹› Puller (T10112)
Page 6947
- Start engine.
- Raise vehicle.
- Press ->.
If a test temperature between 35 °C and 45 °C is displayed:
- Install new seal to plug and tighten to 15 Nm. This completes the ATF check.
If no ATF drips out of inspection hole:

Page 3249
- The engine/transmission angle has changed and therefore the lower edge of the oil fill hole -1- is
located below the new oil level -2-.
- To properly check oil level, transmission must be drained completely and re-filled.
Tip:
The transmission housing must be cleaned and dried before servicing.
Shift fork pins must be removed in order to drain transmission.
Selector shaft, securing
^ Remove air cleaner housing.
^ Remove sound insulation.
^ Clean and dry transmission.
^ Secure selector shaft so that the position of shift fork pins can not move:
^ Press selector shaft down arrow -1-
^ While selector shaft is held in down position, turn bracket -A- upward (clockwise) in direction of
arrow -2- and press inward until the bracket latches in selector shaft.
Tip:
Use a clean 3.0L container with graduated markings to catch draining oil Transmission, draining
Page 7535
Ground (GND)

Page 7760
Final Drive Fluid: Capacity Specifications
Planetary gearbox
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
162
Final drive
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
145
Initial filling ...........................................................................................................................................

.......................................................... 7.2 L (7.6 qts)

........................................................................................................................................................
Lubricant ..............................................................................................................................................
...................................................................... DSG oil
Initial filling ...........................................................................................................................................

........................................................... approx. 7.0 L
Changing .............................................................................................................................................
.............................................................. Filled for life
Lubricant ..............................................................................................................................................
......................................................... ATF G 055 025
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6703
1 - Track Numbers

Page 28
- Antenna cables - New Beetle with Satellite radio (convertible)
- Antenna cables - W8 Passat

DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 1361
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4066
- Remove the nut - 1 - from the bracket. To do so, remove the right main head lamp.
- Disconnect the intake line from the power steering pump. Seal the pump and line with clean
plugs.
- Remove the nut - arrow - for the intake line - A - at the engine mount. Remove the intake line.
- Only slightly loosen the bolts for the engine and transmission mounts at the subframe (less than 1
rotation).
- Install the (T03000) as follows:

Page 4484
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1396
Power Door Lock Switch: Diagnostic Aids
Engine Controls - Exhaust Noise/DTC's P0011/P000A
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Exhaust
Noise/DTC's P0011/P000A
01 07 57
August 24, 2007
2015972 Supersedes;
^ Technical Bulletin 2013355 - CD part number W42SWUP0011

^ Technical Bulletin 2013222 - CD part number W420506JETTAEXH
^ Technical Bulletin 2011742 - CD part number W42COLDSTARTEX
^ Technical Bulletin 2012640 - CD part number W42MILP2097
Vehicle Information
Condition
Note:
Purge CD's associated with the above listed technical bulletins.
Update Programming for ECM part number beginning with "07K"
Updated ECM software resolving various powertrain concerns.
Note:
Prior to performing Update Programming, please inform the customer that this software update
addresses all of the concerns listed above. Once the Control Module programming is complete, the
module cannot be returned to its original state. Please inform the customer that their concern
addressed by this technical bulletin will not be resolved without this software update. Do not
perform Update Programming if the customer does not
Page 3406
- Disconnect all necessary connectors and remove the wiring harness from the cable router.
- Unclip the cable router completely and remove it.
Installing
- Tighten the battery tray screws to 6 Nm.

Page 4557
Part 1
Page 7268
- Loosen bolt - 2 - on forward ball socket of selector lever cable - 1 -.
- Carefully insert selector lever cable in support bracket/transmission and press on to lever/selector
shaft.
‹› Do not bend lever/selector shaft when doing this, otherwise shifting can no longer be adjusted
precisely.
Locking mechanism of selector lever cable must engage in support bracket.
- Tighten bolt - 2 -.
- Engage selector lever cable - 1 - into clip - arrow - on transmission.

Page 2439
WHAT ARE TRACKS?
15-28, and so on).
Page 4159
Page 1860
Ground (GND)

Page 1386
1 - Track Numbers

Dust and Pollen Filter
Cabin Air Filter: Service and Repair Dust and Pollen Filter
Dust and Pollen Filter
The filter is located in the right rear of the instrument panel under a cover.
Components of dust and pollen filter:
1. Frame
2. Filter element
3. Plastic nut, 2.5 Nm

4. Filter housing with seal
Removing
- Push center cover - 1 - forward - arrow A - and lift up to remove.

Page 3117
1 - Cap
2 - Seal -
Replace if damaged
3 - Bolt
With rubber gasket
5-
10 Nm
6 - Vent line -
- Checking
8 - O-ring -
Replace if damaged
In long member
12 - Vent line -
13 - 10 Nm
15 - Fuel tank -
16 - Heat shield
Charging System Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 172
Part 2
Page 4564
terminals.
Checking activation
Final procedures


Page 5371
voltage.
Checking wiring
Page 1084
Removing
arrow 2 -.
"learning" process.
Installing
Page 2402
WHAT ARE TRACKS?
15-28, and so on).
Page 7008
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1343
Part 1
Page 833
Page 7000
1 - Track Numbers

Page 308
Page 980
Part 3
Page 1885
Ground (GND)

Page 349
Page 3937
Page 5708
- Remove nut - 1 -.
- Remove bolt - 5 -.
- Pull off multi-function switch - 4 - with washers - 2 - and - 3 - from selector shaft - 6 -.
Installing
- Connect Multi-Function Transmission Range (TR) Switch (F125) - 4 - to selector shaft - 6 -.
- Installing mounting bolts - 5 - for multi-function switch hand-tight.

- Bend hooks of locking washer - 2 - back.
- Install washers - 2 - and - 3 - onto selector shaft - 6 -.
‹› Install washer - 2 - with hook pointing upward.
‹› Install washer - 2 - with long narrow guides into long narrow recesses of selector shaft - 6 -.
- Secure nut - 1 - on locking washer - 2 - by bending up hooks.
‹› If one or more hooks of the locking plate break off while bending, replace the locking plate.
- Connect lever - 3 - to selector shaft - 4 -.

Page 3318
Brake Bleeding: Service and Repair Brake System Bleeding General Information
Brake System Bleeding General Information
Description covers bleeding of brake system using brake filler bleeder unit (VAS 5234).
Specifically for vehicles with ABS/EDL, ABS/EDL/ASR and ABS/EDL/ASR/ESP
If one chamber of the brake fluid reservoir has run completely empty (e.g. leak in the brake
system), the brake system must be pre-bled first => [ Bleeding Sequence ] See: Bleeding With
Brake Filler/Bleeder Unit VAS 5234.
The hydraulic unit must be bled again via function "basic setting ".
Initiating Basic Setting
- Bleed brake system => [ Bleeding with Brake Filler/Bleeder Unit VAS 5234 ] See: Bleeding With
Brake Filler/Bleeder Unit VAS 5234.
Specifically on vehicles with ABS/EDL/ASR/ESP
After bleeding brake system => [ Bleeding with Brake Filler/Bleeder Unit VAS 5234 ] See: Bleeding
With Brake Filler/Bleeder Unit VAS 5234, zero adjustment of for brake pressure sensor 1 (G201)
must be performed.
A road test must be performed after bleeding. At least one ABS controlled braking must be
performed!
CAUTION! When adding brake fluid using brake filler bleeder unit (VAS 5234), make sure filler
pressure does not exceed 1 bar.
The brake fluid pressure at brake filler bleeder unit (VAS 5234) must be regulated down to 1 bar =>
owner's manual (VAS 5234).
Hydraulic unit may not be bled properly if a filler pressure of 1 bar is exceeded.
CAUTION! Brake fluid is poisonous.
‹› Use only new brake fluid (B 000 700 A.) (please specify brake fluid index).
‹› Due to its caustic nature, it must also never be brought into contact with paint.
‹› Brake fluid is hygroscopic, meaning that it absorbs moisture from the surrounding air, and must
therefore be stored in air tight containers.
‹› Rinse off any spilled brake fluid using plenty of water.

Page 4291
Part 2
Page 5846
Canister Purge Solenoid: Diagnostic Aids
Page 3189
Page 2196

Page 7473
- Lubricate end of plunger with MoS2 grease.
- Install slave cylinder and tighten bolts - arrows B - to tightening supplications.
- Insert hose/line assembly into slave cylinder until stop.
- To secure hose/line assembly, press in clip until stop.
- Install transmission support - arrows A -.
- After installing slave cylinder, bleed clutch system => [ Clutch System, Bleeding ] See: Service
and Repair/Procedures.
- Assembling shift mechanism => [ Shift Mechanism Cable Assembly Overview ] See: Manual
Transmission/Transaxle/Shift Linkage/Shift Cable/Service and Repair.
- Adjust shift mechanism => [ Shift Mechanism, Adjusting ] See: Manual

Transmission/Transaxle/Shifter M/T/Adjustments.
Tightening Specification
Slave cylinder to transmission => [ (Item 13) Hex bolt, 20 Nm ] See: Service and Repair/Removal
and Replacement
Transmission support to transmission bracket and transmission:
Page 7727
Shifter M/T: Removal and Replacement
Shift Mechanism Installation Position
Shift Mechanism Installation Position
- Arrow A - Shift movement
- Arrow B - Selector movement
A - Shift cable for gear movement
B - Selector cable for selector movement
C - Heat shield
‹› Remove before removing shift mechanism
1 - Transmission shift lever
2 - Relay lever
Shift Knob and Boot Assembly Overview
Shift Knob and Boot Assembly Overview

Page 3358
Page 4729
‹› Multimeter.
Test procedure
Start diagnosis
Specified values:
Page 2530
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 6233
Ground (GND)

Page 2747
Page 7720
- Turn locking mechanism on shift cable and on selector cable toward right until stop in direction of
- arrow -.
The spring presses locking mechanism into initial position.
- Rotate lock bracket - A - back into initial position in direction of - arrow -.
- Pull connecting pin (T10027) out of holes - A - and - B -.

Page 69
Part 3
Page 3376
Fuse: Diagnostic Aids
Page 7385
- Remove mounting bolts - arrows -, - arrows A - and - arrows B - of valve body in diagonal
sequence and carefully remove valve body.
- Remove brackets - 1 - and - 2 -.
3 - Valve body designation, here e.g. A2
‹› Bolts have various lengths and must be replaced.
‹› Only marked mounting bolts - arrows - must be loosened.
‹› When loosening other bolts/screws can affect the function of the valve body or separate valve
body.
- When removing valve body, damper piston - 2 - must be secured against falling out if necessary,
or removed together with both springs.
Page 572
Part 2
Page 4256
Page 1126
1 - Track Numbers

Page 3187
- Install and extend Brake pedal depressor (V.A.G 1869/2 ) between driver seat and brake pedal.
- Connect adapter - 1 - to brake fluid reservoir.
‹› If adapter - 1 - cannot be inserted due to reasons of space, use adapter ( VAS 5234/1).
- Connect filler hose of (VAS 5234 ) to adapter.
Vehicles with Manual Transmission
- Remove cover cap from bleeder screw of clutch slave cylinder.
- Connect bleeder hose - arrow - to clutch slave cylinder - 1 -, open bleeder screw and let
approximately 0.1 liters flow out. Close bleeder screw.
- Operate clutch pedal several times.
Continuation for all vehicles
- Remove caps from the bleeder screws.
- Connect collector bottle bleeder hose - 1 - to a rear bleeder screw1), open bleeder screw and
allow the corresponding brake fluid quantity to flow out (see table). Close bleeder screw.
Page 4913
Part 3
Page 7354


Page 1375
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Valve Spring Comp. Support - AST Tool # 2036
Valve Spring: Tools and Equipment Valve Spring Comp. Support - AST Tool # 2036
Valve Spring Comp. Support
AST tool# 2036
Used in conjunction with VW 541 to install valve stem seals with cylinder head installed. May be
substituted for VW 541-2.
- Made in Germany
Additional Tools Possibly Required:
3362 - Valve Spring Compressor

Page 4674
Part 2
Page 4595
Part 1
Page 7538
Part 1
Page 911
Part 2
Page 1934
Part 2
Page 4043

Page 3856
Note the shelf life date.
‹› The lower oil pan must be installed within 5 minutes after application of sealant.
- With the engine removed, apply the sealant bead - A - as shown onto a clean sealing surface of
the upper oil pan.
‹› With the engine installed, apply the sealant in the same manner onto the lower oil pan.
‹› Sealant bead must be routed on inside of the holes for bolts.
- Install all bolts and tighten them in diagonal sequence.
following:
‹› After installing the lower oil pan, allow the sealant to dry for approximately 30 minutes. Only after
then may the engine oil be added.
Page 5186
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7264
Shift Cable: Service and Repair
Selector Lever Cable
Removing
- Move selector lever to Tiptronic gate.
- Disconnect hose for Secondary Air Injection (AIR) pump - 3 - from air filter housing.
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 2 -.
- Disengage selector lever cable - 1 - from clip - arrow - on transmission.

Page 539
Part 3
Page 3961
Timing Chain: Service and Repair Timing Chain Assembly Overview
Timing Chain Assembly Overview

1 Intake Camshaft Adjuster
‹› With the sprocket
‹› Do not disassemble.
2 Exhaust Camshaft Sprocket
‹› Not pressed onto the camshaft.
‹› When removing, press off lightly, if necessary.
3 Cylinder Head
4 Tensioning Rail
‹› For the timing chain tensioner.
‹› Secured to the cylinder block.
‹› Oil before installing the pin.
5 Double Wheel Sprocket
‹› Securing, refer to => [ Oil Pump Drive Chain Assembly Overview ] See: Engine Lubrication/Oil
Pump/Service and Repair/Oil Pump Drive
Page 1933
Part 1
Transmission Input Speed (RPM) Sensor G182, Checking
Transmission Speed Sensor: Testing and Inspection Transmission Input Speed (RPM) Sensor
G182, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
- Disconnect the Transmission Input Speed (RPM) Sensor G182 electrical harness connector - 1 -.
Checking wiring
- Using a multimeter, check the Transmission Input Speed (RPM) Sensor G182 electrical harness
Page 4176
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1196
Ground (GND)

Page 7781

Page 6909
Final procedures
Systems/Testing and
End diagnosis.
Page 6576
Removing
Note: ^
arrow 2 -.
Note: ^
Installing

38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 907
Ground (GND)

Page 7679

‹› Thrust piece (VW 473)
‹› Thrust pad (30 - 205)
‹› Press support-R&I; wheel brg's. (3144)
‹› Thrust pad (2007)

Page 357
1 - Track Numbers

Page 2957
Part 2
Page 3692
Piston: Service and Repair
Piston and Connecting Rod Assembly Overview

1 Bolt, 30 Nm + 90° (1/4 additional turn)
‹› Replace
‹› Lubricate the threads and contact surfaces.
‹› Tighten to 30 Nm to measure radial play, do not turn further.
2 Pressure Relief Valve, 27 Nm
‹› Opening pressure 1.3 to 1.6 bar pressure.
3 Oil Spray Jet
‹› For piston cooling.
4 Connecting Rod Bearing Cap
‹› Note the installed position.
‹› Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position
and only onto the respective connecting rod.
‹› Installed position: Marks - A - point to the belt pulley side.

Page 3836
‹› Loosen cap before draining/extracting so that engine oil can flow out of filter housing.
Installing
- Install oil filter - 3 -
- Replace O-rings - 2 and 4 -.
- Install screw cap - arrow - and tighten to 25 Nm.

Page 4853
Page 7148
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7088
B Assembly lever
Installing
- Moisten outer edges and sealing lip of seal with ATF.
Open side of seal faces transmission.
- Carefully guide inner sealing lip - A - over transmission stub shaft - B -. Sealing lip must not roll
back.
- Press in sealing lip straight and as far as possible by hand - arrows -.
- Then drive seal in to stop of Thrust Piece (T10176 ), do not cant seal when driving in.
Page 7100
1 - Track Numbers

Procedures
Drive Belt: Procedures
Ribbed Belt, Checking Condition
- Crank engine at vibration damper/belt pulley using a socket wrench.
- With vehicle elevated, check ribbed belt - 1 - from below for:
‹› Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
‹› Layer separation (top layer, cord strands), base break-up
‹› Wear at flanks (material wear, frayed flanks, hardening or glazing of flanks, surface cracks)
‹› Replace the belt if any damage is found. By replacing, failures and/or disturbances can be
avoided. Replacing the belt is a repair procedure.
Ribbed Belt, Without Automatic Tensioner, Adjusting Tension

Ribbed Belt, without Automatic Tensioner, Adjusting Tension
‹› Clamping Lever (3297)

Page 690
Page 7980
Page 3798
Engine Oil, Filling
Note oil specifications.
General Information
- After the oil is filled, wait 3 minutes and then check the oil level.
- Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.
Page 3300
Power Steering Fluid: Service and Repair
Power Steering, Checking Fluid Level
Cold Fluid
- With engine not running, move front wheels in straight-ahead position.
4-cylinder Engines:
fluid dipstick.
5-cylinder Engines:
fluid dipstick.
Continuation for all engines:
- Clean dipstick with clean cloth.
- Screw cap on hand-tight and remove again.
‹› Screw cap fully in to get an accurate fluid level reading.
- Check fluid level: the fluid level must be in the hatched area - A -
Page 7193
Checking wiring
terminal 1
45
28

- End diagnosis.
Final procedures
End diagnosis.
Page 254
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5953
1 - Track Numbers

Page 2680
Ground (GND)

Page 3617
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4293
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7370

- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
resistance.

Page 7494
Clutch Release Bearing: Service and Repair Clutch Release Mechanism
Clutch Release Mechanism
‹› MoS2 grease
Remove and Install Clutch Release Lever Along with Release Bearing
- Disengage spring - arrow 1 -.
- Remove clutch release lever - arrow 2 - and release bearing.
- Installation is performed in reverse order of removal.
Release Bearing, Removing and Installing
- Press together retaining tabs - arrows - on rear side of clutch release lever and remove release
bearing - A - from clutch release lever.
- To install release bearing - A -, press into clutch release lever until retaining tabs - arrows -
engage.
Page 5501
Final procedures

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4314
Page 1453
Part 1
Page 2511
Page 5909
1 - Track Numbers

Page 604
Part 2
Dimmer Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5632
Page 6463
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1372
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1866
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7589
‹› Vehicles as of model year 2001
‹› With wear indicator
‹› When the appropriate wear limit has been reached (limit: 2 to 3 mm), brake pad wear indicator
lamp (K32) lights up in instrument panel
‹› Checking thickness=> 14.1
Replacement.
17 Harness connector
‹› For pad replacement, remove from bracket => [ (Item 18) Bracket ]
18 Bracket
19 Bolt
Front Brakes, FN 3
Brake Caliper and Wheel Bearing Housing Component Overview
‹› Brake pedal actuator (V.A.G 1869/2)
CAUTION! Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
‹› After replacing brake pads and before moving vehicle, depress brake pedal several times firmly
to properly seat brake pads in their normal
operating position.
‹› When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid.
‹› Before removing brake caliper housing or disconnecting brake hose from brake caliper housing,
install brake pedal actuator (V.A.G 1869/2 ).
Discharge Air Temperature Sensor / Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3587
WHAT ARE TRACKS?
15-28, and so on).
Page 6409
- Using a multimeter, check the Ignition Coils with Power Output Stage (N70, N127, N291, N292,
N323) electrical harness connector terminal 1 to ground for voltage.
- Check the Ignition Coil electrical harness connector terminal 1 through fuse S130 to the Motronic
Engine Control Module (ECM) Power Supply Relay (J271 ) for an open circuit.
- If necessary, repair the faulty wiring connection and replace fuse if blown.
Checking activation
CAUTION! Do not touch the Ignition Coils connecting parts or adapter cables during the following
test.
- Disable the power supply to the Fuel Injectors ( N30, N31, N32, N33, N83) by removing Fuse
S229.
- Using a diode test lamp connected to ground, check the Ignition Coils with Power Output Stage
(N70, N127, N291, N292, N323 ) electrical harness connector terminal 3 of each coil.
- Operate the starter.
The LED should blink.
If the LED blinked and the voltage was OK:
- Replace the faulty Ignition Coils with Power Output Stage (N70, N127, N291, N292, N323) Refer
to the Repair Information.
If the LED did Not blink:
Checking wiring
- Using a multimeter, Check the Ignition Coil electrical harness connector to the Motronic Engine
Control Module (ECM) ( J220) electrical harness connector T121 for an open circuit.
Page 7211
Shift Interlock Solenoid: Locations 09G Transmission
12 Shift Lock Solenoid (N110)
Shift Lock Solenoid is located in the shift mechanism - arrow -.

Page 3478
WHAT ARE TRACKS?
15-28, and so on).
Engine Control Module: Customer Interest Engine Controls - DTC's 00545/00638 Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 1889
Part 2
Page 3450
Tire Pressure Module: Diagnostic Aids
Page 307
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5398
Control Modules

Removing

Page 5634
Ground.
Ground.
Final procedures
Page 912
Part 3
Page 1763
Part 2
Page 2713
WHAT ARE TRACKS?
15-28, and so on).
Page 5626
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1902
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2663
1 - Track Numbers

Page 2463
Ground (GND)

Page 3927
1 - Track Numbers

Page 3255
Fluid - M/T: Locations
Transmission Drain and Refill Locations
Drain gear oil by removing oil drain plug - arrow 1 - and then removing journal - arrow 2 -.
Fill up gear oil by removing backup light switch (F4) - arrow - , then inserting funnel and hose into
switch opening.
Page 2307
Page 7703
Fluid - M/T: Locations
Transmission Drain and Refill Locations
Drain gear oil by removing oil drain plug - arrow 1 - and then removing journal - arrow 2 -.
Fill up gear oil by removing backup light switch (F4) - arrow - , then inserting funnel and hose into
switch opening.
Page 5747
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
If the DTC does not return: Repair complete, Generate readiness code. See: Testing and
- End diagnosis.
Final procedures
Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
Lock Cylinder
Connecting.
‹› Steel Wire (approximately dia. 1.2 mm)
Removing
- Remove the steering column trim.
- Carefully remove the Anti-Theft Immobilizer Reading Coil (D2) - arrow - from the lock cylinder.
‹› The Anti-Theft Immobilizer Reading Coil (D2) is attached to the lock cylinder and cannot be
Key positions of lock cylinder:
1. Position "Off"
2. Position "Run"
3. Position "Start"
- Insert a steel wire (approximately dia. 1.2 mm) into the hole - arrow - next to the key.
Page 4343
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4720
Ground (GND)

Page 5162
Part 2
Locations

Page 518
Once adaptation is finished, allow 10 minutes before inspecting fuel gauge for a change.
Tip:
It is not necessary to have VAS 5051/5052 connected to vehicle during 10 minute waiting period.
Warranty
* Code per warranty vendor code policy.
Page 1449
legend.
wiring diagram.
harness.


question.)
19 - Legend



DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 1670
When installing, be sure not to twist wheel speed sensor wire in wheel housing.
- Cut 2 pin connector off new wheel speed sensor wire, if present, using wire strip pliers.
- Strip 15 mm of insulation at end of wire and fold un-insulated wire in half.
- Connect wheel speed sensor wire using appropriate crimp connector from wiring harness repair
kit (VAS 1978).
Page 6502
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Tail Lamp Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 221
1 - Track Numbers

Page 4925
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3479
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 654
Part 1
Page 2575
1 - Track Numbers

Cooling System - Coolant Staining Around Water Pump
Area
Water Pump: Technical Service Bulletins Cooling System - Coolant Staining Around Water Pump
Area
19 09 03
July 16, 2009
2021142 Coolant Pump Replacement due to Mistaken Coolant Leak
Vehicle Information
Condition
Coolant staining around coolant pump area may cause incorrect diagnosis and unnecessary
replacement coolant pump.
Production Solution
Service
Upon inspection, a small coolant spot, or coolant staining is acceptable around coolant pump.
Diagrams
Cruise Control Switch: Diagrams
Cruise Control Switch Connector Assignments
Connecting.
10-pin connector D Cruise Control Switch (E45 )
1. not used
2. ON/OFF
3. Set/Accelerate
4. Reset/Resume the stored speed
5. Reset/Resume the stored speed
6. ON/OFF
7. Cruise Control Switch (E45)
8. not used
9. not used
10. not used

Page 7735
‹› Flex joint in front exhaust pipe must not be bent more than 10 degrees, otherwise it may be
damaged.
- Remove crossmember - B - below exhaust system.
- Loosen shield plate - C - in front area.
- Remove shield plate - D -.
- Remove shift mechanism housing from body.
- Swing shift mechanism housing down and remove with shift cables.
Installing
Holes in cable retainers have different diameters.
Application
Page 6208
Ground (GND)

Page 785
1 - Track Numbers

Page 3822
- Loosen sealing cap -1- using oil filter wrench 3417.
- Replace O-rings -2- and -3- as well as oil filter element -4-.
- Tighten sealing cap -1- using oil filter wrench 3417.
- Tightening torque of sealing cap: 25 Nm
Replacing oil filter, 2.5L fuel injection engines
- Oil drain adapter T40057
- Torque wrench V.A.G 1331/ Needle-nose pliers
Warning!
Oil filter housing must be drained before it is removed.

Page 3423
‹› Using the Go To button, select "Functions/Component selection" and the following menu options
in sequence:
‹› Body
‹› Electrical Equipment
‹› Instrument Cluster
‹› Functions
‹› Adapting the instrument cluster
‹› Resetting Service Interval Display
or
‹› with the buttons for the odometer in the instrument cluster.
Reset the service interval display using the knob - 1 - to set the trip odometer to zero when the
instrument cluster is in "reset mode."
Initiating The Reset Mode
- Turn off the ignition.
- Press and hold the knob - 1 - for resetting the trip odometer to zero.
- Switch on ignition.
- Release the knob - 1 -.
"Service" appears in the display.
- Press the button - 1 - for approximately 10 seconds until "Service" goes out.
The displayed Service will be reset and the odometer display returns to its standard setting.

Page 3957
Chain Assembly Overview.
6 Timing Chain
‹› Beginning with Model Year (MY) 2008 the roller chain has been changed to a tooth chain.
‹› Removing:
- Work procedure same as for "Adjust valve timing". Refer to => [ Valve Timing, Adjusting ] See:
Cylinder Head Assembly/Adjustments.
- Remove the vacuum pump. Refer to => [ Brake Booster Vacuum Pump ] See: Brakes and
Traction Control/Power Brake Assist/Vacuum Pump/Service and Repair/Brake Booster Vacuum
Pump.
- Mark direction of travel.
‹› Note when installing:
- Install in original direction of rotation.
- Chain must lie correctly in the tensioning and guide rails.
- Adjust the valve timing. Refer to => [ Valve Timing, Adjusting ] See: Cylinder Head
7 Strainer
‹› Replace
8 Bolt, 10 Nm
9 Timing Chain Tensioner
‹› Secure with locking pin (T03006).
10 Gasket
‹› Replace
11 Timing Chain Guide Rail
‹› Replace
‹› Replace
Page 7002
Ground (GND)

Page 835
terminals.
Checking activation
Final procedures


09.

Code.
Page 7972
Ground (GND)

Page 537
Part 1
Page 4251
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7256
‹› Engages in cable lever of selector mechanism housing
15 Pivot pin
‹› For pawl => [ (Item 14) Pawl ]
‹› Can be replaced with selector mechanism installed
‹› Removing and installing => [ Shift Lock Solenoid ] See: Actuators and Solenoids - A/T/Shift
Interlock Solenoid/Service and Repair
‹› Can be tested in "Guided Fault Finding" using Vehicle Diagnosis, Testing and Information system
(VAS 5051)
17 Locking cable
‹› For ignition key removal lock
‹› Must not be kinked
‹› Removing and installing => [ Locking Cable ] See: Shift Interlock/Shift Interlock Cable/Service
and Repair
‹› Adjusting => [ Locking Cable, Adjusting ] See: Shift Interlock/Shift Interlock Cable/Adjustments
‹› Ignition key removal lock, checking function => [ Ignition Key Removal Lock, Checking Function ]
See: Shift Interlock/Testing and
Inspection.
18 Bolt
‹› For locking cable on selector mechanism
‹› Tightening torque 10 Nm
19 Steering lock
20 Clip
‹› Installation position: Install clip from above. Angled ends of clip point toward steering lock.
Selector Mechanism Frame
Selector Mechanism Frame
Disassembling
- Remove cover => [ Selector Mechanism Cover and Circuit Board ] See: Removal and
- Carefully pry off retaining tabs - arrows -.

Page 1172
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1497
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6391
Page 536
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1328
Part 2
Page 5424
- Disconnect connector - 1 - and bleeder hose - 2 -.
- Remove bolts - arrows -.
NOTE: Seal intake channel in intake manifold using a clean rag.
- Clamp off coolant hoses using Hose Clamps Up to 25 mm dia. 3094 and disconnect them from
throttle valve connection - arrows -.
NOTE: Coolant hoses only for Throttle Valve Control Module J338 heated by coolant
Installing
Installation is in reverse order of removal. When doing this note the following:
- Replace sealing ring for throttle valve control module if damaged.
- Make sure air hoses - 1 - and - 2 - are fitted securely.
valve control module Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided
Functions".
Tightening torques:
Component Nm
Throttle valve control 6.5
module to intake manifold

Page 978
Part 1
Page 6559
Page 142
Global Positioning System Module: Testing and Inspection Telematics Control Module (J499),
Coding
Telematics
Telematics Control Module (J499), Coding
‹› Vehicle Diagnostic, Testing and Information System ( VAS 5051B)
If the Telematics control module was replaced, it must be coded and configured for the OnStar
system.
‹› Do not swap out any Telematics control modules between different vehicles! Each Telematics
‹› To diagnose, use the "Guided Fault Finding" function of the (VAS 5051B). Before removing the
Telematics control module, while diagnosing
with the (VAS 5051B) in the " replacing the J499 - Telematics control module" function, the option
will be offered to read out the coding and then reprogram it in the new Telematics control module
after it has been replaced.
Procedure:
- Connect (VAS 5051B).
- Using the Sprung button, select "Functions/Component selection" and the following menu options
in the following sequence:
‹› Body
‹› 01 - On Board Diagnostic (OBD) capable systems
‹› Telematics NAR
‹› Telematics NAR functions
‹› Control module, coding

Page 140
Global Positioning System Module: Testing and Inspection Telematics, Troubleshooting
Telematics
Telematics, Troubleshooting
Telematics Control Module is capable of self-diagnosis.
Use the Vehicle Diagnosis, Testing and Information System (VAS 5051B) under "Guided Fault
Finding".
Steering Column Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4755

Page 2730
6 Hex bolt
7 Coupling link
8 Hex nut

9 Bracket
10 Stabilizer bar
11 Connector
13 Pop rivet bolt
Page 4356
Water Pump: Specifications
Coolant Pump to Cylinder Block Bolts .................................................................................................
...................................................................... 10 Nm
Page 4722
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2111
Headlamp Alignment Sensor: Adjustments
Left Front Level Control System Sensor G78, Adjusting
- Vehicle Diagnostic Testing and Information System VAS 5051 / VAS 5052.
Prerequisites
- Vehicle must be standing on all four wheels on a flat level surface.
- Handbrake lever must be in off position and a drive gear must not be selected.
- Steering must be in straight-ahead position.
- Vehicle must be unoccupied and not loaded.
- Vehicle must not be moved during basic settings process (i.e.: opening and closing of doors,
people leaning on vehicle, people entering vehicle is not permitted).
- If vehicle was raised using a lifting platform/hoist or a vehicle/workshop jack, then it must be rolled
back and forth several times so that the springs etc. settle, before starting adjustments.
Vehicle Diagnostic Testing and Information System VAS 5051 / VAS 5052, selecting functions.
See On Board Diagnostic Function

Page 1820
Air Door Position Sensor / Switch: Diagnostic Aids
Page 5145
Page 2651
WHAT ARE TRACKS?
15-28, and so on).
Page 7465
- Disengage clip - B - using screwdriver and pull until stop out of master cylinder.
- Disconnect hose/line assembly - C - from master cylinder and seal.
Release operating rod/master cylinder from clutch pedal as follows:
- Pull clutch pedal slightly into passenger compartment.
- Press both sides of mount inward using pliers ( T10005 ) - arrows -.
- Now, remove complete mounting bracket for clutch pedal as follows:
- First remove connecting panel - A - - arrows 1 -.

Page 4376
Part 1
Page 2437
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1694
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3541
- Remove bolts - A - from brake caliper.
- Remove brake caliper and hang on body.
- Pull off wheel hub/wheel bearing unit from stub axle.
A Puller, e.g. (Kukko 20/2)

Page 7251
Selector Mechanism Cover and Circuit Board
Removing
- Remove selector lever handle => [ Selector Lever Handle ] See: Selector Lever Handle.
- Disconnect harness connector - 1 - from circuit board.
- Pull harness connector out of hole - arrow - in bracket - 2 -.
- Carefully pry off retaining tabs - arrows - (qty. 4).
‹› If retaining tabs - arrows - are damaged, cover must be replaced completely.
- Remove complete shift mechanism cover upward.
- Remove circuit board from mounts on frame - arrows -.

Page 4032
Page 2093
Page 6214
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1551
Ground (GND)

Page 7677

‹› Spindle from seal installer set - rear diff (3066)
‹› Slide hammer-complete set (VW 771)
‹› Pulling hook (VW 771/37)

Page 212
Part 2
Page 2340
Part 1
Transmission Control Module (TCM) J217, Replacing
Control Module: Service and Repair Transmission Control Module (TCM) J217, Replacing
NOTE:
- To achieve optimal anti-theft protection for the vehicle, an anti-theft immobilizer was installed. The
anti-theft immobilizer is a system for enabling/locking the Transmission Control Module (TCM)
J217.
- To perform adaptation of the anti-theft immobilizer.
Procedure
Check the identification of the previous Transmission Control Module (TCM) J217 as follows:
- Select "Diagnostic mode 9: Vehicle information."
- Select the "Test-ID 04: Calibration identification".
- The Transmission Control Module (TCM) J217 identification will be displayed, e.g.: 09G27750 L
0301
- End diagnosis and switch the ignition off.
Removal
- Remove the left wheelhousing liner.
- Disconnect the Transmission Control Module (TCM) J217 electrical harness connector - A -.
- If equipped, disconnect the right side - 2 - and the left side - 5 - turn signal electrical harness from
the Transmission Control Module (TCM) J217.
- Remove the Transmission Control Module (TCM) J217 bracket screws - 3 -.
- Remove the Transmission Control Module (TCM) J217 with the bracket attached.
- Remove the bracket screws - 4 - and the bracket from the Transmission Control Module (TCM)
J217.
Installation
Ignition System - MIL ON/DTC's P0300-P0312 Stored
Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/DTC's P0300-P0312 Stored
28 10 01
March 31, 2010
2023121
Page 304
Part 1
Page 5327
WHAT ARE TRACKS?
15-28, and so on).
Page 184
Ground (GND)

Page 5415
Part 3
Page 711
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1439
Part 2
Page 7503
Pressure Plate: Service and Repair Clutch Assembly Overview, LuK
Clutch Assembly Overview, LuK

2 Clutch plate
‹› Removing and installing => [ Clutch, LuK ] See: Service and Repair/Clutch, LuK.
‹› Only replace together with SAC pressure plate
‹› Installed position:=> [ Installation Position of Clutch Plate ] See: Service and Repair/Clutch, LuK
3 SAC pressure plate
‹› SAC = "self-adjusting clutch"
‹› Checking ends of diaphragm spring => [ Checking Ends of Diaphragm Spring ] See: Service and
Repair/Clutch, LuK
‹› Check spring connection and rivet connections => [ Checking Ends of Diaphragm Spring ] See:
Service and Repair/Clutch, LuK
Headlamp Alignment Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 3483
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 688
Relay Box: Application and ID Relay Arrangements on Thirteen Position Auxiliary Relay Panel,
Above Relay Panel, From July 2005
Page 3084
- Loosen the bolts - 1 + 2 -.
3 Clamp
4 Generator
- Insert clamping lever, secure with pin - arrow - and tip generator down (use e.g. torque wrench as
drive for 3297).
- Press generator as far as clamp stop at least three times using clamping lever to ensure optimum
ease of movement.
- Tighten first the lower, then the upper generator bolt to 25 Nm.
Page 6891
plan)
TCM.
Warranty
Information only.
Page 2379
End diagnosis.
Page 3363
Page 157
Part 2
Page 2101
Ground (GND)

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 1931
WHAT ARE TRACKS?
15-28, and so on).
Page 4474

Specifications
Differential: Specifications

Page 671
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3004
Alignment: Service and Repair Vehicle Data Label
Vehicle Data Label
Explanation of the PR. No. on vehicle data sticker
Different suspensions are installed depending on engine version and equipment. These are
identified by PR numbers.
Page 4673
Part 1
Page 5409
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1516
Ground (GND)

Page 7581
- Insert cage with hub into joint body.
- Press in opposing balls in sequence, during this the previous position of the ball hub to ball cage
and to joint body must be re-established.
- Install new circlip into the hub.
- Distributed remaining grease in the cover.

Page 2089
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7105
Part 1
Fluid - A/T: Capacity Specifications
Planetary gearbox Initial filling .............................................................................................................

.......................................................................................... approx. 5.3 L Changing ............................
..............................................................................................................................................................
.................. Filled for life
Final drive Initial filling .........................................................................................................................

............................................................................ approx. 0.75 L Changing ........................................
..............................................................................................................................................................
...... Filled for life
Planetary gearbox and final drive Initial filling .....................................................................................

................................................................................................................. 7.2 L (7.6 qts)
..........................................................................................................................................................
Initial filling ...........................................................................................................................................

............................................................ approx. 7.0 L Changing ..........................................................
.................................................................................................................................................. Filled
for life
Page 3243
Warranty

Page 3186
the strainer).

Specifications
Oil Pan: Specifications
Lower Oil Pan
Upper Oil Pan

Page 6740
Your Service Center should place the vehicle owner on notice in writing, that their ECM or TCM
was found to have been tuned, and that any damage caused by the tuning of the ECM or TCM
(including any adverse emissions consequences) will not be covered by Volkswagen of America,
Inc. warranties.
For any repair requested by the owner under warranty or outside warranty that requires Pass -
Thru Vehicle Programming, which will automatically wipe out the "Tuning" program, your Service
Center should advise the owner of the above and get Owner's written consent (see Control Module
Tuning form shown) to the flashing procedure.
^ Battery MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update
process can lead to ECM/TCM failure)
^ Battery voltage must be maintained throughout procedure (always use an approved battery
Charger / Maintainer).
Page 2417
WHAT ARE TRACKS?
15-28, and so on).
Page 7389
‹› Ensure that wires - 3 -, - 5 - and - 9 - are not jammed.

- Tighten new bolts - arrows -, - arrows A - and - arrows B - to tightening torque => [ (Item 8) Bolt, 8
Nm plus an additional / turn
(90°) ] See: Valve Body Assembly Overview, starting from inside and working outward.
Page 2639
Part 3
Fuel Door Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1944
1 - Track Numbers

Page 3644
5 Bearing Shell
‹› Note the installed position, refer to => [ Bearing Shells, Installed Location ].
‹› Do not interchange used bearing shells.
Wear limit: 0.4 mm
‹› Measure radial clearance with Plastigage(R):
New: 0.02 to 0.06 mm
Wear limit: 0.09 mm
Do not turn the crankshaft when measuring radial play.
6 Connecting Rod
‹› With a cracked bearing cap.
‹› Separate new connecting rods. Refer to => [ New Connecting Rod, Separating ] See:
Procedures.
‹› Only replace as a set.
‹› Installed position: Marks - A - point to belt pulley side.
7 Circlip
8 Piston Pin
‹› If difficult to move, heat the piston to 60 °C (140 °F).
‹› Remove and install using pilot drift (VW 222A).
9 Piston
‹› Checking, refer to => [ Pistons, Checking ] See: Testing and Inspection.
‹› Mark the installed position and cylinder allocation.
‹› Arrow on piston face points toward the belt pulley side.
‹› Install with a piston ring compressor.
‹› Checking cylinder bore, refer to => [ Cylinder Bore, Checking ] See: Testing and Inspection.
‹› Piston and cylinder dimensions. Refer to => [ Piston and Cylinder Dimensions ] See:
Specifications/Piston and Cylinder Dimensions.
10 Piston Rings
‹› Offset gaps by 120°
‹› Use piston ring pliers for removal and installation.
‹› Marks face toward the piston crown.
‹› Checking ring gap, refer to => [ Piston Ring Gap, Checking ] See: Testing and Inspection.
‹› Checking piston ring groove clearance, refer to => [ Piston Ring Groove Clearance, Checking ]
Bearing Shells, Installed Location


F125

Specifications
Flywheel: Specifications
Flywheel/Drive Plate Bolts to Crankshaft

........................................................................................... 60 Nm Final pass .....................................
..............................................................................................................................................................
...... Tighten 90°
Door Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1473
Power Trunk / Liftgate Lock Actuator Position Sensor: Diagnostic Aids
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 7073
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6844
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4255
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Tow Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2637
Part 1
Page 6303
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2012
Page 2298
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7974
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5487
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5205

Page 7955

Page 4930
Page 49
Ground (GND)

Transmission Control Module (TCM) -J217-

Page 1111
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7053
Checking
- Multimeter.
- Wiring diagram.
Requirements
- Fuse SA6 OK.
- Fuse SB28 OK.
- Fuse SC14 OK.
Test procedure
Start diagnosis
Checking voltage


Page 1059
plan)
TCM.
Warranty
Information only.
Page 7329
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 2158
Interior Light Switch: Diagnostic Aids
Page 5464
order)
Tip:
Locations
Airbag Control Module J234

Page 4732
Checking wiring
Final procedures

Page 6031
1 - Track Numbers

Page 7392
‹› Interchanged connection may possibly destroy the transmission.

‹› If a harness connector is damaged, wiring harness or valve body must be replaced together with
solenoid valves.
- Route wiring harness - 1 - as shown in illustration.
- Connect harness connector - 2 - and - 5 -.

Page 3773
Ca-Va
Locations

Page 6134
‹› Checking valve for throughput:
Valve vertical: Open
Valve angled at 45°: Closed
30 Pressure Retention Valve
‹› For fuel tank ventilation.
‹› Checking, refer to => [ Pressure Retention Valve Checking ].
31 Ground Connection
‹› Ensure the connection is securely seated.
Fuel Delivery Unit Installed Position
The tab - 4 - on the fuel delivery unit must lie between tabs - 3 and 5 -.
‹› - Arrow - points in direction of travel.
‹› Fuel delivery unit can only be installed in this position.
Switch Over Valve Checking
Pin in rest position: Closed

Locations
Luggage Compartment Light Switch F5

Page 7729
Shift Mechanism Assembly Overview
Shift Mechanism Assembly Overview

1 Shift mechanism
‹› Consists of shift rod and shift cover
‹› Components cannot be separated from each other
2 Backup light switch (F4)
‹› Tighten to 20 Nm
‹› Lightly lubricate tab with MoS2 grease
3 Locking pin
‹› For adjustment of shift mechanism
‹› Removing => [ Removing locking pin from
shift cover ] See: Service and Repair/Overhaul/Shift Mechanism
‹› Pressing in => [ Pressing locking pin into
shift cover ] See: Service and Repair/Overhaul/Shift Mechanism
4 Relay lever
‹› Installed location => [ Installation Position of Transmission Shift
Lever/Actuator Lever ] See: Shift Linkage/Shift Cable/Service and Repair

Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 272
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6710
Part 3
Page 4641

Page 5705
Requirements:

Work procedure:
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7107
Part 3
Page 3256
Fluid - M/T: Service and Repair
Gear Oil, Checking and Filling
Checking gear oil level using the familiar method is no longer possible.
Engine/transmission inclination was changed
Lower edge of filler hole - arrow 1 - is therefore located beneath new oil level - arrow 2 -.
Gear oil level can only be checked if gear oil is drained completely and then filled up again:
‹› Hose (approximately 600 mm long, outside diameter 10 mm) with commercially available funnel
Preparation
- Disconnect battery ground (GND) cable with ignition switched off.
- Remove battery and battery tray.
- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.
Page 3025
1318).
Checking Injection Quantity and for Leaks ] See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Testing and Inspection/Fuel Injectors, Checking Injection Quantity and For
Leaks.
disconnected.
Check Valve, Checking ] See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Pump/Testing and Inspection/Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank).
Regulator ] See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and

Suspension Mode Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2300
WHAT ARE TRACKS?
15-28, and so on).
Page 7226
Part 2
Page 2694
1 - Track Numbers

Page 6308
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 2007
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2772
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 187
Part 1
Page 4049
Spark Plug Pliers
AST tool# H 1849
- Spark Plug Pliers

Locations
Number One Cylinder: Locations
Firing order
1-2-4-5-3
Page 4602
terminals.
Checking activation
Final procedures


Page 7550
Ground (GND)

Page 3451
Control Modules

Removing

Page 3366
1 - Track Numbers

Locations

Page 7157
- Remove nut - 1 -.
Installing


Specifications
Piston Ring: Specifications
Piston and Cylinder Dimensions
Note: Cylinder bore must not be measured if cylinder block is secured to engine stand with Engine
Lateral Bracket T03001, or else results may be incorrect.
Piston and cylinder dimensions
* Measurement does not include graphite coating (thickness = 0.02 mm). The graphite coating
wears off.
Piston Ring Gaps
Ring to Groove Clearance
Piston Inspection
Take measurement approx. 10 mm from lower edge of piston skirt and offset 90° to piston axis.
Deviations from nominal dimension

............................................................................................................................................................
max. 0.04 mm
Cylinder Bores
Page 7870
Page 1695
Part 1
Page 1532
Ground (GND)

Page 214
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3499
Part 2
Page 7380
‹› For solenoid valves
‹› Component locations of solenoid valves and wiring harness routing => [ Solenoid Valve
Identification ] See: Transmission Control
Systems/Locations/Solenoid Valve Identification
‹› Removing and installing => [ Wiring Harness with 14-Pin Connector ] See: Wiring
Harness/Service and Repair/Wiring Harness With 14-Pin
Connector
35 Bolt, 6 Nm
Brake Caliper and Wheel Bearing Housing Component
Overview
Wheel Bearing: Service and Repair Brake Caliper and Wheel Bearing Housing Component
Overview
Front Brakes, FS III
operating position.
1 Phillips-head screw 4 Nm
2 Brake disc
Page 2614
Clutch Switch: Service and Repair
Clutch Pedal Switch
In order to assure secure fitting, clutch pedal switch (F36) must not be installed more than once.
Removing
- Slide driver's seat toward rear as far as possible and bring steering wheel to highest position.
- Disconnect connector from clutch pedal switch ( F36).
- Rotate clutch pedal switch (F36) at housing 45 degrees toward left and remove from mount.
Installing and Adjusting
During installation of clutch pedal switch, clutch pedal always remains in rest position (not
operated).
‹› Check clutch pedal switch first.
‹› Stop - A - must be located in front of section - B -.
‹› Stop - C - is then located directly below take-up hook.
If this is not the case, plunger must not be pulled out.

‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 3500
Part 3
Page 3359
Page 1327
Part 1
Page 6307
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 721
‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 413
Page 7713
Seals and Gaskets: Service and Repair Right Drive Flange Shaft Oil Seal
Right Drive Flange Shaft Oil Seal
Seal and Sleeve are Designed as Two Parts
‹› Assembly tool (3253/2)
‹› Drip tray for shop crane (VAS 6208)
Seal and Sleeve are Designed as One Part
‹› Spindle from seal installer set - rear diff (3066)

Removing
- Remove center and right sections of sound insulation below engine/transmission.
- Turn steering as far as possible toward right.
- Remove protective cap for drive axle from engine, if present.
- Remove drive axle - 1 - from flanged shaft.
- Tie up drive axle as high as possible. Do not damage paint on drive axle when doing so.
- Place drip tray under engine.
- Remove bolt for flange shaft. To do this, screw two bolts into flange and counter-hold flange shaft
centrally using a pry bar.
Page 7665
Differential: Adjustments Differential, Adjusting
Differential, Adjusting
‹› Magnetic plate 50 MM dia. (VW 385/17)
‹› Dial gauge holder (VW 387)
‹› Thrust pad (30 - 205)
‹› Internal puller (Kukko 21/7)
‹› Support (Kukko 22/2 )
‹› Dial gauge
Readjustment of differential is necessary when the following components have been replaced:
‹› Transmission housing
‹› Clutch housing
‹› Differential housing
or
‹› Tapered roller bearing for differential
Adjustment overview => [ Adjustment Overview ] See: Adjustment Overview.
- Press tapered roller bearing outer race into transmission housing without shim using thrust pad
(30 - 205) => [ Pressing outer race/tapered roller bearing into
transmission housing ] See: Service and Repair/Overhaul/Differential
‹› Inner and outer race of tapered roller bearing are paired. Do not interchange!
- Press tapered roller bearing outer race into clutch housing using thrust pad (30 - 205) => [
Pressing outer race/tapered roller bearing into
clutch housing ] See: Service and Repair/Overhaul/Differential
- Insert differential into clutch housing.
- Install transmission housing and tighten 5 bolts to 25 Nm.
- Install dial gauge and set to "0" with 1 mm preload.
- Move differential up and down, read off play on dial gauge and note. (Example: 0.70 mm).
Page 7234
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
Page 7874
Requirements:

Work procedure:
Final Drive Fluid: Capacity Specifications
Planetary gearbox
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
162
Final drive
Initial filling ...........................................................................................................................................

........................................................................................................................................ Filled for life
Lubricant ..............................................................................................................................................
.............................................................................................................................................. G 052
145
Initial filling ...........................................................................................................................................

.......................................................... 7.2 L (7.6 qts)

........................................................................................................................................................
Lubricant ..............................................................................................................................................
...................................................................... DSG oil
Initial filling ...........................................................................................................................................

........................................................... approx. 7.0 L
Changing .............................................................................................................................................
.............................................................. Filled for life
Lubricant ..............................................................................................................................................
......................................................... ATF G 055 025
Page 2537
1 - Track Numbers

Page 5579
Final procedures

Page 2686
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7953

Specifications
Connecting Rod: Specifications
Connecting Rod Bolts

........................................................................................... 30 Nm Final pass .....................................
................................................................................................................................... Tighten 90° (1/4
additional turn)
Bearing Shells
Axial play
New .....................................................................................................................................................
............................................... 0.10 to 0.35 mm Wear limit ..................................................................
...................................................................................................................................... 0.4 mm
Radial clearance
New .....................................................................................................................................................
............................................... 0.02 to 0.06 mm Wear limit ..................................................................
.................................................................................................................................... 0.09 mm
Installed Location

Page 2086
Part 1
Page 3322
Page 6249
WHAT ARE TRACKS?
15-28, and so on).
Page 636
WHAT ARE TRACKS?
15-28, and so on).
Page 1020
1 - Track Numbers

Page 7358
Transmission Input Speed Transmission Control Module (TCM)
3 51
4 39
- Replace the Transmission Input Speed (RPM) Sensor G182.
- End diagnosis.
Final procedures
End diagnosis.
Page 6640


Page 7378
6 Gasket
7 Magnet
‹› 2 pieces in webs of oil pan
‹› Clean before installing
8 Bolt, 8 Nm plus an additional 1/4 turn (90°)
‹› Qty. 12 with various lengths for securing valve body to transmission
‹› Always replace bolts
‹› Note allocation => [ Valve Body ] See: Valve Body, removing and installing valve body
9 Bolt, 11 Nm
‹› 3x
‹› For securing oil strainer to valve body
10 Oil strainer
‹› Removing and installing => [ Oil Strainer ] See: Fluid Filter - A/T/Service and Repair
13 Valve body
‹› Removing and installing => [ Valve Body ] See: Valve Body
‹› Identification of solenoid valves => [ Solenoid Valve Identification ] See: Transmission Control
Systems/Locations/Solenoid Valve
Identification
‹› Allocation according to transmission code letters
14 Bolt, 7 Nm
15 Bolt, 6 Nm
‹› Removing and installing => [ Transmission Input Speed Sensor ] See: Sensors and Switches -
A/T/Transmission Speed Sensor/Service and
Repair/Transmission Input Speed Sensor
17 Bolt, 7 Nm
18 Transmission Output Speed (RPM) Sensor (G195 )

‹› Removing and installing => [ Transmission Output Speed Sensor ] See: Sensors and Switches -
A/T/Transmission Speed Sensor/Service and
Repair/Transmission Output Speed Sensor
20 Breather cap
Specifications
Firing Order: Specifications
Firing order
1-2-4-5-3
Page 5483
1 - Track Numbers

Page 1970
Door Switch: Diagnostic Aids
Page 490
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4230
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 958
1 - Track Numbers

Page 1552
WHAT ARE TRACKS?
15-28, and so on).
Page 2109
Headlamp Alignment Sensor: Diagnostic Aids
Page 7861
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6786
1 - Track Numbers

Coolant: Capacity Specifications
Cooling system
Coolant Capacity .................................................................................................................................

................................................. 9.0 liters (9.5 quarts)
Page 2561
be scrapped.

Removal
- Remove the front side.
- Remove harness connector - 3 - and combination nuts - 2 -.
Installation
- Close doors.
- Connect the battery ground cable.
CAUTION! Make sure no one is in the vehicle.
‹› After connecting the battery, the vehicle options (radio, clock, electric window regulator) must be
checked according to the repair information
and/or user manual.
Driver/Front Passenger Side Airbag Sensor Assembly Overview
Airbag

Page 4026
- For fuel tank
17 - Lock washer
18 - Cover for fuel tank
19 - 20 Nm plus an additional 1/4 turn (90 degrees) -
Replace
20 - Securing strap -
Observe varying lengths
- Installed location: Locating point (hole) points in driving direction
21 - Fuel filter -
Installed location: Arrow points in direction of flow
- Fuel filter with attachments. - Fuel supply system must be bled after replacing fuel filter.
22 - Supply line -
Black
- Ensure seated tightly
- To disconnect from fuel filter, press in securing ring on connecting piece.
- To fuel rail
23 - Vent line -
White
- Clipped in at top of fuel tank
- To Evaporative Emission (EVAP) Canister Purge Regulator Valve N80
24 - Seal -
Replace
- To install, place into opening of fuel tank dry
- Only coat inner part with fuel when installing fuel delivery unit.
25 - Fuel delivery unit -
Note installation position on fuel tank
- Fuel gauge sensor, removing and installing.
- Check fuel pump.
- Clean strainer if soiled
26 - Locking ring, 110 Nm -

- Use wrench T10202 for removal and installation
27 - Supply line -
Black
- To fuel filter
- To disconnect from flange and fuel filter, press in securing ring on connecting piece.
- Clipped to side of fuel tank
28 - Return line -
Blue
- To fuel filter
29 - Gravity valve -
To remove valve unclip upward out of support
- Checking valve for throughput:
- Valve vertical: Open
- Valve angled at 45 degrees : Closed
30 - Pressure retention valve -
For fuel tank ventilation
31 - Ground (GND) connection -

Page 2420
Part 2
Page 6607
WHAT ARE TRACKS?
15-28, and so on).
Page 5731


Page 5830
Specified value: 10.6 volts +/- 2 volts.
- Leave the multimeter positive lead on terminal 1 and connect the multimeter negative lead to
engine ground.
- Engine still running.
Specified value: 10.6 volts +/- 2 volts.
- Remove fuse S-243. Check the wire from the electrical harness connector terminal 1 to fuse
S-243 for open or high resistance.
Check Ground activation
- Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve
(N80) electrical connector terminal 2 to Motronic Engine Control Module (ECM) (J220 ) electrical
connector T121 terminal 64 for an open circuit.
Page 4954
Part 3
Page 5476
guided function.
Removing
Installing

Page 7299
legend.
wiring diagram.
harness.


question.)
19 - Legend



Locations

Page 5373
accessible.
‹› Multimeter.
Test requirements
box B is OK.
Test procedure
Start diagnosis

Control (EPC)) G188

Page 5489
Part 2
Page 1420
WHAT ARE TRACKS?
15-28, and so on).
Page 5612
Checking wiring
Final procedures

Page 3140
prevents leaks.

Or

Page 6495
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1984
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6631
Part 3
Page 1044
plan)
TCM.
Warranty
Information only.
Page 160
Page 407
Track 1-14
named Track 1-14.
Track 169-182
reference box.

P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 4482
Part 1
Page 1693
WHAT ARE TRACKS?
15-28, and so on).
Page 6028
Needle Lift Sensor G80

Page 67
Part 1
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3381
Fuse: Application and ID Relay and Fuse Arrangements on Relay Panel, From July 2005
Locations

Page 1428
Power Mirror Switch: Service and Repair
Mirror Adjusting Switch and Mirror Selector Switch
The Mirror Adjustment Switch (E43) and the Mirror Selector Switch (E48) are a single unit and
cannot be replaced separately.
Removing
- Remove door trim panel.
- Disconnect the connector on the mirror switch.

- Bend the frame outward on the long side of the switch and remove the switch.
Installing

Page 286
Ground (GND)

Page 3487
Installing

Owner's Manual
General Information
Page 4886
Part 1
Page 6120
Ground (GND)

Page 1486
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3982
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3150
VW/Audi Oil filter housing drain. This tool is used for draining the oil filter housing on 2005 1/2-2008
VW/Audi models with the new 2.0L Turbo (engine codes; BPG, BPY, BWT) and the 2.5L inline 5
cyl VW engine.
- Prevents spillage during oil filter change and allows for drainage of oil from the filter housing
- Used for draining the oil filter housing on 2005 1/2-2008 VW/Audi models with the new 2.0L Turbo
(engine codes; BPG, BPY, BWT) and the 2.5L inline 5 cyl VW engine
- Easy to use

Refrigerant Temperature Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5536
Part 3
Page 6240
Page 4117
removal.
Page 5273
6 (Can_Bus Low) 58
- End diagnosis.
Final procedures
erased, generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes
End diagnosis.
‹› Multimeter.
Test requirements

Test procedure
Page 2042
- Fit brake light switch connector.
- Check function of brake light.
- Install footwell vent.


F125

Page 6575
Final procedures
Page 5738
WHAT ARE TRACKS?
15-28, and so on).
Page 2009
Part 2
Page 6822
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 271
WHAT ARE TRACKS?
15-28, and so on).
Page 1085
See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Scan
Tool Testing and Procedures.

Cooling System - Coolant Identification/Mixing
Coolant: Technical Service Bulletins Cooling System - Coolant Identification/Mixing
19 10 03
March 18, 2010
2022548 Supersedes T.B. Group 19 number 10-02 dated March 17, 2010 to improve coolant table
view.
Condition
Identifying and Mixing Factory Fill Engine Coolants
Discontinuation and mixing of Volkswagen approved engine coolants.
Coolants G11, G12 and G12+ have been replaced by an improved version. New coolant G12++
will be introduced on all engines.
Production Solution

Service.
Identify which coolant the vehicle was filled with from the factory. The photo shows the color of
each type of engine coolant.
The table identifies which coolant can be added to the factory coolant.
Tip: If a vehicle is found to have the incorrect coolant, the cooling system should be flushed using
the repair manual procedures in Elsa Web and then filled with the correct coolant.
Page 4053
Conditions
Stages ] See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair.
Engine Control Module DTC Memory, Checking and Erasing ] See: Powertrain
Management/Computers and Control Systems/Engine Control Module/Testing and
Page 4190
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4123
^ Install the VAS 6096 onto the fill tank using the appropriate adapter (fig. 2).
^ Install air compressor hose (fig. 4).
^ Verify both valves are in the closed position (fig. 5).
^ Open valve on air hose side (fig. 6)

Page 7331
End diagnosis.
Page 891
Ground (GND)

Page 3743
Ground (GND)

Page 1607
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4952
Part 1
Page 1720
Page 2701
Part 3
Page 481
Part 3
Refrigerant: Capacity Specifications
A/C Refrigerant System Capacities
Refrigerant R-134a, Capacity
Obtain R-134a refrigerant from a local A/C supplier under one of the following names:
‹› R-134a
‹› Tetrafluoroethane
‹› CH2F CF3
‹› H-FKW 134a
‹› SUVA(R) TRANS A/C
‹› ARCTON(R) 134a
‹› R-134a refrigerant is packaged in different containers. Some are used only for commercial
applications which are sold in cylinders using a 1/4"
flare fitting. This does not connect to the vehicle fittings and servicing equipment. Use only R-134a
which come in containers having the correct type of service fitting.
Page 4609
Variable Induction Control Module: Service and Repair
Throttle Valve Control Module
‹› Torque wrench (VAG 1410)
Removing
and Air Induction/Service Precautions/Clean
Working Conditions/Multiport Fuel Injection.
- Remove the intake hose - 4 - between the throttle valve control module (J338) and the Mass Air
Flow (MAF) sensor (G70). To do so, disconnect air hoses - 1 and 2 - (compress securing ring) and
remove spring clamp - 3 -.
- Disconnect the connector - 1 - and bleeder hose - 2 -.
- Remove the bolts - arrows -.
‹› Seal the intake passage in the intake manifold using a clean cloth.
- Clamp off the coolant hoses using (3094) and disconnect them from the throttle valve connections
- arrows -.
Page 4363
- Guide the coolant pump - A - through between the longitudinal member and cylinder block and
remove it.
Installing
components.
Note the installed position of coolant pump before installing.
- Rotate the pulley so that the arrow - A - (relative to engine axis) points upward vertically. Holes in
the pulley must align opposite the bolts - arrows -.
- First, firmly bolt the engine mount to the engine, then align the engine/transmission assembly free
of tension via a shaking motion and tighten the bolts to the subframe.
‹› Tightening specifications for the engine and transmission mounts. Refer to => [ Fastener
Tightening Specifications ] See:
Engine/Specifications/Engine Assembly - Fastener Tightening Specifications.
- Install the lock carrier.
- Install the bracket for the reservoir and power steering line.
Page 4234
Part 3
Page 7391
‹› Install the nut so the centralizing shoulder faces the washer and runs into it when installed.
‹› Wiring harness must be routed under selector lever.
- Tighten nut to tightening torque => [ (Item 30) Nut, 10 Nm ] See: Valve Body Assembly Overview.
‹› Carefully hold selector lever - 1 - in place using pliers - 2 -, so that torque is not transferred onto
Multi-Function Transmission Range (TR) Switch
(F125).
‹› Make sure that slide valve - 3 - on valve body, in which the selector lever engages, is not
damaged.
- Connect connectors to solenoid valves - 2 - to - 9 - according to markings made previously.

Page 6707
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7567
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3645
Bearing shell - 2 - without oil bore for connecting rod cover.
- Place the bearing shells centrally into the connecting rod and connecting rod cap.

Page 5741
Part 2
Page 6255
Locations

Page 2510
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7873
End diagnosis.
Page 7156
- Remove nut - 1 -.
Refrigerant Oil: Capacity Specifications
Refrigerant Oil R134A, Capacities
Refrigerant Oil R134a, Capacities
Replacement A/C compressors supplied by the Parts Department are filled with 135 cc (fl. oz.) of
refrigerant oil. This is the total A/C system refrigerant oil capacity.
Refrigerant Oil R134a, Distribution
The total refrigerant oil quantity is distributed in the refrigerant circuit as follows:
Compressor approximately 50%
Condenser approximately 10%
Suction pipe approximately 10%
Discharge pipe --
Evaporator approximately 20%
Receiver drier approximately 10%
When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as
indicated above) into the new part before installation.
Refrigerant Oil R134A, Distribution
Refrigerant Oil R134a, Distribution
The total refrigerant oil quantity is distributed in the refrigerant circuit as follows:
Compressor approximately 50%
Condenser approximately 10%
Suction pipe approximately 10%
Discharge pipe --
Evaporator approximately 20%
Receiver drier approximately 10%
‹› When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as
indicated above) into the new part before
installation.
Refrigerant Oil R134A, Identification
Refrigerant Oil R134a, Identification
Use only the correct type of refrigerant oil (PAG oil) specified for use with R-134a and compressor
type.
Power Mirror Position Switch/Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 658
Page 4957
Page 6347
Note
Tip:
Warranty
Page 3177
8 Bracket
9 Intake hose
P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 2784
legend.
wiring diagram.
harness.


question.)
19 - Legend



‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 5763
Part 1
Page 3497
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 826
WHAT ARE TRACKS?
15-28, and so on).
Page 4846
Ground (GND)

Page 7725
- Turn locking mechanism on shift cable and on selector cable toward right until stop in direction of
- arrow -.
The spring presses locking mechanism into initial position.
- Rotate lock bracket - A - back into initial position in direction of - arrow -.
- Pull connecting pin (T10027) out of holes - A - and - B -.

Page 6796
Page 7384
- Carefully pull out Transmission Fluid Temperature Sensor (G93) - 7 - together with bracket from
valve body.
‹› For reinstallation, pay attention to mounting of bracket on Transmission Fluid Temperature
Sensor (G93).
- Unclip wiring harness at bracket - 8 -.
- Remove selector lever - 1 - on selector shaft.
‹› Carefully hold selector lever - 1 - in place using pliers - 2 -, so that torque is not transferred onto
Multi-Function Transmission Range (TR) Switch
(F125).
‹› Ensure the slide valve - 3 - on valve body, in which the selector lever engages, is not damaged.
Page 4503
Page 1515
legend.
wiring diagram.
harness.


question.)
19 - Legend



Service Precautions
Fuse Block: Service Precautions
Fuse And Relay Panels
CAUTION: Before beginning repairs on the electrical system:
- Obtain the Anti-Theft radio security code.
- Switch off all electrical consumers, switch off ignition and remove ignition key.
- Disconnect negative ( - ) battery terminal.
- When Disconnecting and Connecting battery terminals, observe all applicable Notes and torque
specifications, as well as instructions on performing OBD program and electrical system function
checks as specified.
Page 5142
Part 2
Page 6092
- Check the Fuel Primer Relay J643 socket 16/MOT to the Motronic Engine Control Module (ECM)
J220 electrical harness connector T121 terminal 65 for an open circuit or a short to Battery (+).
If no malfunctions are found in the wiring and the voltage supply was OK:
- Replace the Fuel Primer Relay J643.
If the fault does not return: Repair complete, Generate readiness code. See: Computers and
- End diagnosis.
If the fault does return and no malfunction is detected in the wiring and the voltage supply was OK:
Final procedures
End diagnosis.
Page 103
Page 3294
- Install dust cap - arrow - hand-tight in oil filter housing.
Oil Filter, TDI PD, Replacing
Removing
‹› Oil new O-rings before installation.
Loosen sealing cap - arrow - e.g. using ring wrench AF 36 or using socket insert AF 36 (T10125 ).
Installing
Page 5098
1 - Track Numbers

Page 7324
Part 2
Page 1279
Ground (GND)

Page 7445
Clutch Disc: Service and Repair Clutch Assembly Overview, LuK
Clutch Assembly Overview, LuK

2 Clutch plate
‹› Only replace together with SAC pressure plate
‹› Installed position:=> [ Installation Position of Clutch Plate ] See: Service and Repair/Clutch, LuK
3 SAC pressure plate
‹› SAC = "self-adjusting clutch"
Repair/Clutch, LuK
‹› Check spring connection and rivet connections => [ Checking Ends of Diaphragm Spring ] See:
Service and Repair/Clutch, LuK
A/T - Fluid Leaking Between Case Halves
Case: Technical Service Bulletins A/T - Fluid Leaking Between Case Halves
37 07 11
July 5, 2007
2015499
Condition
Vehicle Information
Transmission, Automatic Transmission Leaking Fluid
Transmission leaking automatic transmission fluid between case halves.
Production Solution
Implementation of starter area wash and clean process.
Service
^ Verify fluid leak at transmission case.
Note:
DO NOT replace the transmission pan gasket.
^ Photograph the transmission fluid leak.
Note:
Photo of transmission leak required for verification.
^ Contact technical assistance by selecting the "Technical Assistance" tab in ElsaWeb and follow
the instructions to obtain a 6 digit pin.
Warranty
Page 2209
Part 1
Page 378
Part 1
Page 4157
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3063
‹› Puller (T10112)
Page 4663
Checking wiring
Final procedures

Parking Assist Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Fuel Injectors, Checking
Fuel Injector: Testing and Inspection Fuel Injectors, Checking
Fuel Injectors, Checking
The following test procedure is used to diagnose all fuel injectors.
‹› Multimeter.
‹› Diode test lamp (12 V).
Test requirements
‹› The Fuel Injector fuse is OK.
‹› The Engine Speed (RPM) Sensor (G28) OK.
- Observe safety precautions.
- Observe rules for cleanliness.
Test procedure
Start diagnosis
- Disconnect the Fuel Injector electrical harness connectors from Fuel Injectors (N30, N31, N32,
N33, N83 ).
- Using a multimeter, check the Fuel Injector electrical terminals 1 to 2 for resistance.
- Replace the malfunctioning Fuel Injector Refer to the Repair Information.

Checking activation and wiring
- Connect a Diode test lamp (12 V) to the electrical harness connector terminals 1 and 2 of the Fuel
Injector to be tested.
Page 2149
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2981
Rain Sensor: Service and Repair
Flush-Bonded Windows
Rain Sensor
Removing
- Unclip rain sensor cover - 1 - using plastic wedge.
- Unhook clip - 1 - from retaining ring - 2 - and remove rain sensor - 3 - from windshield (light
bonding).
- Disconnect harness connector - 4 -.
Installing
When installing rain sensor after replacing windshield or rain sensor, the following must be
observed:
‹› As a replacement part, windshields are supplied with retaining ring. After installing windshield,
clean glass thoroughly in area of retaining ring
using cleaning solution (D 009 401 04).
‹› It is not possible to reuse rain sensor. Replacement is supplied with adhesive already applied for
installation of rain sensor to windshield. Bonding
can be used for only one installation.
‹› To guarantee function of rain sensor, rain sensor must be bonded to windshield completely free
of bubbles.
- Remove protective cover for adhesive from new sensor.
- Connect harness connector - 4 -.

Page 377
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6013
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1697
Part 3
Page 1979
WHAT ARE TRACKS?
15-28, and so on).
Page 3404
Protective Housing For Relays In Engine Compartment
Connecting.
Protective Housing for Relays in Engine Compartment
Removing
- Remove the housing forward - arrow -.
- Remove the cap.
- Disconnect the connectors.
Installing
Cable Router In Engine Compartment

Page 1270
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2526
cylinder.
Page 4598
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4308
WHAT ARE TRACKS?
15-28, and so on).
Generic Scan Tool
Air Injection Control Valve: Testing and Inspection Generic Scan Tool
Secondary Air Injection Solenoid Valve, Checking
‹› Multimeter.
Test requirements
‹› The Secondary Air Injection (SAI) Solenoid Valve ( -N112-) fuse OK.
‹› The Motronic Engine Control Module (ECM) Power Supply Relay (J271) fuse OK.
Test procedure
Start diagnosis
‹› Voltage is supplied to the Secondary Air Injection (SAI) Solenoid Valve (-N112-) from the
Motronic Engine Control Module (ECM) Power
Supply Relay (J271).
Procedure
- Disconnect the Secondary Air Injection (SAI) Solenoid Valve (-N112-) electrical harness
connector.
- Using a multimeter, check the Secondary Air Injection (SAI) Solenoid Valve (-N112-) terminals 1
to 2 for resistance.
Specified value: 3.5 - 8.5ohms (at approx. 20 °C)
- Replace the Secondary Air Injection (SAI) Solenoid Valve (-N112-).
Switch the ignition ON.
- Using a multimeter, check the Secondary Air Injection (SAI) Solenoid Valve (-N112-) electrical
connector terminal 1 to ground for voltage.
Switch the ignition OFF.

Page 7487
Clutch Switch: Service and Repair
Clutch Pedal Switch
In order to assure secure fitting, clutch pedal switch (F36) must not be installed more than once.
Removing
- Disconnect connector from clutch pedal switch ( F36).
- Rotate clutch pedal switch (F36) at housing 45 degrees toward left and remove from mount.
Installing and Adjusting
During installation of clutch pedal switch, clutch pedal always remains in rest position (not
operated).
‹› Check clutch pedal switch first.
‹› Stop - A - must be located in front of section - B -.
‹› Stop - C - is then located directly below take-up hook.
If this is not the case, plunger must not be pulled out.

Wiring Harness: Customer Interest A/T - Won't Shift Out of PARK/DTC's U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 4192
WHAT ARE TRACKS?
15-28, and so on).
Page 1397
Power Door Lock Switch: Service and Repair
Driver/Front Passenger Interior Locking Switch
Removing
- Disconnect the connector on the switch.
- Loosen the switch housing - A - by pushing it on the side from the frame - B - and remove it.
Installing
Page 7075
Part 2
Page 1500
Part 3
Page 7893
Warranty

Specifications
Valve Clearance: Specifications
Valve Clearance
This engine is equipped with hydraulic lash adjusters. No adjustment is required.

Page 7313

Fluctuation
Condition
Production Solution
Service
the driver has
position.
Warranty
Information only.
required.
M/T - Humming Noise When Turning at Low Speeds
Fluid - M/T: All Technical Service Bulletins M/T - Humming Noise When Turning at Low Speeds
34 06 02
June 12, 2006
2011899
Affected Vehicles
Supersedes TB Group 34 number 06-01 dated June 5, 2006 due to Golf model
Condition Customer States Humming Sound From Front of Vehicle During Cornering
Customer may state humming sound coming from front of vehicle on turns in vehicles equipped
with 02J or 0A4 manual 5 speed transmission. The hum may be more noticeable during slow
speed turning maneuvers with steering wheel almost to full travel. The hum diminishes with
steering wheel straight.
Hum may be generated by the differential spider gear contacting the one piece thrust washer when
under load.
Production Solution
New transmission oil Part No. G 055 726 A2 incorporated in transmission production plant.
Transmissions with new oil installed begin with VINs in table.
Service
0A4 Manual 5 Speed Transmission, Draining and Re-filling
If the vehicle exhibits this condition, drain and re-fill transmission as follows:
- It is no longer possible to accurately check transmission oil level in the same manner as previous
model years.
Page 7595
1 Pressure bolt (E-15)
2 Bell (E-40)
5 High pressure hose with quick-release
Wheel Bearing, Removing
- Assemble thrust piece - 1 - with collar to wheel bearing, thrust sleeve - 2 - with four stepped inside
diameters to wheel bearing housing, hollow piston cylinder - 3 - with tie bolt and special nut - 4 -.
- Pull out wheel bearing by actuating pump.
2 Thrust sleeve (E-65-1)
Bearing Inner Race, Removing from Hub

Page 3320
Brake Bleeding: Service and Repair Brake and Clutch System, Changing Brake Fluid
Brake and Clutch System, Changing Brake Fluid
Application Information and Safety Precautions
‹› From model year 2006, a new brake fluid is introduced.
‹› The new brake fluid can also be used for older vehicles.
‹› New brake fluid can be mixed with previous brake fluid.
CAUTION! ‹› Brake fluid must never come into contact with fluids containing mineral oils (oil, gas,
cleaning solutions). Oils containing minerals
damage seals and sleeves on brake systems.
‹› Brake fluid is poisonous. Also, do not let brake fluid come into contact with paintwork.
‹› Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake
fluid in air-tight containers.
‹› Wash off brake fluid spillage using plenty of water.
‹› Do not reuse used / extracted brake fluid!

Brake Fluid Specifications
Permitted specifications:
‹› Brake fluid corresponding to US standard FMVSS 116 DOT 4 (previous brake fluid).
‹› Brake fluid conforming to VW norm, VW 501 14 (new brake fluid).
Brake Fluid, Changing
‹› Brake filling and bleeding tool ( VAS 5234)

Page 2970
WHAT ARE TRACKS?
15-28, and so on).
Page 5887
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7943
Part 1
Page 6375
Workshop procedure
on the DTC log.
misfires.
any steps.
Warranty
None
Page 1595
Lateral Accelerometer: Locations Electrical and Electronic Component Locations, From MY 2006

4 ESP sensor unit (G419)
‹› Removing and installing => [ ESP Sensor Unit, from 12.01 ] See: Service and Repair/ESP
Sensor Unit, From 12.01.
‹› Combined transverse acceleration sensor (G200) and rotation rate sensor (G202)
‹› Combined in one housing

Page 7537
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1409
Part 3
Page 6469
Part 3
Page 2803
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4257
Page 1628
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6401
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4139
Part 2
Page 4774
accessible.
‹› Multimeter.
Test requirements
box B is OK.
Test procedure
Start diagnosis
Page 2324
‹› Multimeter.
Test requirements
Test procedure
Testing and Procedures/Preliminary Check.
Start diagnosis


Page 541
Page 4323
WHAT ARE TRACKS?
15-28, and so on).
Page 3797
Removing
Installing
Page 687
Front Axle
Wheel Speed Sensor: Service and Repair Front Axle
ABS Component Overview

‹› Removing and installing parts of the ABS system is the same for brake calipers FS III and FN3.
4 Cover plate
5 Hex bolt, 10 Nm
6 Wheel bearing
8 Brake disc

Diagrams
Coolant Line/Hose: Diagrams
Coolant Hose Connection Diagram

1 Radiator
‹› Removal and installation, refer to => [ Radiator ] See: Engine, Cooling and Exhaust/Cooling
System/Radiator/Service and Repair.
‹› Replace the coolant after replacing.
2 Oil Cooler
3 Coolant Pump and Coolant Thermostat
‹› Coolant pump removal and installation, refer to => [ Coolant Pump ] See: Engine, Cooling and
Exhaust/Cooling System/Water Pump/Service
and Repair.
‹› Thermostat removal and installation, refer to => [ Coolant Thermostat ] See: Engine, Cooling and
Exhaust/Cooling System/Thermostat/Service
and Repair.
‹› Checking coolant thermostat - item 16 - => [ Coolant Thermostat ] See: Engine, Cooling and
Exhaust/Cooling System/Service and
Repair/Removal and Replacement/Cooling System Components, Engine Side.
4 Cylinder Head/Cylinder Block
5 Expansion Tank
‹› With the sealing cap

Page 5108
Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioner Bolt ...............................................................................................................
....................................................................... 10 Nm
Page 364
Part 3
Page 43
- Antenna cables - New Beetle with Satellite radio (convertible)
- Antenna cables - W8 Passat

Page 5625
WHAT ARE TRACKS?
15-28, and so on).
Page 5484
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1929
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6773
^ Obtain the owners written consent (see Control Module Tuning form) for any requested repair
under warranty or outside warranty that requires flashing, which will automatically overwrite the
"Tuned" program.
Production Solution
Service
1. Ensure the Technical Bulletin stating the condition in the vehicle applies to the customer concern
and the operator has a valid GeKo user ID and
password. Only perform operations explicitly stated in the Technical
Bulletin or RVU.
Page 4750
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2768
1 - Track Numbers

Page 1888
Part 1
Page 1565
1 - Track Numbers

NOTE:
J217.
Procedure
0301
Removal
J217.
Installation
Page 72
Audio Control Relay: Diagnostic Aids
Page 3221
Fluid - A/T: Testing and Inspection ATF Level, Checking
ATF Level, Checking

The ATF temperature should not be more than approx. 30° C at start of test.
‹› Transmission not in emergency running mode; ATF temperature not above approx. 30 °C
‹› Vehicle must be standing level
‹› Selector lever in "P".
- Connect "tester" and continue switching until it is ready for operation => [ VAS 5051, Connecting
and Selecting Functions ] See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Scan Tool Testing and Procedures.
- Press "right" Guided Functions.
- Press ->.
Page 366
Page 2381
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 5172
Final procedures

Page 52
Part 1
Page 159
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 945
Ground (GND)

Page 2769
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2163
- Insert rain sensor - 3 - in retaining ring - 2 - and bond to windshield without bubbles.
- Install clip - 1 -.
- Install rain sensor cover - 1 -.

Page 1901
WHAT ARE TRACKS?
15-28, and so on).
Page 5929
Part 1
Page 2227
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6045

Page 408
Part 1
Page 358
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1609
WHAT ARE TRACKS?
15-28, and so on).
Page 7867
Part 3
Locations
Page 3918
- Insert a drift - 1 - into bore in (3364).
- Using the drift - 1 - as a lever, pull out the valve stem oil seal - arrow -.
Installing
- Place the plastic sleeve - A - on the valve stem to prevent damage to the new valve stem oil seal -
B -.
- Oil the sealing lip of valve stem oil seal - B -, insert in into the (3365) and carefully slide it onto the
valve guide.
- Remove the plastic sleeve - A -.
- Install the valve spring and valve spring retainer.
- Install the (VAS 5161) as shown.
Intake Side
U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 4812
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6696

- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
resistance.

Page 2840
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3586
Ground (GND)

Page 1852
Page 7434
- Carefully pull out Transmission Fluid Temperature Sensor (G93) - 7 - together with bracket from
valve body.
‹› Pay attention to mounting of bracket on Transmission Fluid Temperature Sensor (G93) for
reinstallation.
- Disengage wiring harness at bracket - 8 -.
- Disconnect connector - 1 - from transmission connector.
- Remove bolt of 8-pin transmission connector.
- Disconnect connector and wiring harness outward from transmission housing.

Page 1830
Ground (GND)

Page 4210
Part 2
Page 5156
1 - Track Numbers

Page 4391
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3661
- Remove the locking bolt - 1 - from the rear of the cylinder block.
- Look through the threaded hole and check whether the bore - 2 - in the crankshaft aligns with the
threaded hole.
Use a mirror to do so.
- Rotate the crankshaft slightly if necessary.
- If the holes align, install the (T40069) completely into the threaded hole and tighten it to 10 Nm.
- Check whether the crankshaft can be rotated.
After Disassembly and Assembly Work
- Remove the (T40069) and install the locking bolt - 1 - to the cylinder block.
Page 4449
WHAT ARE TRACKS?
15-28, and so on).
Page 6410
If the wiring was OK and the LED did not blink:
- Connect the Ignition Coils with Power Output Stage (N70, N127, N291, N292, N323) electrical
harness connectors to the Ignition Coils with Power Output Stage (N70, N127, N291, N292, N323).
- Install the Ignition Coils with Power Output Stage (N70, N127, N291, N292, N323) electrical
harness screws.
Final procedures

Page 3825
- Lay sealing ring in oil filter housing seal groove so service flag -A- is aligned toward top.
- Press sealing ring into seal groove and check whether ring contacts entire groove evenly by
feeling above sealing ring with finger -arrows-.
- Press new oil filter insert -2- onto oil filter housing center tube -4- as far as stop.
- Install oil filter housing -4- with new sealing ring -3- and new oil filter insert -2- by hand until almost
on oil filter housing stop -1-.
- Tighten oil filter housing -2- to 25 Nm.

Page 7345
Warranty

Page 3464
Part 1
Page 1502
Page 2873
- Remove nut - 1 -.
Installing


Page 2778
Suspension Fluid Temperature Sensor: Diagnostic Aids
Page 1762
Part 1
Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's 00545/00638
Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 5918
Page 2480
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4358
- Disconnect the hose - 3 - from the air filter housing.
- Remove the bolts - 4 and 6 - and remove the air filter housing.
- Remove the battery.
- Remove the battery holder bolts - arrows - and holder.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] See: Engine/Drive Belts, Mounts, Brackets
and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Ribbed Belt.
- Remove the rear bolt - arrow - for the engine mount through the wheel housing.
Page 5307
- Using a multimeter, check the ABS Control Module (J104) electrical harness connector through
the Data Bus Diagnostic On Board Interface (J533) in the instrument cluster wiring harness to the
Engine Control Module (ECM) ( J220) electrical harness connector for short to ground, high
resistance or an open circuit. Refer to the Wiring Diagrams for harness details.
- Check the wiring connection for short to ground, high resistance or an open circuit.
If no malfunction is found in the wiring and the Terminal Resistance was Not OK:
If no malfunction is found in the wiring and the Terminal Resistance was OK:
- Replace the Data Bus On Board Diagnostic Interface (J533) (a component of the instrument
cluster).
Final procedures
Data Bus On Board Diagnostic Interface Gateway

Instrument clusters from 06.99 are integrated into the vehicle CAN Data Bus network (may also be
known as "CAN-Bus" or "Data-Bus ").
The data bus on board diagnostic interface (J533 ) (which is integrated into the instrument cluster)
enables data to be exchanged between the vehicle CAN Data-Bus network and the Data Link
Connector (DLC) "K-wire".
The data bus on board diagnostic interface (J533 ) has specific On Board Diagnostic (OBD)
capabilities and requires a separate address word.
On replacement instrument clusters, the data bus on board diagnostic interface (J533) must be
coded according to vehicle market version and equipment level variables.
Page 2442
Part 2
Page 5788
Air Injection Control Valve: Service and Repair
‹› Assisting hose, for example, coolant hose
Sequence
‹› Do not use compressed air during the following check!
- Disconnect the pressure hose - 2 - from Secondary Air Injection (AIR) solenoid valve (N112) - 3 -.
To do so, compress the securing ring.
- Disconnect the harness connector - 4 -.
- Slide the assisting hose - 1 -, for example, coolant hose, into the AIR solenoid valve.
- Blow forcefully into the assisting hose - arrow -.
Valve must be closed.
If air can be blown through the valve with the assisting hose properly sealed:
- Replace the AIR solenoid valve.
If valve is closed:
- Connect terminals on the connector connection - 5 - with adapter cables from (VAG 1594C) to the
battery positive (+) and negative (-).
Valve must be opened.
If no air can be blown through the valve with the assisting hose properly sealed:

Page 7223
WHAT ARE TRACKS?
15-28, and so on).
Page 4024
- For fuel filter
Page 3985
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 71
Page 5667
Part 3
Ignition Coil: Customer Interest Ignition System - MIL ON/DTC's P0300-P0312 Stored
28 10 01
March 31, 2010
2023121
Page 1101
Part 3
Page 5961
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4292
Part 3
Page 2918
WHAT ARE TRACKS?
15-28, and so on).
Page 7570
Part 2
Page 1938
Ventilation Switch: Diagnostic Aids
Page 7533
1 - Track Numbers

Page 6096
9 Breather Valve
Page 3122
3 Fuel Supply Line
‹› Black
4 Fuel Return Line
‹› Blue
‹› 4 bar
BPS ] See: Tune-up and Engine Performance
Checks/Fuel Pressure/Testing and Inspection/Fuel Pressure Regulator and Residual Pressure

Checking, Engine Code BPS.
6 Gasket
‹› Replace
7 O-ring
‹› Replace
8 Fuel Supply Line
‹› Black
9 Bolt, 3 Nm
10 Bracket

Page 1703
Checking wiring


Page 2206
Ground (GND)

Page 1144
1 - Track Numbers

Page 7115
7 24
8 25
- End diagnosis.
Final procedures
End diagnosis.
Service and Repair
Neutral Start Relay: Service and Repair
‹› New Beetle
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Service and Repair
Lock Cylinder
Connecting.
Removing
1. Position "Off"
2. Position "Run"
3. Position "Start"
Page 586
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7403
Page 2282
Page 2562
1 - Driver/Passenger Sensor
2 - Bolt
‹› 9 Nm
3 - Connector
4 - Carpet
Driver/Front Passenger Side Airbag Sensor Assembly Overview From 05/03
Airbag
Driver/Front Passenger Side Airbag Sensor Assembly Overview from 05/03

Page 3302
fluid dipstick.
Continuation for all engines:
- Clean dipstick with clean cloth.
- Screw cap on hand-tight and remove again.
‹› Screw cap fully in to get an accurate fluid level reading.
- Check fluid level: the oil level must be between the min. and max. markings.
‹› If fluid level is above MAX. marking, the fluid must be extracted.
‹› If fluid level is below MIN. marking, then the power steering system must be checked for leaks
(repair measure). It is not sufficient just to add
fluid. If power steering system is properly sealed, fill with fluid ( G 002 000).
- Screw in sealing cap hand-tight (using screwdriver).

Page 7059
Removing
arrow 2 -.
"learning" process.
Installing
Page 1812
Ground (GND)

Page 5423
Removing
spring clamp - 3 -.
Page 7646
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7215
- Install selector lever handle => [ Selector Lever Handle ] See: Shifter A/T/Service and
Repair/Removal and Replacement/Selector Lever Handle.
- Check selector mechanism => [ Selector Mechanism, Checking ] See: Shifter A/T/Testing and
Inspection.

Page 1777
legend.
wiring diagram.
harness.


question.)
19 - Legend



Electronic Throttle Actuator: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2403
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3351
Fuse: Locations Fuse Arrangements In Fuse Bracket/Battery, From July 2005
Fuse Arrangements In Fuse Bracket/Battery
Sealing Flange and Drive Plate/Flywheel Assembly
Overview
Sealing Flange, Engine Front: Service and Repair Sealing Flange and Drive Plate/Flywheel
Assembly Overview
Sealing Flange and Drive Plate/Flywheel Assembly Overview
2 Bolt, 50 Nm + 90 (1/4) additional turn
‹› Quantity: 5
‹› Replace
3 Bolt, 10 Nm
4 Sealing Flange, Belt Pulley Side
‹› With a integrated seal.
‹› Removal and installation, refer to => [ Sealing Flange, Belt Pulley Side ] See: Sealing Flange,
Belt Pulley Side.
5 Cylinder Block
6 60 Nm + 90° (1/4) additional turn
‹› Replace
Page 7647
Ground (GND)

Page 4211
Part 3
Application and ID
Torque Converter: Application and ID
Torque Converter Identification
Different types of torque converters exist. Identification is performed via code letters - arrow -.
Torque converter code letters - arrow -
(Transmission installed)
Torque converter/transmission allocation

Page 248
Vehicle Information
Sunroof and Central Control Module -J393- Diagnosis
Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged,
battery being disconnected, power to sunroof being interrupted while in operation, or a faulty
central control module.
Production Solution
Service
Symptoms
Sunroof inoperative.
Sunroof will not close (stuck open or stuck open in the tilt position).
Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when
sunroof switch is turned to the open position).
Warranty
When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty
Policy and Procedures Manual and ElsaWeb.
removal.
Page 2060
1. Headlamp Dimmer/Flasher Switch (E4) -> terminal 30
3. Turn Signal Switch (E2) -> terminal L
4. Parking Lamp Switch (E19) -> terminal P
5. Turn Signal Switch (E2) -> terminal 49a
6. Signal Horn Activation (H) -> terminal 71

8. Headlamp Dimmer/Flasher Switch (E4) -> terminal 56b
9. Parking Lamp Switch (E19) -> terminal PL
10. Parking Lamp Switch (E19) -> terminal PR
11. Turn Signal Switch (E2) -> terminal R
12. Headlamp Dimmer/Flasher Switch (E4) -> terminal 56a

Page 5076
Checking wiring
Final procedures

Page 2541
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2935
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4955
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2805
Part 2
Page 4783
WHAT ARE TRACKS?
15-28, and so on).
NOTE:
J217.
Procedure
0301
Removal
J217.
Installation
Specifications
Technical Data
‹› 2 Replace the ECM. Refer to => [ Engine Control Module ] See: Powertrain
Management/Computers and Control Systems/Engine Control
Module/Service and Repair.

Body - Door Lock Rotary Switch Diagnostic Aid
Door Lock Cylinder Switch: Technical Service Bulletins Body - Door Lock Rotary Switch Diagnostic
Aid
57 07 08
July 30, 2007
2015633 Supersedes T.B. Group 57 number 07-07 dated July 18, 2007 due to modified door ajar
switch testing procedure.
Condition
Vehicle Information
Door Lock Rotary Switch Diagnostic Aid
Instrument cluster display shows door ajar, anti-theft alarm may intermittently sound, Battery may
discharge and / or power door lock inoperative.
Information only, to assist with diagnosis of door lock rotary switch and / or door ajar switch.
Production Solution
Service
Tip:
When performing the following procedure, two keys will be required.
To Check Rotary Switch Function (all vehicles except Passat):
2. Insert key into lock cylinder.
3. Rotate key to lock position and hold, windows should roll up.
4. Rotate key to unlock position, windows should roll down.
If windows do not operate as stated above:

1. Verify rotary position via Measured Value Block with VAS 5051/5052.
a. Select Guided Functions.
b. Select Door Control Module.
c. Read measure value block 5, function 4, Drivers Side Key Switch.
d. Cycle the key cylinder back and forth several times while monitoring measure value block 5,
function 4.
Tip: Ensure door is closed during the key cycling procedure.

Page 2990
3. Terminal 53e
4. Terminal 53c
5. not used
6. Terminal 53b
7. Interval operation
8. Terminal 53a
Page 5668
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1817
Part 3
Page 3289

Locations

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Pedal Assembly Overview
Clutch Pedal Assembly: Service and Repair Pedal Assembly Overview
Pedal Assembly Overview

1 Bulkhead
‹› With mount for bracket and master cylinder
2 Gasket
3 Mounting bracket
‹› For mounting clutch pedal
4 Bolt
5 Mounting bracket
‹› For mounting accelerator pedal and brake pedal
‹› For mounting bracket to bulkhead
Page 1130
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4261
18 - Bracket For radiator Note installation position
19 - 5 Nm
Page 4796

Page 6819
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3845
‹› Checking, refer to => [ Oil Pressure and Switch, Checking ] See: Engine Oil Pressure/Testing
and Inspection.
5 from Intake Hose
‹› See - item 1 - in => [ Intake Tube ] See: Tune-up and Engine Performance Checks/Air Cleaner
Housing/Service and Repair/Removal and
Replacement.
6 Vent Hose
7 Dust Cap
‹› Draining, refer to => [ Oil Filter Housing, Draining ] See: Oil Filter Housing/Service and Repair.
9 Seal
‹› Replace
‹› Drain the oil filter housing before removing, refer to => [ Oil Filter Housing, Draining ] See: Oil
Filter Housing/Service and Repair.
11 Gasket
‹› Replace
12 Oil Cooler
‹› See note in => [ General Repair Information ] See: Description and Operation/General Repair
Information.
‹› Coolant hose connection diagram, refer to => [ Coolant Hose Connection Diagram ] See: Cooling
System/Diagrams.
13 Bolt, 25 Nm
15 Gasket
‹› Replace
Page 4807


Page 5944
Final procedures

Page 2138
Part 1
Page 270
Ground (GND)

Page 3548
Wheel Bearing: Aftermarket Tools
Rear Wheel Bearing Press
AST tool# 3420
VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle.
- VW/Audi Rear Wheel Bearing Press
- Applicable to Newer Golf, Jetta and New Beetle

Page 4795

Page 2566
Installation

- Close doors.
and/or user manual.

Page 6419
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 2831
7 24
8 25
- End diagnosis.
Final procedures
End diagnosis.
Page 7420
Tip:
Page 6827
Page 7070
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 884
NOTE
If a connection error is indicated for Seat Occupant Recognition Module not found", an "ERROR"
indicator on the VAS 5052 / VAS 6150 screen is highlighted.
^ Check all connections.
^ Restart application by pressing EXIT".
^ Switch ignition key ON and then OFF
^ Begin procedure again.

If error continues, try rebooting scan tool and re attempt to perform programming update.
After programming is complete or verified flash was already applied,
^ Disconnect VAS 6103/2 pods connector and VAS 6103 from scan tool.
^ Reconnect 5052/3 diagnostic cable to VAS 5052 I VAS 6150 tester and reconnect vehicle Data
Link Connector.
^ Reconnect and lock Seat Occupant Recognition Module 10 pin connector to body 10 pin
connector. Be sure that the connector snaps locked.
^ Switch ignition ON.

Page 1976
1 - Track Numbers


Muffler With Mounts Assembly Overview
Muffler: Service and Repair Muffler With Mounts Assembly Overview
Muffler with Mounts Assembly Overview

1 from Catalytic Converter
2 Double Clamp
‹› Note the installed position, refer to => [ Installed Position of Double Clamp ].
3 Bolt, 25 Nm
4 Suspended Mount
‹› Note the installed position, refer to => [ Installed Location of Mountings ] See: Service and
Repair/Removal and Replacement/Exhaust
System, Installing.
5 Front Muffler
‹› Aligning, refer to => [ Installing Front Muffler Free of Tension ] See: Service and Repair/Removal
and Replacement/Exhaust System,
Installing.
6 Separating Point
‹› For repairs.
‹› At the factory, the front and rear mufflers are installed as a single component. Replacement front
and rear mufflers are supplied separately,
with a double clamp for connecting the joint.

Page 4869
Page 3197
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5975

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 7653
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 493
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7508
Pressure Plate: Service and Repair Clutch, LuK
Clutch, LuK
‹› Flywheel retainer (3067)
‹› Centering mandrel (3190 A)
‹› Grease for clutch disc splines (G 000 100 )
Removing
- Remove transmission => [ Transmission, Removing ] See: Manual

Transmission/Transaxle/Service and Repair/Removal and Replacement/Transmission, Removing.
- Insert flywheel retainer (3067) to loosen bolts.
- Loosen bolts in a diagonal sequence and in stages.
- Remove pressure plate and clutch plate.
Installing

‹› Pressure plate and clutch plate must only be replaced together. Allocate pressure plate and
clutch plate via engine code.
Installation Position of Clutch Plate

Page 7590
2 Brake disc
3 Brake pads
‹› Vehicles until model year 2000
Replacement.
4 Retaining spring
‹› Insert in both holes of brake caliper housing
5 Brake carrier
Page 3335
Page 857
Air Bag Control Module: Removal and Replacement
Airbag
be scrapped.
Airbag Control Module J234
Removing
‹› Prior to assembly of the control module, disconnect the battery ground cable.
- Remove the center console and remove the trim for the instrument panel center part.
- Press retaining tabs - 4 - down, tilt bracket - 5 - - arrow - and pull harness connector - 3 - out of
control module - 1 -.
- Remove nuts - 2 - and pull the control module from the stud (nut - 2 - = 6 Nm).
Installing
Further installation is performed in the reverse order of removal.
- Close all doors.

Page 5169
Electronic Throttle Actuator: Description and Operation Electronic Engine Power Control
Electronic Engine Power Control
For EPC, the throttle valve is not operated by a cable from the accelerator pedal. There is no
mechanical connection between the accelerator pedal and the throttle valve.
The position of the accelerator pedal is communicated to engine control module (ECM) by the
throttle position sensor / accelerator pedal position sensor 2 (variable resistances; stored in one
housing) that are connected with the accelerator pedal.
The accelerator pedal position (driver's intention) is a main input unit for the ECM.
Operation of the throttle valve occurs via an electric motor, the throttle drive for in the throttle valve
control module. This is true across the entire engine speed and engine load spectrum.
The throttle valve is operated by the EPC according to specifications of engine control module
(ECM).
With engine off and ignition switched on, the ECM controls the throttle drive according to
specifications of throttle position sensor / accelerator pedal position sensor 2. This means, if the
accelerator pedal is pressed half way, the throttle drive opens the throttle valve to the same
degree; i.e. throttle valve is then opened approximately half way.
With engine running under load, ECM can open or close the throttle valve independently of the
throttle position sensor / accelerator pedal position sensor 2.
This means, for example, that the throttle valve could be fully opened even though the accelerator
pedal has only been pressed half way. This has the advantage of preventing torque losses at the
throttle valve.
In addition, it results in a significant reduction in emissions and fuel consumption under certain load
conditions.
It would be incorrect to think that EPC consists of only one or two components. EPC is much more
of a system containing all components that contribute to recognizing, controlling and monitoring the
position of the throttle valve.
Page 4006
‹› Press in the securing ring to disengage the fuel line.
- Connect the (VAG 1318) with (VAG 1318/9) and (VAG 1318/17) to the fuel filter - 1 - and to the
supply line - 2 -.
- Open the shut off lever on the (VAG 1318). The lever points in the direction of flow.
- Reconnect the 4 pin harness connector to the fuel delivery unit.
- Measure the fuel pressure.
‹› Specified value: approximately 4.0 bar
If the specification is not obtained
- Check the delivery quantity of the fuel pump. Refer to => [ Delivery Quantity, Checking ] See:
Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Testing and Inspection/Fuel
Pump Checking, Engine Code BPS (Plastic Fuel Tank).
- If the fuel pump is OK, replace the fuel pressure regulator - item 5 - in => [ Fuel Pressure
Page 6278
Part 2
Page 5309
Rapid data transfer Q Tester sends address word 19
Indicated on display (example only):
[ 6N0909901 Gateway K -] CAN 0001 Coding XXXXXX WSC 00000
Readout, top line
‹› 6N0 909 901 = Control module identification
‹› Gateway K [-] CAN = System designation*
‹› 0001 = Software version
Readout, bottom line
‹› Coding XXXXXX: Code dependent on engine version and optional equipment
‹› WSC 00000 = Workshop Code
* The Data Bus On Board Diagnostic Interface (J533) (which is integrated into the instrument
cluster) is identified as "Gateway"
- Press -> button.
Indicated on display (select function):
Rapid data transfer HELP Select function XX
List of Available Functions
‹› Press the HELP button to print out a complete list of available functions. This list indicates the
function capability of the scan tool (VAG 1551)
only, and does not necessarily reflect the function capability of vehicle systems equipped with
OBD. For address word 19, do not attempt to select functions other than those listed above.
‹› After the function is completed and forwarded with the -> button, the scan tool (VAG 1551)
returns to the following start position:
Read Measuring Value Block Display Groups, Interpreting
Read Measuring Value Block Display Groups, Interpreting
=> [ Display Group 125, Overview ]

Page 247
2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to
removal of Jetta Wagon (A5) Models and reformatting of flowcharts.
Condition
Locations
Valve Body
Page 7865
Part 1
Page 1097
WHAT ARE TRACKS?
15-28, and so on).
Page 1518
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2986
3. Terminal 53e
4. Terminal 53c
5. not used
6. Terminal 53b
7. Interval operation
8. Terminal 53a
Page 5235
^ Check for DTC in the table shown.
If DTC is listed in the table:
The ECM hardware is not the cause of the DTC, further diagnosis is required.
DO NOT replace an ECM for DTCs listed in the table.
See "EXCEPTION!" notes following table
Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software:
see "EXCEPTION!" notes following table.
If DTC IS NOT listed in the following table:
DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or
Repair Manual as necessary).
ALWAYS check for Technical Bulletins with possible software updates for the condition.
Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding.
Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions,
first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or
Guided Fault Finding before replacing ECM.
Page 7820
1 - Track Numbers

Page 7253
‹› If retaining tabs - arrows - are damaged, cover must be replaced completely.
- Install center console.
- Install selector lever handle => [ Selector Lever Handle ] See: Selector Lever Handle.
Page 2299
Ground (GND)

Page 585
WHAT ARE TRACKS?
15-28, and so on).
Page 2025
Part 3
Page 5164
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4743
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4694
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2100
legend.
wiring diagram.
harness.


question.)
19 - Legend



Ultrasonic Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2305
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4504
Page 576
Hazard Flasher Relay: Diagnostic Aids
Page 6432
Final procedures

Page 881
New Beetle:
^ Plug pods connector end of VAS 6103/2 onto seat harness going to the PODS.
^ Use adapter cable VAS 6103/2-1 and connect it to VAS 6103/2 cable as shown above.
^ Connect remaining end of VAS 6103/2-1 to seat harness going to the PODS.
New Beetle:
^ Move passenger seat height adjustment to fully upright position.
^ Identify 10 pin Seat Occupant Recognition Module connector (1) underthe right front edge of
seat.
TIP
^ Disconnect black Seat Occupant Recognition Module harness connector from bracket.
Page 6074
Page 605
Part 3
Page 5023

Page 555
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4218
- Remove the fan shroud.
Installing
Page 2971
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3897
‹› For line - item 4 -.
8 Fuel Rail
‹› Assembly overview, refer to => [ Fuel Rail and Injectors Assembly Overview ] See: Powertrain
Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Fuel Rail and Injectors Assembly Overview.
9 Fuel Supply Line
10 Gasket
‹› Replace
Casting mark points upward.
11 Intake Manifold
‹› Removal and installation, refer to => [ Intake Manifold ] See: Intake Manifold.
12 O-ring
13 Manifold Absolute Pressure (MAP) Sensor (G71 )
14 Bolt, 3.5 Nm
15 Coolant Connections
‹› Only for the throttle valve control module heated by coolant.
16 Bolt, 6.5 Nm
‹› With the throttle drive (for Electronic Power Control (EPC)) (G186), throttle drive angle sensor 1
(for EPC)) (G187) and throttle drive angle
sensor 2 (for EPC) (G188)
18 Seal
Humidity Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3049
Fuel Filter
Removing
connection.
Installing

Page 4212
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 119
Page 6876
plan)
TCM.
Warranty
Information only.
Page 5880
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3734
6. Ribbed belt, for the A/C compressor
7. Crankshaft pulley/vibration damper
8. Ribbed belt tensioner pulley, for the A/C compressor belt
9. Ribbed belt tensioner pulley, for the generator, power steering pump and coolant pump belt
10. Coolant pump pulley
Ribbed Belt
Ribbed Belt
‹› Locking pin (T10060A)
Removing
- Remove the right main headlamp.
- Remove the noise insulation.
- Remove the right front wheel housing liner.
Removing the Ribbed Belt for the Air Conditioning (A/C) Compressor
- Mark the direction of rotation of the ribbed belt.

- Rotate the belt tensioner - 1 - as shown using a 15 millimeter (mm) box end wrench - A - in the -
direction of the arrow - and secure using (T10060A ).
- Remove the ribbed belt for the A/C compressor.
Removing the Ribbed Belt for the Generator, Power Steering and Coolant Pumps
- Relieve the tension on the belt tensioner - 1 - for the A/C compressor belt (pull out the
(T10060A)).
- Mark the running direction of the ribbed belt for the generator, power steering and coolant pumps.
- Insert the (T10060A) into the belt tensioner - 2 -.

Page 2564
Installation

- Close doors.
and/or user manual.

Page 6125
Part 3
Page 4151
Ground (GND)

Page 3628
Checking wiring
open circuit.
Ground.
Final procedures

09.

Code.
Page 4143
Radiator Cooling Fan Control Module: Diagnostic Aids
Page 4182
Checking wiring


Page 3485
Page 7069
1 - Track Numbers

Computers/Controls - Software Version Management
Info.
PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls -
Software Version Management Info.
01 10 05
April 1, 2010
2014603 Supersedes T.B. Group 01 number 08-36 dated Dec. 10, 2008 due to additional SVM
function information and to include Response Codes with explanation.
Vehicle Information
Condition
Software Version Management
This Technical Bulletin details the general process for carrying out a Software Version
Management (SVM) software update for any Technical Bulletin/RVU.
Troubleshooting information is included in the Additional Information Section.
SVM is a function within GFF with the options illustrated in Figure 1.
SVM is a process to update the programming in flashable (re-programmable) control modules

and/or to document changes in software levels in Volkswagen vehicles. This system uses the VAS
5051B, VAS 5052, VAS 5052A or VAS 6150 diagnostic tools to send vehicle-specific data to the
SVM database, to download instructions from the SVM database, and to program control modules
for identified software updates.
The technician must first diagnose the condition in the vehicle and find a Technical Service Bulletin
that describes that condition. This conditional bulletin specifies the appropriate Unit Code (Action
Code) for the programming update. SVM eliminates the need to wait for Flash CDs to be sent to
the dealer and problems such as scratched or missing discs, and allows the updates to be
performed faster and more efficiently at the dealership.
Note:
An Update Programming procedure (flash) may overwrite any "TUNED" ECM or TCM
programming. A "TUNED" ECM or TCM is described as any ECM or TCM altered so as to perform
outside the normal parameters and
specifications approved by Volkswagen Group of America, Inc.
Current Tuned ECM or TCM requirements:
If you encounter a vehicle with a "Tuned" ECM or TCM, your dealership must do the following
before performing any procedure that updates ECM or TCM programming:
^ Notify the owner that their ECM or TCM was found to have been tuned
^ Notify the owner any damage caused by the tuning of the ECM or TCM (including any adverse
Page 5440
Page 5737
Ground (GND)

Page 4788
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5161
Part 1
Page 4064
- Disconnect the hose - 3 - from the air filter housing.
- Remove the bolts - 4 and 6 - and remove the air filter housing.
- Remove the battery holder bolts - arrows - and holder.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] See: Drive Belts, Mounts, Brackets and
- Remove the rear bolt - arrow - for the engine mount through the wheel housing.
Angle Sensor -1- For Throttle Drive (Power Accelerator
Actuation) G187
Angle Sensor -1- For Throttle Drive (Power Accelerator Actuation) G187
Page 5759
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3426
Adaptation channel 45 adapts the instrument panel insert to the quality of oil.
- Confirm entry with "Q" button on display number block.
- Drag the cursor - arrow - on the display to the left, until the adaptation value - 1 - is indicated
above the scroll bar 1.
‹› The adaptation value shows the current status of the engine oil quality:
4 LongLife Service diesel engines: engine oil conforming to VW standard 506 00 (TDI) or VW
standard 506 01 (PD TDI)
2 LongLife Service for gasoline engines: engine oil conforming to VW standard 503 00
1 Time- or distance-dependent service: no engine oil according to VW-Norm 503 00 (gasoline

engines), 506 00 (TDI) or 506 01 (pump injector TDI)
‹› If the instrument panel insert is to be coded to "flexible" (LongLife service), the adaptation value 4
must be selected for diesel engines and/or the
adaptation value 2 must be selected for gasoline engines.
By selecting the adaptation value 1, the instrument panel insert is coded "non-flexible", i.e. "time or
distance dependent ".
- Press the "Save" button - 2 - on display.
Page 1865
Part 3
Page 7452
- Use centering mandrel (3190 A) to center clutch plate.

Page 4851
Part 3
Page 1832
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Fuel Pressure Regulator: Testing and Inspection
Injection.
replaced.
‹› Observe the safety precautions. Refer to => [ Safety Precautions ] See: Service
Injection.
connection.
Page 1325
WHAT ARE TRACKS?
15-28, and so on).
Page 7444
Repair/Clutch, Sachs
‹› Check spring connections and rivet connections => [ Check Spring Connections and Rivets ]
See: Service and Repair/Clutch, Sachs
‹› Only replace together with clutch disc
4 M7 bolt, 20 Nm

Page 1764
Part 3
Page 89
Vehicle Information
Production Solution
Service
Symptoms
Warranty
removal.
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Page 4863
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 795
Page 2185
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 7390
- Hook wiring harness - 3 - into retainer - 7 - - arrow B -.
- Install selector lever - 2 - to selector shaft - 6 -.
Make sure pin of selector lever - 2 - engages in slide valve- 1 - - arrow A -, slider valve must be
positioned accordingly if necessary.
- Install washer - 5 - and nut - 4 - onto selector shaft - 6 -.

Locations

‹› Fuel level sensor removal and installation, refer to => [ Fuel Level Sensor ] See: Powertrain
Induction/Fuel Tank/Service and Repair/Removal and Replacement.

Oxygen Sensor Before Catalytic Converter, Checking
Heater
Heater
Oxygen Sensor before Catalytic Converter, Checking Heater
‹› Multimeter.
Test requirements
‹› The Heated Oxygen Sensor (HO2S) (G39) fuse S-243 is OK.
‹› Ignition switched off.
Test procedure
Start diagnosis
- Using a multimeter, check the Heated Oxygen Sensor (HO2S) (G39) connector between
terminals 3 and 4 for resistance.
Page 5714

Page 5117
WHAT ARE TRACKS?
15-28, and so on).
Page 1129
WHAT ARE TRACKS?
15-28, and so on).
Page 4481
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Navigation Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 302
WHAT ARE TRACKS?
15-28, and so on).
Page 1735
Temperature Switch (Warning Indicator): Diagnostic Aids
Page 996
Part 3
Page 3796

Page 284
1 - Track Numbers

Page 4124
^ Open the valve on the supply side for 2 seconds to purge the air from the hose (fig. 7).
^ Open valve on air hose side.
Leave valve open for ten minutes.

^ Close the valve on the air hose side and open the valve on the supply side.
^ Leave valve open on reservoir side while monitoring the gauge.
^ Wait for the gauge to settle at it lowest point and close the valve.
^ Remove VAS 6096 from vehicle.
^ Adjust coolant level as necessary.
^ Allow engine to idle for 5 minutes and re-check heater temperature output.
Warranty
Page 2665
Ground (GND)

Page 7705
- Remove center section of noise insulation below engine/transmission.
Clean transmission.
CAUTION! To drain gear oil, journal for shift forks in transmission must be removed.
To avoid that the position of the shift forks is changed, e.g. by involuntarily operating shift
mechanism, shift rod must be secured.
Secure Shift Rod as Follows
- Press down shift rod - direction of arrow 1 -.

Page 797
terminals.
Checking activation
Final procedures


09.

Code.
Locations
Cabin Air Filter: Locations
Dust and pollen filter
The filter is located in the right rear of the instrument panel under a cover.
Page 328
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3699
Piston Ring: Testing and Inspection
Piston, Rings and Cylinder Bore, Checking
Piston Ring Gap, Checking
‹› Feeler gauge
- Insert the ring into the bottom of the cylinder opening at a right angle from above, approximately
15 millimeter (mm) from cylinder edge.
Piston Ring Groove Clearance, Checking

Page 118
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 513
NOTE:
If condition exists, and instrument cluster has been updated, follow normal distonic procedures.
^ Replace instrument cluster with one of the selections from Required Parts table below.
^ See Repair Manual Group 90-Instruments for replacement procedure.
Tip:
Updated clusters will have the same part number as the old part, however they will be marked with
the letter "C" as mentioned above.
Make note of the odometer mileage of the vehicle.
^ Adapt instrument cluster using the GFF plan.
^ Verify correct odometer mileage setting of new instrument cluster after replacement.
NOTE:
It mat take up to 6 attempts to program the instrument cluster. If after 6 attempts instrument cluster
does not program, contact technical assistance or selecting the "Technical Assistance" tab in
ElsaWeb and follow the instructions to obtain a 6 digit access code.
Warranty
Information only.
Page 1948
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Locations

Page 1487
Page 6442
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 1928
1 - Track Numbers

Page 6331

Page 2057
Combination Switch: Diagnostic Aids
Page 1977
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 128
WHAT ARE TRACKS?
15-28, and so on).
Page 4881
1 - Track Numbers

Page 7822
Ground (GND)

Page 1676
- Remove nuts - a - from sender for rotation rate G202 - 1-.
- Remove sender for rotation rate G202.
Removing sensor for transverse acceleration G200
- Pry retainer - 1 - off sensor for transverse acceleration G200 - 2 - using a screwdriver.
- Remove sensor for transverse acceleration G200.
Installing
Installing sender for rotation rate G202
- Insert sender for rotation rate G202 and align so that it is straight.
- Tighten nuts - a - on sender for rotation rate G202 - 1 -.
Installing lateral acceleration sensor G200
- Insert lateral acceleration sensor G200 into bracket.

Page 2019
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 275
Part 3
Page 1493
1 - Track Numbers

Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 1263
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6071
Part 3
Page 2519
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 6135
Pin pressed in the - direction of the arrow -: Open
‹› Before installing change over valve, remove the cover from the fuel tank.
Pressure Retention Valve Checking
The pressure retaining valve is opened in both flow directions - arrow 1 - on the gravity valve side.
It is only open in one flow direction - arrow 2 - from the T-piece of the EVAP canister/solenoid valve
1.
Page 788
WHAT ARE TRACKS?
15-28, and so on).
Page 3017
Alignment: Tools and Equipment
Special Tools

Page 4715
Intake Air Temperature Sensor: Locations Component Locations Overview

Page 7975
Part 1
Page 3037
11 Air Duct
13 Intake Tube

Page 5904
Final procedures

Page 643
Tail Lamp Control Module: Diagnostic Aids
Page 6231
1 - Track Numbers

Page 2376
Page 7419
Page 4737
Ground.
Final procedures


Page 6713
Page 962
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Locations

Page 2479
WHAT ARE TRACKS?
15-28, and so on).
Page 3281
Wu-Ze
Worldwide List of Engine Oils

Page 913
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2377
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 6462
1 - Track Numbers

Page 4307
Ground (GND)

Heated Oxygen Sensor (HO2S) G39

Page 6472
Page 1305
Ultrasonic Sensor: Diagnostic Aids

F125

Page 4527
Page 3921
Valve Guide Seal: Tools and Equipment
Valve Seal Installer
AST tool# 3365
This tool is used to install valve stem seals on VW 2.8 liter V-6 5 valve per cylinder engines, 1.8
liter turbo 5 valve per cylinder engines, 4.0 liter W-8 4 valve per cylinder engines, Audi 4.2 liter V-8
5 valve per cylinder engines, 1.8 liter turbo 5 valve per cylinder engines and 3.0 liter V-6 5 valve
per cylinder engines.
- Made in Germany

Page 5264
order)
Tip:
Page 2897
G195, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
-.
Checking wiring
Page 656
Part 3
Specifications
Flex Plate: Specifications
Flywheel/Drive Plate Bolts to Crankshaft

........................................................................................... 60 Nm Final pass .....................................
..............................................................................................................................................................
...... Tighten 90°
Page 3424
Maintenance Required Lamp/Indicator: Testing and Inspection
Service Interval Display, Coding/Adapting
Service Interval Display, Coding in Vehicle OBD Using VAS 5051A
- On the display, press the button for "Vehicle On-Board Diagnostics " - arrow -.
‹› If the indications shown in the work procedure are not indicated on the display: User manual for
VAS5051 tester.
- Press "17 - Instrument panel insert" - arrow - on the display.
Page 963
Part 1
Page 2270

Page 209
WHAT ARE TRACKS?
15-28, and so on).
Page 2925
Page 7805
Ground (GND)

Page 3981
1 - Track Numbers

Page 449
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 495
Part 2
Page 6578
See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Scan
Tool Testing and Procedures.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Voice Activation Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7029
Warranty
Information only.
removal.
Page 6393
Workshop procedure
on the DTC log.
misfires.
any steps.
Warranty
None
Page 7191

Connector
Page 2380
Requirements:

Work procedure:
Page 4485
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4329
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Page 6613
Page 5192
Page 6741
^ No Stored DTCs, erase any stored DTCs.
Tool requirements:
^ Pass - Thru Vehicle Programming tool must be connected to the vehicle Data Link Connector
(DLC) and is connected to an Internet connection (Persistent connection is recommended).
^ Approved Battery charger.

Note:
Under no circumstances should the diagnostic connector or the Programming tool be unplugged
during the Pass - Thru Vehicle Programming procedure (damage to the ECM / TCM can occur).
Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF.
Procedure:
Page 3218
Fluid - A/T: Fluid Type Specifications
Planetary gearbox Lubricant ................................................................................................................

.................................................................................................. VW ATF Part number .......................
..............................................................................................................................................................
....................... G 052 162
Final drive Lubricant ............................................................................................................................

................................................... SAE 75w-90 Synthetic Gear oil Part number ..................................
..............................................................................................................................................................
............ G 052 145
Planetary gearbox and final drive Lubricant ........................................................................................

............................................................................................................................ DSG oil
Lubricant ..............................................................................................................................................
.......................................................... ATF G 055 025
Page 1890
Part 3
Page 6437
1. Lock Cylinder
3. Securing lever
Installing
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.


Page 5821
Part 3
Page 343
WHAT ARE TRACKS?
15-28, and so on).
Page 609
Headlamp Control Module: Service and Repair
HID Headlamp
HID Headlamp Control Module
‹› The Left HID Lamp Control Module (J343)/Right HID Lamp Control Module (J344) is not
equipped with OBD.
‹› The HID lamp control module for the right headlamp is attached to the right longitudinal member
and to the left longitudinal member for the left
headlamp. Removal and installation is the same for both sides.
‹› The illustrations show a Left HID Lamp Control Module (J343).
‹› Remove the ignition key.
Removing
- Remove front bumper cover.
- Remove the screws - arrows - on the bracket for the Left HID Lamp Control Module (J343).
- Remove both the bracket and the Left HID Lamp Control Module (J343).
- Remove the screws - arrows - on the Left HID Lamp Control Module (J343).
- Disconnect the connector from the Left HID Lamp Control Module (J343).
Page 3531
Note: ^
Be sure there is sufficient room when pulling out drive axle.
CAUTION: Place engine/transmission jack V.A.G 1383 A underneath (danger of accident if parts
Pulling out wheel hub
1. Pressure bolt E-15 2. Bell E-40 3. Hollow piston cylinder HKZ-15 4. Special nut E-8-214 and tie
bolt 5. High pressure hose with quick-release
Pulling out wheel bearing

Page 1590
Braking Sensor/Switch: Diagnostic Aids
Page 5054
Final procedures

Page 6121
WHAT ARE TRACKS?
15-28, and so on).
Emissions - Interim Repair For Recall 28F3
Ignition Coil: Recalls Emissions - Interim Repair For Recall 28F3
28 10 02
May 10, 2010

2021320 Supersedes T.B. Group 28 number 09-03 dated December 22, 2009 to remove vehicle
applicability covered by 28F3 campaign.
Vehicle Information
MIL ON or Flashing, Misfire DTCs P0300-0312 Stored in ECM

Specifications
Clutch Fluid: Specifications
Brake Fluid Type
Note: Does not apply to vehicles equipped with DSG transmissions. Refer to Automatic
Transmission/Transaxle for correct fluid specifications See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Specifications
Page 7335
- Remove nut - 1 -.
Installing


Page 1174
Antitheft Mode Switch: Diagnostic Aids
Page 37
- Antenna Selection Control Module -J515- (Diversity box)
All models use an Antenna Selection Control Module -J515- item -4-.
^ Location: Above rear glass under headliner.
Antennas
All models use four antennas.
^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5-
^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-.
- Jetta / Golf / Passat (non W8) - Antenna system
^ All models use External amplified antenna mast -1-.

Specifications
Thermostat: Specifications
Thermostat
Starts to open ......................................................................................................................................

......................................................... approx. 87° C End of opening ...................................................
........................................................................................................................................ approx. 102°
C Open distance ..................................................................................................................................
.............................................................. at least 7 mm
Bypass Thermostat
Starts to open ......................................................................................................................................

......................................................... approx. 75° C Opening end .......................................................
.......................................................................................................................................... approx. 85°
C Opens ..............................................................................................................................................
............................................................. approx. 5 mm
Page 1297
Ground (GND)

Page 4274
Page 2099
1 - Track Numbers

Page 4910
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2938
Part 3
Page 6072
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3873
Part 2

Page 3044
- For fuel tank
17 - Lock washer
Replace
21 - Fuel filter -
22 - Supply line -
Black
- To fuel rail
23 - Vent line -
White
24 - Seal -
Replace
- Check fuel pump.

27 - Supply line -
Black
- To fuel filter
28 - Return line -
Blue
- To fuel filter

Page 6624
1 - Track Numbers

Page 3270
Ca-Va
‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 6933
Part 1
Page 3588
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1194
1 - Track Numbers

Page 383
Auxiliary Cabin Heater Control Module: Diagnostic Aids
Page 1586
Part 2
Specifications
Engine Oil Pressure: Specifications
Engine Oil Pressure at 2000 RPM, oil temperature 80° C (176° F)
.................................................................................................................. 2.7 to 4.5 bar
Page 7834
- Multimeter
- Wiring diagram
Test procedure
Start diagnosis
1 -.
Checking wiring

Locations
Oil Filter: Locations
1.8L - 2.0L
- Loosen oil filter -arrow-
TDI - Diesel engines:
- sealing cap -1-
- O-rings -2- and -3-
- oil filter element -4-.
2.5L
- oil filter housing stop -1-

Page 2401
Ground (GND)

Page 1711
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6280
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7258
‹› If magnets are not on cover strips, replace cover strips.
- Insert cover strip - 2 - into lower section of frame - 3 -.
- Install upper section of frame - 1 - onto lower section of frame.
- Carefully engage upper and lower sections of frame to each other - arrows -.
‹› Replace the frame if the retaining tabs are damaged.
- Install cover => [ Selector Mechanism Cover and Circuit Board ] See: Removal and
Page 1295
1 - Track Numbers

Page 944
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5062
1 - Track Numbers

Page 3519
‹› Remove brake caliper housing before removing
‹› Do not separate brake discs from wheel hub with force or rust solvent, otherwise brake discs will
be damaged.
3 Brake pads
‹› Vehicles up to model year 2000
Replacement.
6 Concealment cap
‹› Remove
9 Socket-head bolt 8 Nm
11 Cover plate
12 Hex bolt, 10 Nm
13 Wheel bearing
14 Circlip
16 Brake pads
Page 2954
WHAT ARE TRACKS?
15-28, and so on).
P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Locations


Page 655
Part 2
Page 2600
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 174
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4264
1 - Track Numbers

Page 5599
legend.
wiring diagram.
harness.


question.)
19 - Legend



Hazard Flasher Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 959
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1006
Ground (GND)

Page 5523
Final procedures
1. Check the DTC memory => [ Diagnostic Mode 03 - Read DTC Memory ] See: Testing and
Inspection/Scan Tool Testing and
Testing and Inspection/Scan Tool Testing and
3. If the DTC memory was erased, generate readiness code => [ Readiness Code ] See: Testing
and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes/Readiness Code.

Page 4502
Page 6591
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4116
^ Open the valve on the supply side for 2 seconds to purge the air from the hose (fig. 7).
^ Open valve on air hose side.
Leave valve open for ten minutes.

^ Close the valve on the air hose side and open the valve on the supply side.
^ Leave valve open on reservoir side while monitoring the gauge.
^ Wait for the gauge to settle at it lowest point and close the valve.
^ Remove VAS 6096 from vehicle.
^ Adjust coolant level as necessary.
^ Allow engine to idle for 5 minutes and re-check heater temperature output.
Warranty
U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 7979
Page 2625
strip - 2 -.
Page 1649
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7672
No shim will be installed on side of clutch housing.
Pulling off inner races/tapered roller bearing
- Before installing puller, set thrust piece ( 40 - 105) onto differential housing.
‹› Both tapered roller bearing inner races are pulled off from the differential housing in the same
way.
Pressing on inner races/tapered roller bearing
‹› Tapered roller bearing inner race for transmission housing and clutch housing are pressed on
using the same special tools.
Pulling outer race/tapered roller bearing out of transmission housing
A Support, e.g. ( Kukko 22/2) B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
Pressing outer race/tapered roller bearing into transmission housing

Page 5091

Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 5124
Page 5321
Page 3143
Page 4198
A/T Shift Indicator Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Radiator Cooling Fan Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6946
Fluid - A/T: Testing and Inspection ATF Level, Checking
ATF Level, Checking

The ATF temperature should not be more than approx. 30° C at start of test.
‹› Transmission not in emergency running mode; ATF temperature not above approx. 30 °C
‹› Vehicle must be standing level
‹› Selector lever in "P".
- Connect "tester" and continue switching until it is ready for operation => [ VAS 5051, Connecting
and Selecting Functions ] See: Testing and Inspection/Scan Tool Testing and Procedures.
- Press "right" Guided Functions.
- Press ->.
Page 2851

Page 3267
Ag-Ig
Page 3501
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Locations

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 4844
1 - Track Numbers

Page 1891
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7635
‹› Drive plate, removal and installation. Refer to => [ Drive Plate ] See: Flex Plate/Service and
Repair/Drive Plate.
8 Sensor Wheel
‹› Removal and installation, refer to => [ Crankshaft Seal, Transmission Side ] See: Engine,
Cooling and Exhaust/Engine/Seals and
Gaskets/Crankshaft Main Bearing Seal/Service and Repair/Crankshaft Seal, Transmission Side.
‹› Removal and installation, refer to => [ Control Housing Cover ] See: Engine, Cooling and
Exhaust/Engine/Camshaft, Lifters and Push
Rods/Variable Valve Timing Cover / Housing/Service and Repair.
11 O-ring
‹› Replace
12 Bolt, 25 Nm
14 Bolt, 5 Nm
16 Seal
‹› Replace
Page 6639

Page 4447
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7543
Page 1357
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3679
(T03004) must stand out approximately 3 millimeter (mm) on the inner side - B -. The surface - A -
is the outer side. The surface - B - is the inner side (sealing surface).
- Cut the tube nozzle at the front mark (jet nozzle approximately 2 mm).
‹› The sealing flange for the crankshaft must be installed within 5 minutes after application of
sealant.
- Apply a sealant bead - A - as shown into the groove of the sealing flange.
‹› Width of sealant bead: 2.5 to 3.0 mm

Page 2933
Ground (GND)

Page 1992
29 Gravity Valve
‹› To remove the valve, unclip upward out of the support.
‹› Checking valve for throughput:
Valve vertical: Open
Valve angled at 45°: Closed
30 Pressure Retention Valve
‹› For fuel tank ventilation.
‹› Checking, refer to => [ Pressure Retention Valve Checking ].
31 Ground Connection
‹› Ensure the connection is securely seated.
Fuel Delivery Unit Installed Position
The tab - 4 - on the fuel delivery unit must lie between tabs - 3 and 5 -.
‹› Fuel delivery unit can only be installed in this position.
Switch Over Valve Checking

Page 790
Part 1
Page 6438
cylinder.
Page 125
1 - Track Numbers

Page 6053
- Remove the wiring harness - 3 - from the transport strap.
- Pull all clamps - 4 - and retaining ring - 5 - from the locking mechanism.
- Remove bolts - 7 - and remove the transport strap.
- Remove bolts - 1 - and pull the fuel rail with injectors evenly out of the intake manifold.
- Seal or cover the openings in the intake manifold.
- Pull off the retaining clips - 3 - and then the injectors.
Installing
- Install new O-rings for the injectors and lubricate them lightly with clean engine oil.
- Press the injectors into the fuel rail so that the tabs - 1 and 2 - align.
Page 7505
Pressure Plate: Service and Repair Clutch, Sachs
Clutch, Sachs
Removing

‹› When removing, stop - 2 - must loosen together with stud - 1 -.
- If stop does not loosen: Press stud in direction of dual-mass flywheel.

Installing
‹› If alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises
from the transmission (loose gear chatter) may
develop.

Page 2800
legend.
wiring diagram.
harness.


question.)
19 - Legend



Fuse: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1355
Ground (GND)

Page 5895
Page 3932
Part 1
Page 1837
Page 3463
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 719
Page 794
Page 1761
Track 1-14
named Track 1-14.
Track 169-182
reference box.

- Multimeter.
- Wiring diagram.
Test requirement
Test procedure
Procedure
step.
Checking wiring
resistance.
terminals terminals
6 (Can_Bus Low) 34

Page 3824
- Remove oil filter insert -2- from oil filter housing center tube -4-.
Warning!
The oil filter housing sealing ring -3- must be replaced each time the oil filter insert is changed -2-
or every other time the oil filter housing is loosened. The sealing ring is equipped with a so-called
"service flag" -A-. The sealing ring can be gripped at the "service flag" -A- with a suitable tool and
then removed from the seal groove.
- Remove sealing ring -1- from oil filter housing seal groove -2- by pulling sealing ring out with
needle-nose pliers -3- on the "service flag" -arrow-.
- Lubricate sealing ring -3-.

Page 726
Installing
Functions".
Tightening torques:
Component Nm

Engine - Measurement Of Oil Consumption
Engine Oil: Technical Service Bulletins Engine - Measurement Of Oil Consumption
17 11 01
March 25, 2010
2017813 Supersedes T.B. V171003 dated July 12, 2010 to include additional model year
applicability and special tool purchase information.
Vehicle Information
Condition
Oil Consumption Measurement
Customer states oil consumption is higher than the Volkswagen oil consumption standard of up to
0.5 quarts per 600 miles, or 0.5 liters per 1000 km.
In order to provide effective lubrication and cooling of internal engine components, all internal
combustion engines consume a certain amount of engine oil. Oil consumption varies from engine
to engine and may change significantly over the life of the engine.
Typically, engines with specified break-in periods consume more oil during the break-in period, and
the oil consumption will stabilize after the break-in period. Refer to the Owners Manual for specific
break-in procedures.
Under normal conditions, the rate of oil consumption depends on the quality and viscosity of the oil,
the RPM at which the engine is operated, the ambient temperature and road conditions.
Further factors are the amount of oil dilution from water condensation or fuel residue and the
oxidation level of the oil.
Production Solution
Not applicable.
Service
If the customer complains that their engine is apparently consuming oil in excess of the
Volkswagen oil consumption standard above, an oil consumption test must be performed using the
test plan in the VAS 5051 B, 5052/A, 6150 tester, before any repair is carried out.
Tip
Using the VAS tester, navigate to the Oil consumption measurement using one of the provided
methods below:
^ GFF- Function/Component Selection: Powertrain >> Engine >> Systems capable of self
diagnosis >> Motronic engine control >> Functions >>
General functions» Oil consumption measurements.
^ GFF- Function/Component Selection: Drivetrain >> Engine >> Lubrication >> Sub-systems,
marginal conditions >> Oil consumption measurements.
1. Follow VAS 5051B, 5052/A, 6150 test protocol exactly, and document all information on oil
measurement sheets.
2. Archive the VAS 5051B, 5052/A, 6150 diagnostic log and oil measurement test sheet (attached)
in the dealership vehicle service file.
3. When the customer returns the vehicle to the dealership after a minimum of 630 miles (1014
km), complete part # 2 of the oil consumption test plan
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2241
1 - Track Numbers

Page 5986
Final procedures

Page 2508
Part 2
Turbo Boost Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 777
Final procedures

09.

Code.
Fuel Gauge Sender: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2303
Part 2
Page 2476
1 - Track Numbers

- Multimeter.
- Wiring diagram.
Test requirement
Test procedure
Procedure
step.
Checking wiring
resistance.
terminals terminals
6 (Can_Bus Low) 34

Fluid - M/T: Customer Interest M/T - Humming Noise When Turning at Low Speeds
34 06 02
June 12, 2006
2011899
Affected Vehicles
under load.
Production Solution
Service
model years.
Page 1964
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 301
Ground (GND)

Page 6787
legend.
wiring diagram.
harness.


question.)
19 - Legend



Ignition Coil: All Technical Service Bulletins Emissions - Interim Repair For Recall 28F3
28 10 02
May 10, 2010

Vehicle Information

Locations

Page 2654
Part 2
Engine Mount Control Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Procedures
Crankshaft: Procedures
Crankshaft, Locking
Crankshaft, Locking
‹› Crankshaft adapter (T03003)
‹› Locking pin (T40069)
Locking the crankshaft for checking/adjusting valve timing. Refer to => [ Crankshaft, Locking to
Check/Adjust Valve Timing ] See: Crankshaft, Locking to Check/Adjust Valve Timing.
Procedure
- Remove the front part of the right front wheel housing liner.
- Install the (T03003) onto the crankshaft pulley/vibration damper.
(T03003) can only be installed correctly in one position.
- Rotate the crankshaft in the direction of engine rotation - arrow - far enough until arrow - A - on
the (T03003) points downward vertically, relative to the engine axis.
This position corresponds approximately to the Top Dead Center (TDC) position of the crankshaft
at cylinder 5.
‹› With the engine removed, the TDC marking can also be seen on the belt pulley and belt pulley
side sealing flange. Notches - A and B - must align.
Page 3116
- For fuel filter
Page 7369

Connector
Page 3440
1 - Track Numbers

Page 6805
- Install selector lever handle => [ Selector Lever Handle ] See: Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Removal and Replacement/Selector Lever
Handle.
- Check selector mechanism => [ Selector Mechanism, Checking ] See: Automatic

Transmission/Transaxle/Shifter A/T/Testing and Inspection.

Page 1627
1 - Track Numbers

Page 5539
Page 2037
Brake Light Switch: Adjustments
Brake Light Switch, Adjusting, from 03.00
Removing
Brake light switch (F) must be removed for adjustment.
- Disconnect connector from brake light switch ( F).
- Remove brake light switch (F) by rotating counterclockwise 45 degrees.
- Before installing, remove plunger completely.
- Guide brake light switch (F) through assembly hole, press against pedal and secure by rotating 45
degrees toward right
- Brake always remains in rest position while doing so (not operated).
- Connect connector for brake light switch (F).
After adjusting brake light switch ( F), check whether brake pedal is in end position (released
position).
Page 2421
Part 3
Page 4953
Part 2
Page 5963
Page 6486
Checking wiring

Page 841
Final procedures

09.

Code.
Page 1904
Part 2
Page 4233
Part 2
Page 5864
1 - Track Numbers

Page 367
- Multimeter.
- Wiring diagram.
Test requirement
Test procedure
Procedure
step.
Checking wiring
resistance.
terminals terminals
6 (Can_Bus Low) 34

Page 2384
stops.

Page 2790
Part 3
Page 5786
- Check the wiring from the Secondary Air Injection (SAI) Solenoid Valve (-N112-) electrical
connector terminal 1 through Fuse S130 to the Motronic Engine Control Module (ECM) Power
Supply Relay (J271) for a short circuit to Ground, or an open circuit.
Checking wiring
- Using a multimeter, check the Secondary Air Injection (SAI) Solenoid Valve (-N112-) electrical
harness connector terminal 2 to the Motronic Engine Control Module (ECM) (J220) electrical
harness connector T121 for an open circuit.
Final procedures


Page 3668
Crankshaft: Tools and Equipment Crankshaft Counter-hold - AST Tool # 3415
Crankshaft Counter-hold
AST tool# 3415
Required to lock spur belt sprocket on most 4 cylinder water cooled inline VW/Audi engines,
including engines equipped with aluminum oil pan. Used to counter hold crankshaft toothed belt
sprocket when replacing the crankshaft oil seal. Accessory pin design also allows holding of some
cam or counter shaft gear sprockets.
- Made in Germany

Page 7005
Part 1
Page 1987
Fuel Gauge Sender: Service Precautions
Safety Precautions
connection.

components.
Module DTC Memory, Checking and Erasing ] See: Powertrain Management/Computers and
Control Systems/Engine Control Module/Testing and Inspection/Reading and Clearing Diagnostic
Trouble Codes.
Page 886
Warranty
No Special Parts Required
Page 6181
Part 3
Page 7808
Part 1
Page 7973
WHAT ARE TRACKS?
15-28, and so on).
Fuse: Customer Interest A/T - Won't Shift Out of PARK/DTC's U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 4130
19 - 5 Nm
Page 2005
Ground (GND)

Page 6373
Page 3164
Power Steering Line/Hose: Specifications Pressurized Line Mount to Transmission Tightening
Specifications
Pressurized Line Mount to Transmission Tightening Specifications
Pressurized Line to Manual Transmission 02J
Pressurized Line to Manual Transmission 0A4
Pressurized Line to Manual Transmission 02M
Pressurized Line to Automatic Transmission 01M
Pressurized Line to Automatic Transmission 09G
Pressurized Line to DSG Transmission 02E

Page 1498
Part 1
Page 2204
1 - Track Numbers


Page 7221
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5521

Page 831
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1914
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3357
Page 625
Headlamp Igniter Module: Diagnostic Aids
Electrical / Mechanical Repair
Wheel Bearing: Electrical / Mechanical Repair
Rear Wheel Bearing Press for VW/Audi
AST tool# 3420
VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle
2008 suggested user price: 25.92
Assenmacher Specialty Tools 1 800 525 2943

Locations
Electronic Power Control (EPC) Warning Lamp: Locations
Electronic Power Control (EPC) Warning Lamp K132
Location of Electronic Power Control (EPC) Warning Lamp K132
Meaning of Electronic Power Control (EPC) Warning Lamp K132 "EPC" is an abbreviation and
stands for Electronic Power Control, this means "electronic engine load control" (EPC).
If malfunctions in "EPC" system are detected during engine operation, Motronic Engine Control
Module (ECM) J220 switches on the Electronic Power Control (EPC) Warning Lamp K132.
Page 740
Page 4296
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 4747
Part 1
Page 4083
Part 2
Page 3579
Engine Mount Control Solenoid: Diagnostic Aids
Page 7315
strip - 2 -.
Page 590
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2367
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1363
Fuel Door Switch: Diagnostic Aids
Page 1147
WHAT ARE TRACKS?
15-28, and so on).
Page 3066
Installing
audibly.

Page 6119
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 702
Removing

Installing
Page 6070
Part 2
Page 5416
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4232
Part 1
Page 5649
‹› Multimeter.
Test requirements
Test procedure
See: Testing and Inspection/Scan Tool Testing and Procedures/Preliminary Check.
Start diagnosis

Page 3427
- Press the "Accept" button - arrow -on display.
- Press the - arrow - button on the screen display.
Adapting service event:

Page 3276
Lo-NI
Page 4780
1 - Track Numbers

Page 2937
Part 2
Page 670
1 - Track Numbers

Page 22
^ Location: Above rear glass under headliner.
Antennas
All models use four antennas.
^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5-
^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-.
- Jetta / Golf / Passat (non W8) - Antenna system
^ All models use External amplified antenna mast -1-.

Page 1333
Door Lock Cylinder Switch: Service and Repair
Door Contact Switch
Door contact switch is integrated in door lock and cannot be replaced separately.
If the door contact switch is faulty, then the entire door lock must be replaced.
Page 3526
1 Pressure bolt (E-15)
2 Bell (E-40)
5 High pressure hose with quick-release
Wheel Bearing, Removing
2 Thrust sleeve (E-65-1)
Bearing Inner Race, Removing from Hub

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 146
- Remove cover - 2 - at the protective housing.
- First disconnect 42-pin harness connector - 2 - at the Telematics control module.
- Disconnect antenna connectors - 1 - and - 3 - on the Telematics control module.
Installing
The Telematics control module was replaced:
- Code the Telematics control module, refer to => [ Telematics Control Module , Coding ] See:
Testing and Inspection.
- Configure the Telematics for the OnStar functions, refer to => [ Telematics Control Module ,
Configuring ] See: Testing and Inspection.
Page 1819
Page 5233
Page 2320

- Start the engine.

Page 6209
WHAT ARE TRACKS?
15-28, and so on).
Page 5578
Page 6914
Final procedures
Page 4327
Part 3
Page 7091
- Remove right drive axle - B - from transmission direction of - arrow -.
‹› There is no separate flange shaft in the transmission but rather the drive axle is inserted into
transmission.
‹› When prying the drive axle out of transmission, only the special tool must be used.. When using
other tools to remove the axle shaft, such as a
screwdriver or an assembly lever, the transmission or the axle shaft will be damaged and must
therefore be replaced.
- Raise right drive axle and secure (tie up).
- Place drip tray (V.A.G 1306) underneath.
- Seal drive axle opening on transmission with a clean cloth - A -.
- Using a standard drill bit - B - carefully drill a (2 to 4 mm in size), hole into outer metal ring of seal.
‹› Grease drill bit - B - so that drill shavings remain held.
‹› Drill through metal ring - C - only, otherwise transmission could be damaged.
‹› Illustration shows the left seal, procedure is the same on the right seal.
- Install a metal bolt (approx. 4 mm diameter) into drilled hole of seal - arrow -.
Page 6448
‹› Puller (T40039)

Specifications
Firing order
1-2-4-5-3
Page 1499
Part 2
Page 928
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5543
Checking wiring
Final procedures

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4325
Part 1
Page 5115
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1378
Part 3
Page 225
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6671
Warranty

Page 4453
Part 3
Page 1135
Page 2207
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4070
- Install the ribbed belt. Refer to => [ Ribbed Belt ] See: Drive Belts, Mounts, Brackets and
- Fill with coolant. Refer to => [ Draining and Filling ] See: Cooling System/Service and
- Fill the power steering system with hydraulic oil.
Page 2565
Driver/Front Passenger Side Airbag Sensor
Airbag
be scrapped.
Driver/Front Passenger Side Airbag Sensor
Removal
- Remove the driver/front passenger seat ( install the airbag adapter (VAS 5094)).
- Remove carpet - 4 - and the insulation mats in the sensor area.
- Remove harness connector - 3 - and bolts - 2 -.

Page 6553
plan)
TCM.
Warranty
Information only.
Page 6001
- For fuel tank
17 - Lock washer
Replace
21 - Fuel filter -
22 - Supply line -
Black
- To fuel rail
23 - Vent line -
White
24 - Seal -
Replace
- Check fuel pump.

27 - Supply line -
Black
- To fuel filter
28 - Return line -
Blue
- To fuel filter

Page 5281
Checking wiring
Final procedures

Page 1778
Ground (GND)

Pressurized Line/Intake Hose to Engine Tightening
Specifications
Power Steering Line/Hose: Specifications Pressurized Line/Intake Hose to Engine Tightening
Specifications
Pressurized Line/Intake Hose to Engine Tightening Specifications

Pressurized Line/Intake Hose TDI Engines
Pressurized Line/Intake Hose 1.8L Engines
Pressurized Line/Intake Hose TDI Engines

Page 7078
Page 7181
G195, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
-.
Checking wiring
Page 1743
Ground (GND)

Page 2260
Checking wiring
Final procedures

09.
Page 7435
Installing
- Replace O-ring on connector.
- Press connector with new O-ring into transmission up to limit stop.
- Tighten bolt of 8-pin transmission connector => [ (Item 24) Bolt, 6 Nm ] See: Valve Body/Service
and Repair/Valve Body Assembly Overview.
- Tighten bolt for bracket of Transmission Fluid Temperature Sensor (G93) to 11 Nm.
Page 7314


Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7333
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 6166
- Multimeter.
- wiring diagrams.
Test requirements
- Fuse SB42 OK.
- The generator OK.
Test procedure
Start diagnosis
Ground (GND).
- Crank the engine.
16/MOT 65

Page 1183
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5139
WHAT ARE TRACKS?
15-28, and so on).
Page 5662
Ground (GND)

Page 6185
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 3134
- Remove oil filter insert -2- from oil filter housing center tube -4-.
Warning!
The oil filter housing sealing ring -3- must be replaced each time the oil filter insert is changed -2-
or every other time the oil filter housing is loosened. The sealing ring is equipped with a so-called
"service flag" -A-. The sealing ring can be gripped at the "service flag" -A- with a suitable tool and
then removed from the seal groove.
- Remove sealing ring -1- from oil filter housing seal groove -2- by pulling sealing ring out with
needle-nose pliers -3- on the "service flag" -arrow-.
- Lubricate sealing ring -3-.

Page 7583
‹› Chamfer on inner diameter of ball hub (splines) must face large diameter of joint piece.
- Swing in ball hub, to do so swing out hub far enough from cage - arrows - so that the balls have
the distance of the running paths.
- Swing in hub with balls by pressing forcefully onto cage - arrow -.
Check Constant Velocity Joint for Function
Constant velocity joint is properly assembled, if the ball hub can be slid back and forth by hand
over the whole compensation length.
Page 5159
WHAT ARE TRACKS?
15-28, and so on).
Audio System - Poor Radio Reception
Technical Service Bulletin # 9105-01 Date: 050502
Group: 91
Number: 05-01
Date: May 2, 2005
Subject: Radio, Reception Diagnosis
Model(s): All with Premium V and VI Radio
1998 > 2006
Condition
Poor radio reception.
Service Procedure
For concerns of poor radio reception:
- Use the following as a guide for trouble shooting.
Tip:
This Technical Bulletin is divided into four sections:
^ Section 1: Includes antenna systems by vehicle.
^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using
internal radio diagnostics.
^ Section 3: Includes antenna lead diagnosis.
^ Section 4: Antenna cables
Tip:
^ Perceived reception issues may be a result of environmental factors.
^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses.
^ Aftermarket window tint may interfere with reception.
^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is
same, condition may be normal).
Section 1 - Antenna systems by vehicle
Tip:
For more detail see Repair Manual Group 91- Communication of the vehicle you are working on.
Passat (W8 only)

Page 1179
1 - Track Numbers

Page 6299
1 - Track Numbers

Page 116
Part 2
Page 380
Part 3
Page 1779
WHAT ARE TRACKS?
15-28, and so on).
Page 6399
Ground (GND)

Page 5257
Page 6032
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6267

Page 5745
Page 3170
Power Steering Line/Hose: Service and Repair Pressurized Line and Intake Hose to Power
Steering Pump Overview
Pressurized Line and Intake Hose to Power Steering Pump Overview
1 Banjo fitting
‹› M16 x 1.5

2 Seals
‹› Replace
3 Pressurized line
‹› Checking delivery pressure => [ Low Mounted Power Steering Pump, Checking Delivery
Pressure ] See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Testing and Inspection/Low Mounted

‹› Before installing, fill with power steering fluid => See: Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and
Repair/Low Mounted Power Steering Pump.
5 Socket
Page 5038
Service and Repair
Valve Guide Seal: Service and Repair
Valve Stem Seals
(with cylinder head installed)
‹› Spark plug removal tool (3122 B)
‹› Valve seal removal tool (3364)
‹› Valve stem seal driver (3365)
‹› Adapter (T40012)
‹› Valve cotters asm/disasm device (VAS 5161)
‹› Guide plate for FSI engine (VAS 5161/19B)
Removing
To remove the valve stem oil seals, the following components must be removed as follows:
‹› Intake valves cylinder 1: Transport strap
‹› Intake valves cylinder 5: Camshaft adjustment valve 1 (N205)

‹› Exhaust valves cylinder 5: Secondary Air Injection (AIR) solenoid valve (N112)
- Remove the plenum chamber cover
- Remove the camshafts. Refer to => [ Camshafts ] See: Camshaft, Lifters and Push
Rods/Camshaft/Service and Repair.
- Remove the roller cam follower and set it down on a clean surface. Make sure that the roller cam
followers are not interchanged.
- Using the (3122B), remove the spark plugs.
- Install the (VAS 5161/19B) with the (VAS 5161/12) onto the cylinder head as shown.
- Adjust the piston of the respective cylinder to the Bottom Dead Center (BDC) position.
- Install (T40012) into the spark plug hole and connect a compressed air hose of at least 6 bar
positive pressure.
- Using the (VAS 5161/3) and a plastic mallet, tap loose any stuck valve keepers.
Page 2738
1 - Track Numbers

Page 389
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4140
Part 3
Page 3964
3391 - Camshaft Alignment Tool
6700 - 1.8T Tensioner Holder Set
Page 4787
Part 3
Page 5166
Electronic Throttle Actuator: Diagnostic Aids
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Interior Light Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4017
11 Air Duct
13 Intake Tube

Drive Plate
Flex Plate: Service and Repair Drive Plate
Drive Plate
‹› Depth gauge
Removing
- Remove the transmission.
- Lock the crankshaft => [ Crankshaft, Locking ] See: Engine, Cooling and Exhaust/Engine/Cylinder
Block Assembly/Crankshaft/Service and Repair/Procedures/Crankshaft, Locking, and remove the
drive plate.
Installing
- Install the drive plate only by using the washer with recesses - 1 - (without compensating shim - 2
-).
- Install new bolts - 3 - and tighten to 30 Nm.
- Check dimension - a - at three points and calculate the mean value.
Specified value: 18.8 to 20.4 millimeter (mm)
‹› Measure through the drive plate hole to a surface on the control housing cover.
Steering Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5317
Ground.
Final procedures


-G195-
Page 6272
1 - Track Numbers

Page 7645
1 - Track Numbers

Page 1298
WHAT ARE TRACKS?
15-28, and so on).
Page 1698
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 842
Removing
- arrows -.
Page 3522
8 Concealment cap
‹› Remove
10 Ribbed bolt w/washer assembly, 125 Nm
14 Cover plate
15 Hex bolt, 10 Nm
16 Wheel bearing
17 Circlip
19 Brake pads
lamp ( K32) lights up in instrument panel
Replacement.
21 Bracket
Page 2128
Headlamp Switch: Service and Repair Headlamp Adjuster and Instrument Panel Illumination
Dimmer Switch
Removing

Installing

Page 2952
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6677
Warranty

Page 5752
- Remove nut - 1 -.
Installing


Page 2070
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4286
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6987
Part 2
Page 3896
Intake Manifold: Service and Repair Intake Manifold and Attachments Assembly Overview
Intake Manifold and Attachments Assembly Overview

1 Hose for Crankcase Ventilation
‹› From the cylinder head cover.
2 Ventilation Hose
3 Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 (N80)
4 Line
‹› Vehicles through Model Year (MY) 2009 only.
‹› On vehicles from MY 2010, the vacuum connection on the intake manifold is sealed with a cap
(new vacuum connection on the vacuum
pump/brake booster vacuum line).
5 Vacuum Hose
‹› Vehicles through MY 2009 only.
‹› From the Leak Detection Pump (LDP) (V144).
6 Bolt, 9 Nm
7 Bracket
Page 641
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1356
WHAT ARE TRACKS?
15-28, and so on).
Page 7447
Clutch Disc: Service and Repair Clutch, Sachs
Clutch, Sachs
Removing

‹› When removing, stop - 2 - must loosen together with stud - 1 -.
- If stop does not loosen: Press stud in direction of dual-mass flywheel.

Installing
‹› If alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises
from the transmission (loose gear chatter) may
develop.

Page 263
Trunk / Liftgate Closer Module: Diagnostic Aids
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5059

Page 4086
Page 7828
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 6065
legend.
wiring diagram.
harness.


question.)
19 - Legend




Page 2247
Part 2
Page 6641
strip - 2 -.
Specifications
Crankshaft Gear/Sprocket: Specifications

......................................................................................................................................... 50 Nm plus
Page 3443
WHAT ARE TRACKS?
15-28, and so on).
Page 3634
- Finally, tighten the bolts to the cylinder block and upper oil pan to 25 Nm.
- Wipe off any sealant, which has leaked out.
- Drive the alignment bushings in until seated, if necessary.
- Install a new seal. Refer to => [ Crankshaft Seal, Transmission Side ] See: Seals and
following:
‹› Install the brake booster vacuum pump. Refer to => [ Brake Booster Vacuum Pump ] See:
Brakes and Traction Control/Power Brake
Assist/Vacuum Pump/Service and Repair/Brake Booster Vacuum Pump.
‹› Install the cylinder head. Refer to => [ Cylinder Head ] See: Cylinder Head Assembly/Service and
Repair/Removal and Replacement/Cylinder
Head.
‹› Install the drive plate. Refer to => [ Drive Plate ] See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Drive Plate.
Page 1150
Part 2
Page 1815
Part 1
Page 2640
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5383
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6881
Page 6051
8 Protective Cap
9 Breather Valve
Page 3626
Page 7427
Warranty

Page 4847
WHAT ARE TRACKS?
15-28, and so on).
Page 2956
Part 1
Page 3444
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5001
- For fuel filter
Page 1118
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3939
pressure.
‹› => [ Oil Pump, through MY 2007 ] See: Engine Lubrication/Oil Pump/Service and Repair/Oil
Pump, Through MY 2007.
‹› => [ Oil Pump, from MY 2008 ] See: Engine Lubrication/Oil Pump/Service and Repair/Oil Pump,
From MY 2008.

Page 5698
Part 3
Page 724
Final procedures

09.

Code.
Page 6501
Part 3
Page 2760
Part 3
Page 2302
Part 1
Page 6201

Locations
Brake Booster Vacuum Sensor: Locations
10- Sender 1 for brake booster -G201 -
^ Vehicles with ABS/EDL/ASR/ESP only

^ Checked by OBD
^ When the sender 1 for brake booster -G201 - is replaced, a zero compensation must be
performed
^ Initiate basic setting, perform display group number 066

Page 404
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2509
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7743
Holes in cable retainers have different diameters.
Installation Position of Transmission Shift Lever/Actuator Lever
1 Transmission shift lever with counterbalance weight
2 Relay lever engages over shoe - arrow - into glide track of transmission shift lever.
Service and Repair
Lock Cylinder
Connecting.
Removing
1. Position "Off"
2. Position "Run"
3. Position "Start"
Page 324
1 - Track Numbers

Page 5458
Page 2919
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3616
1 - Track Numbers

Page 5195
Final procedures

Page 3144
- Lubricate sealing ring - 3 -.
- Lay sealing ring in oil filter housing seal groove so service flag - A - is aligned toward top.
feeling above sealing ring with finger - arrows -.
Page 6226
Final procedures

Page 6192
Final procedures

Page 6383

Page 4199
Page 269
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7629
Flex Plate: Service and Repair Sealing Flange and Drive Plate/Flywheel Assembly Overview

‹› Quantity: 5
‹› Replace
3 Bolt, 10 Nm
‹› Removal and installation, refer to => [ Sealing Flange, Belt Pulley Side ] See: Engine, Cooling
and Exhaust/Engine/Cylinder Block
Assembly/Sealing Flange, Engine Front/Service and Repair/Sealing Flange, Belt Pulley Side.
5 Cylinder Block
‹› Replace
Page 975
Ground (GND)

Page 3089
6. Ribbed belt, for the A/C compressor
7. Crankshaft pulley/vibration damper
8. Ribbed belt tensioner pulley, for the A/C compressor belt
9. Ribbed belt tensioner pulley, for the generator, power steering pump and coolant pump belt
10. Coolant pump pulley
Ribbed Belt
Ribbed Belt
‹› Locking pin (T10060A)
Removing
- Remove the right main headlamp.
- Remove the right front wheel housing liner.
Removing the Ribbed Belt for the Air Conditioning (A/C) Compressor
- Mark the direction of rotation of the ribbed belt.

- Rotate the belt tensioner - 1 - as shown using a 15 millimeter (mm) box end wrench - A - in the -
direction of the arrow - and secure using (T10060A ).
- Remove the ribbed belt for the A/C compressor.
Removing the Ribbed Belt for the Generator, Power Steering and Coolant Pumps
- Relieve the tension on the belt tensioner - 1 - for the A/C compressor belt (pull out the
(T10060A)).
- Mark the running direction of the ribbed belt for the generator, power steering and coolant pumps.
- Insert the (T10060A) into the belt tensioner - 2 -.

Page 3102
Page 870
^ Verify all connections are properly secure.
^ Insert CD, Part No: W42DTC02511014-2, into CD drive of VAS 5052 / VAS 6150.
^ Go to "My computer" to access the CD-ROM
^ Double click on the file named PODS- B_VW_Action_695606.exe"
The following text will appear when programming is successful.
Trying to find Seat Occupant Recognition Module
Press ■EXIT" to cancel if software update has been performed successfully, the following screen
will appear in VAS 5052 / VAS 6150 display.
Check System
- Power?
- Connection to VAS Tester
- Connection to Seat
Seat Occupant Recognition Module found and connected to System
Apply Action 695606
This can take a minute, please wait
"Action 695606 applied successfully".
TIP
Page 4180
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 3382
Page 7876
- Remove nut - 1 -.
Page 5700
Page 2997
Alignment: Specifications Ride Height
Ride Height Specifications: Vehicle transverse inclination "Zero position"
If the measured values exceed tolerances, the cause may be an incorrect vehicle attitude.
Example: vehicles with an automatic transmission can lean to one side slightly. This is due to the
installation position of the assemblies and their associated weight transfer and is normal.
- If vehicle leans to one side, measure dimension "a" on left and righthand sides.
- Correct differences if necessary. ^
On front axle, compensate by adding weight to top of relevant strut tower.
^ On rear axle, compensate by adding weight to relevant side of luggage compartment.
^ Sand filled bags weighting approx. 10 kg (22 lbs.) are suitable for this.
Page 1373
Ground (GND)

Page 1348
Fuel Door Lock Switch: Diagnostic Aids
Page 139
The Telematics indicator lamp illuminates red.
Indicates fault on vehicle side. Proceed as follows:
Use on board diagnostic with the Vehicle Diagnosis, Testing And Information System (VAS 5051B)
in the "Guided Fault Finding" mode.
‹› If any Telematics button in the Telematics Control Head (E264) is pressed either inadvertently or
deliberately for longer than 15 seconds, on board
diagnostic assumes that a button is sticking. The red LED illuminates and the malfunction 01526 -
mechanical malfunction is stored in the DTC memory. Make sure buttons are fully operable, erase
DTC and inform customer.
Page 1632
Part 1
Page 3572
WHAT ARE TRACKS?
15-28, and so on).
Page 4607
Checking wiring

Page 6577
Removing
arrow 2 -.
"learning" process.
Installing
Page 5236
removal.
Page 5706
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 3367
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 617
Ground (GND)

Locations
Engine Speed Sensor: Locations

Door Lock Cylinder Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6843
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5468
Engine Control Module: Application and ID
Technical Data
Technical Data
Page 1816
Part 2
Page 497
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5200
Electronic Power Control (EPC) Warning Lamp: Description and Operation
Electronic Power Control System Function
For Electronic Power Control (EPC), the throttle valve is not operated by a cable from the
accelerator pedal. There is no mechanical connection between the accelerator pedal and the
throttle valve.
The position of the accelerator pedal is transmitted to the Engine Control Module (ECM) via two
accelerator pedal position sensors (adjustable resistances, accommodated in one housing), that
are connected to the accelerator pedal.
The position of the accelerator pedal (driver controlled) is a main input for the ECM.
Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle
valve control module. This is true across the entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle drive according to the instructions of the ECM.
With the engine at a stand still and the ignition switched on, the ECM activates the throttle valve
actuator precisely according to the specifications of the Throttle Position (TP) sensor. This means,
if the accelerator pedal is pressed half way, the throttle drive opens the throttle valve to the same
With engine running (under load) the ECM can open and close the throttle valve independently of
the accelerator pedal position sensor.
throttle valve.
After evaluating the torque requirements of the various components such as the Air Conditioning
(A/C) system, automatic transmission, Anti-lock Brake System (ABS)/Electronic Stabilization
Program (ESP), etc., the ECM calculates the optimal throttle valve opening angle for the current
situation.
Aside from that, it results in clearly better pollutant output and consumption values under certain
load conditions.
"EPC" is a system containing all components that contribute to determining, controlling and
monitoring the throttle valve position, for example, TP sensor, throttle valve control module, EPC
warning light, ECM.
Vacuum Pump Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2844
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Shock Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2980
Page 2462
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5530
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5600
Ground (GND)

Page 1843
1 - Track Numbers

U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 6503
Page 5611
- Check the ground circuit for an open or high resistance.
- If necessary, repair the faulty wire or connection.
°Testing if display is - 40 C :
- Using a jumper wire, connect the MAF / IAT sensor (G70 / G42) harness connector terminals 1 to
2.
If indication jumps to approx. 140 °C:
If indication remains at approx. -40 °C or -46 °C:
Checking wiring
- Using a multimeter, check the MAF / IAT sensor ( G70 / G42) harness connector terminal 2 to the
Motronic Engine Control Module (ECM) (J220) electrical harness connector T121 terminal 42 for an
open circuit or a short to voltage, refer to the wiring diagram.
open, high resistance or a short to voltage, refer to the wiring diagram.
Specified resistance: 1.5 ohms Max.
- Check the wiring for an open, high resistance or short circuit to Battery (+).
°Testing if display near 140 C:
If indication jumps to approx. -40° C to -46° C:

Page 7086
Seals and Gaskets: Service and Repair Final Drive, Differential (09G Transmission)
Left Side Flange Shaft Seal
Left Side Flange Shaft Seal
‹› Puller (T10055)
‹› Adapter (T10055/2)
‹› Standard drill
Removing
- Remove left noise insulation.
- Remove left drive axle.
- Drive axle seal opening on transmission with a clean cloth - A -.

Page 7007
Part 3
Page 4621
Final procedures

Page 725
Removing
spring clamp - 3 -.
Page 2051
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4861
Ground (GND)

Page 7047

Page 3264
using the VAS 5051 The results and diagnostic log must be sent to the Volkswagen Technical
Assistance Center (TACS) before any repairs are performed.
4. Advise the customer that if the low oil level warning light comes on before the 630 mile (1014
km) test is completed, the vehicle must be taken
directly to the Dealership for part # 2 of the oil consumption test, regardless of the miles
accumulated. The customer should not add any oil.
Note:
Page 1231
Ground (GND)

Electronic Throttle Actuator Position Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1677
- Installation position: The angled section - arrow - of lateral acceleration sensor G200 - 1 - must
face toward the retainer - 2 -.
- Slide retainer - 2 - over lateral acceleration sensor G200 - 1 - until it engages. Installation is
carried out in reverse sequence or removal
- Enter radio code.
Torque settings:
Torque settings
Page 2438
Ground (GND)

Page 1102
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4948
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5764
Part 2
Page 2667
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Antitheft - No Start Condition Below 40 Degrees F.
Instrument Panel Control Module: Customer Interest Antitheft - No Start Condition Below 40
Degrees F.
90 08 03
February 6, 2008
2011326, Supercedes T.B. Group 90 number 05-08 dated November 18, 2005 due to Service
Action M4 expiring.
Affected Vehicles
Condition
Immobilizer Activated If Ambient Temperature Is Below 4°C (40°F)
An intermittent No Start condition may exist in ambient temperatures below 4°C (40°F):
^ The vehicle cranks but does not start after sitting for long periods or over night
^ The electronic immobilizer light is flashing
^ The vehicle cannot be started with any of the keys
When the concern can be reproduced the following fault codes may be present:
^ P1570 in 01 - Engine Electronics
^ 01176 in 25 - Immobilizer
N/A
Production Solution
N/A
Service
^ Verify if instrument cluster has already been updated:
^ Tilt steering wheel down in order to see white label on bottom of instrument cluster.
If a letter "C" is printed on the label, part has already been updated.
If a letter "C" is not on label, a new instrument cluster has to be ordered for the vehicle based on
the Vehicle Identification Number (VIN).
Page 2345
Page 1234
Part 1
Page 5332
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Telescoping Wheel Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2135
Ground (GND)

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 7555
Part 3
Page 4555
WHAT ARE TRACKS?
15-28, and so on).
Page 1665
- Disengage secondary engagement device (violet) in direction of - arrow - using small screwdriver.
ABS Mark 20 IE Harness Connector (T25)
Page 4929
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5874
EGR Control Solenoid: Diagnostic Aids
Page 5346
Part 1
Page 1668
When installing, be sure not to twist wheel speed sensor wire in wheel housing.
- Insert connector for brake pad wear indicator into bracket at suspension strut.
- Guide terminal into connector housing.
- Push in single wire seal until stop using assembly tool from (VAS 1978).
- Secure terminals with secondary engagement device and attach multi-pin connector cap.
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2979
IMPORTANT NOTE:
Page 7093
- Press in seal straight and as far as possible by hand - arrows -.
- Drive in seal to stop of sealing ring installer ( T10177), do not cant seal when driving in.
- Replace transmission-side circlip on right drive axle.
- Press drive axle into stub shaft in transmission.
Bolt ball joint to control arm with new bolts - arrows - on to old impression and install coupling rod -
A - on control arm.
Page 7224
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1900
Ground (GND)

Page 6811
circuit.
- End diagnosis.
Final procedures
Page 7878
stops.

Page 2788
Part 1
Page 7877
- Remove nut - 1 -.
Installing


1 - Fuel filter -
Black
- From fuel tank
Blue
- To fuel tank
4 bar
6 - Gasket
Replace
7 - O-ring
Replace
Black
- To engine
9 - 3 Nm
10 - Bracket
Page 4591
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1166
Ground (GND)

Page 2753
1 - Track Numbers

Page 1437
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3846
Oil Filter Adapter: Service and Repair

1 Bolt, 25 Nm
‹› Removing:
3 Gasket
‹› Replace

Page 5191
Page 1023
WHAT ARE TRACKS?
15-28, and so on).
Page 3097

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 5399
Installing

Owner's Manual
General Information
Page 475
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4344
Page 3514
Wheels: Service and Repair
Wheel Centering Seat, Protecting against Corrosion
Valid for light metal alloy and steel wheels
When replacing wheel, wheel centering seat should be waxed with
Wax spray (D 322 000 A2 )
in order to prevent corrosion between wheel centering seat and rim.
- Remove wheel.
- Always clean wheel centering seat at wheel hub and centering of rim.
- Apply wax in area of the centering - arrow - using a brush.
Always make sure that only the centering - arrow - is waxed and not the rim contact surfaces.
Consequences of this would be a soiling of the brakes during vehicle operation and poor braking
performance would result.
CAUTION! Wheel bolts, contact surfaces of wheel/wheel hub and threads in wheel hub must not be
waxed. Threads of wheel bolts must never be handled with grease or corrosion protection agents!
- Install wheel and tighten => [ Wheel Bolt Tightening Specifications ] See: Wheel
Fastener/Specifications.
Page 276
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Locations
Fuel Gauge Sender: Locations


Page 7715
STACK:
Page 5631
Page 1930
Ground (GND)

Page 5009
Page 621
Part 2
Page 2682
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5413
Part 1
Page 4824
End diagnosis.
Page 1072

Page 332
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2787
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2454
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 6316
Final procedures

Page 760
Instruments - Fuel Gauge May Not Read Full
Instrument Panel Control Module: Customer Interest Instruments - Fuel Gauge May Not Read Full
20 07 05
Apr. 2, 2007
2010432, Supersedes Technical Bulletin Group 20 number 07-04 dated March 29, 2007 due to
removal of Jetta (A5) from Metadata.
Vehicle Information
Condition
Fuel Gauge Sender, Incorrect Reading
Instrument Cluster Fuel Gauge may not read full.
Instrument Cluster software does not recognize tolerances in fuel sender signal which prevents the
fuel gauge from reading full.
Production Solution
Not applicable.
Service
Tools required:
^ VAS 5051 or 5052 diagnostic tool.
Procedure
^ Connect VAS 5051/5052.
^ Turn Ignition switch ON.
^ Select Guided Functions" on screen.
^ Select Brand.
^ Select appropriate vehicle model year and engine code.

^ Select continue.
^ Select J285-Instrument Cluster.
^ Select Fuel Gauge-Adapting.
^ Select continue.
^ Select fuel gauge adaption from programming list and select continue.
^ Select Option 2.
^ Continue with program.

Page 294
ABS Light Relay: Diagnostic Aids
Fuse: All Technical Service Bulletins A/T - Won't Shift Out of PARK/DTC's U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 6705
Ground (GND)

Air Bag Deactivation Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7689
Tip:
Tip:
Page 1464
legend.
wiring diagram.
harness.


question.)
19 - Legend



Trunk / Liftgate Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1345
Part 3
Page 450
Page 4196
Part 3
Page 4629

Page 5974
11 Air Duct
13 Intake Tube


Page 1262
1 - Track Numbers

Page 210
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3453
Module Components, Adapting ] See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection.
Removing

Installing
[ Comfort System Central Control Module, Coding ] See: Body and Frame/Body Control
Systems/Body Control Module/Testing and Inspection.
Heater
Heater
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 6190
stop:
Checking resistance
Page 3771
Li-Pe
Page 7167
Warranty

Information Bus: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7608
18 Circlip
‹› Check for proper seating
19 Wheel bearing
‹› Pressing out => [ Pressing out wheel bearing from wheel bearing
housing ] See: Wheel Bearing Housing
‹› Replace, destroyed during pressing out
‹› Pressing in => [ Pressing wheel bearing into wheel bearing housing ] See: Wheel Bearing
Housing
‹› Removing and installing with wheel bearing housing installed => [ Front Wheel Bearing, Hub and
Inner Race, with Wheel Bearing Housing
Installed ] See: Front Wheel Bearing, Hub and Inner Race, With Wheel Bearing Housing Installed.
For vehicles:
‹› With gasoline engine from 110 kW

Page 489
1 - Track Numbers

Page 6215
Page 7840
1 - Track Numbers

Page 6610
Part 2
Page 1479
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5385
Part 2
Page 1314
Removing
- Loosen the switch housing - arrow - from the frame with a screwdriver and then remove it.
Installing

Page 185
WHAT ARE TRACKS?
15-28, and so on).
Page 6337
1-800-525-2943
Page 329
Part 1
Page 3014
- Using engine/transmission jack, lift wheel bearing housing until dimension - a - has been reached.
CAUTION! ‹› Do not lift or lower vehicle with the engine/transmission jack below the vehicle.
‹› Do not leave Engine/transmission jack below the vehicle any longer than necessary.
- Tighten respective bolts/nuts.
- Lower wheel bearing housing.
- Remove engine/transmission jack from below vehicle.
- Remove wheel hub support (T10149).
Front Axle Toe, Adjusting
Front Axle Toe, Adjusting
to Measure.
- Loosen lock nut - 1 -.
- Set toe by twisting left and/or right tie rod.

Page 2291
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 2004
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5047

Page 1224
Hood Sensor/Switch (For Alarm): Diagnostic Aids
Page 2341
Part 2
Page 4270
Part 2
Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 4195
Part 2
Page 2013
Parking Brake Warning Switch: Diagnostic Aids
Page 110
1 - Track Numbers

Wiring Harness: All Technical Service Bulletins A/T - Won't Shift Out of PARK/DTC's
U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 5601
WHAT ARE TRACKS?
15-28, and so on).
Antenna Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3585
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1049
Page 6561
Page 6498
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1411
Page 2739
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1359
Part 2
Page 5345
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5121
Part 3
Page 4229
Ground (GND)

Page 7230
Locations
Steering Angle Sensor: Locations

6 Steering angle sensor (G85)
‹› Only in vehicles with ABS/EDL/ASR/ESP
‹› Location: On steering column between steering wheel and steering column switch.
Page 5805

Page 4885
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1835
Part 3
Page 582
1 - Track Numbers

Page 6652
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6304
Part 1
Page 4907
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2756
WHAT ARE TRACKS?
15-28, and so on).
Wheel Speed Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5475
Final procedures

Page 3837
Engine Oil, Filling
General Information
A Oil must not be topped off. B Oil can be topped off. After topping off, oil may be in range - A -. C
Oil must be topped off. It is sufficient when oil level is in area - B - (grooved field).
Page 5414
Part 2
Page 5215
Part 3
Page 4963

Locations

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 4767
Heater
‹› Multimeter.
‹›
Test requirements
Test procedure
Start diagnosis
arrows -.
correct resistance.
- Start the engine.


Page 3999
- Finally, tighten the bolts to the cylinder block and upper oil pan to 25 Nm.
- Wipe off any sealant, which has leaked out.
- Drive the alignment bushings in until seated, if necessary.
- Install a new seal. Refer to => [ Crankshaft Seal, Transmission Side ] See: Seals and
following:
‹› Install the brake booster vacuum pump. Refer to => [ Brake Booster Vacuum Pump ] See:
Brakes and Traction Control/Power Brake
Assist/Vacuum Pump/Service and Repair/Brake Booster Vacuum Pump.
‹› Install the cylinder head. Refer to => [ Cylinder Head ] See: Cylinder Head Assembly/Service and
Repair/Removal and Replacement/Cylinder
Head.
‹› Install the drive plate. Refer to => [ Drive Plate ] See: Transmission and Drivetrain/Flex
Plate/Service and Repair/Drive Plate.
Page 2540
WHAT ARE TRACKS?
15-28, and so on).
Page 4889
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2378
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 2559
Impact Sensor: Service and Repair Driver/Front Passenger Side Airbag Sensor Assembly
Overview From 05/03
Airbag
Driver/Front Passenger Side Airbag Sensor Assembly Overview from 05/03
2 - Bolt
‹› 9 Nm
3 - Connector
Page 2672
Oxygen Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 7809
Part 2
Page 4597
Part 3
Page 2231
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1813
WHAT ARE TRACKS?
15-28, and so on).
Page 2715
Part 1
Service and Repair
Fluid Filter - A/T: Service and Repair
Oil Strainer
Removing
- Remove oil strainer bolts - arrows -.
- Pull oil strainer - A - off valve body.
Installing
- Lightly coat seals on intake union of oil strainer with ATF.
‹› If the oil seals are loose or faulty replace the oil strainer
- Place oil strainer - A - on to valve body and tighten bolts - arrows - => [ (Item 9) Bolt, 11 Nm ]
Left Front Level Control System Sensor Overview
Ride Height Sensor: Application and ID Left Front Level Control System Sensor Overview

Service and Repair/Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
Basic setting of headlights
1 Bracket
2 Hex nut
‹› Tightening specification => See: Steering and Suspension/Suspension/Specifications/Front

Suspension.
3 Left front level control system sensor (G78)
‹› For complaints => Perform Basic Setting in "Guided Fault Finding" using VAS 5051
4 Coupling rod of left front level control system sensor (G78)
‹› Tightly coupling rod bolt in area of marking - arrow - of bracket -=> [ (Item 9) Bracket ] -
5 Control arm
Page 699
Control Modules
‹› Body

Page 6900
Warranty
Information only.
removal.
Locations

Page 2208
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3361
Component Tests and General Diagnostics
Information Bus: Component Tests and General Diagnostics
CAN Bus Terminal Resistance, Checking
CAN Bus Terminal Resistance, Checking
‹› Multimeter.
Test requirement
‹› A CAN-Bus malfunction was recognized.
‹› The Engine Control Module (ECM) ( J220) fuses OK.
Function
The Engine Control Module (ECM) (J220) communicates with other CAN-Bus capable control
modules.
The control modules are connected by two data bus wires which are twisted together (CAN High
and CAN Low), and exchange information (messages). Missing information on the CAN bus is
recognized as a malfunction by the Engine Control Module (ECM) (J220) and the other control
modules connected to the CAN bus.
Trouble-free operation of the CAN Bus requires that it have a Terminal Resistance. This central
Terminal Resistance is located in the Engine Control Module (ECM) (J220).
Test Procedure
‹› The Engine Control Module (ECM) (J220) must remain connected for the following test.
- Remove the air cleaner assembly.
- Disconnect the ABS Control Module (J104) electrical harness connector.
- Using a multimeter, check the ABS Control Module (J104) electrical harness connector terminals
11 to 15 for the correct Terminal Resistance.
Specified value: 57 to 62 ohms (at approx. 20° C)

Checking wiring
Fluid - M/T: Capacity Specifications
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 1.8 liters
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 2.0 liters
Transmission fluid
Capacity ...............................................................................................................................................
..................................................................... 2.3 liters
Page 1457
Specifications - Clutch
Clutch Disc: Specifications Specifications - Clutch
‹› 1 Always replace
Page 1581
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 143
Global Positioning System Module: Testing and Inspection Telematics Control Module (J499),
Configuring
Telematics
Telematics Control Module (J499), Configuring
‹› Vehicle Diagnostic, Testing and Information System ( VAS 5051B)
After replacement of the Telematics control module, it must be coded and configured for the
OnStar system. Have the VIN and customer data ready.
‹› Do not swap out any Telematics control modules between different vehicles! Each Telematics
‹› If the configuration of the Telematics control module is not performed, OnStar service and other
functions will not work so that the customer will
need to return to repair service.
Procedure:
‹› The Telematics control module was coded, refer to => [ Telematics Control Module , Coding ].
See: Telematics Control Module (J499), Coding
- Make a note of the 8-digit Station Identification Number (STID) and the Electronic Serial Number
(ESN) on the sticker on the Telematics control module.
- Connect (VAS 5051B).
After all DTC memories have been queried, continue with.
If the STID number and ESN are not on the sticker of the new Telematics control module, continue
as follows:
‹› Body
‹› Check control module version
- Make a note of the ESN and STID number on the display.
Continuation for all:
‹› Body

Page 5294
WHAT ARE TRACKS?
15-28, and so on).
Page 3595
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage

wiring diagram.
Page 2892


Page 2400
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4649
1 - Track Numbers

Page 2731
Ride Height Sensor: Service and Repair Left Rear Level Control System Sensor Overview

Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
4 Bracket
5 Axle beam
6 Hex bolt
Page 3269
Pe-Ca
Page 1463
1 - Track Numbers

Page 3232
- Drain ATF.
- Finally, check ATF level and top off => [ ATF Level ] See: Testing and Inspection/ATF Level.
Page 7521
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Overview

1 Fuel Filter

and Replacement.
2 Retaining Clip

Page 1701
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 1077
Final procedures
Systems/Testing and
End diagnosis.
Page 4298
Checking wiring


Page 4019
11 Air Duct
13 Intake Tube

Page 4403
1 - Track Numbers

Page 567
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4377
Part 2
Page 3733
19 Coolant Pump
‹› In the cylinder block.
‹› Removal and installation, refer to => [ Coolant Pump ] See: Water Pump/Service and Repair.
20 Ribbed Belt Tensioner, for the A/C Compressor Belt, 35 Nm
21 Ribbed Belt Tensioner, for the Generator, Power Steering Pump and Coolant Pump Belt, 35 Nm

‹› Replace
23 Bolt, 25 Nm
24 Bushing
‹› Quantity: 2
25 Engine Mount
Ribbed Belt Routing
1. Power steering pump
2. Generator pulley
3. Lower idler pulley
4. Ribbed belt, for the generator, power steering pump and coolant pump
5. A/C compressor pulley

Page 6648
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7304
Part 2
Page 3371
Part 1
Page 6618
- Multimeter
- Wiring diagram
Test procedure
Start diagnosis
1 -.
Checking wiring


Page 1620
Steering Angle Sensor: Service and Repair
Steering Angle Sensor
Removing
- Remove airbag and steering wheel.
- Put wheels in straight-ahead position.
- Remove cover in footwell.
- Remove bolts - 1 -.
- Remove handle for height and length adjustment - 5 -.
- Remove bolts - 2 -, - 3 - and - 4 -.
- Remove lower part of trim for steering column switch.
- Remove upper part of steering column switch trim - 1 -.
Steering angle sensor (G85) is installed in housing - 1 - together with spiral spring.
Page 4313
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6823
Part 1
Page 5459
removal.
Page 6911
- End diagnosis.
Final procedures
Systems/Testing and
End diagnosis.
Page 2374
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7482
Clutch Pedal Assembly: Service and Repair Clutch Pedal
Clutch Pedal
‹› Pliers (T10005)
Removing
- Remove clutch pedal switch (F36) => [ Clutch Pedal Switch ] See: Clutch Switch/Service and
Repair.
- Remove over-center spring => [ Over-Center Spring ] See: Over-Center Spring.
- Separate clutch pedal from master cylinder => [ Master Cylinder ] See: Clutch Hydraulic
System/Clutch Master Cylinder/Service and Repair, and push operating rod toward engine
compartment until stop.
- Remove nut - A -.
- Loosen bolt until clutch pedal can be removed.
Installing
‹› Replace self-locking nut.
- Mount - A - must be located on operating rod - B - of master cylinder.

Page 3826
- Install dust cap -arrow- hand-tight in oil filter housing.
Replacing oil filter (Diesel engines)
Removing
Note: Observe waste disposal regulations! Oil new O-rings before installation.
- Loosen sealing cap -arrow- e.g. using ring wrench AF 36 or using socket insert AF 36 T10125.
Note: Loosen cap before draining/extracting so that engine oil can flow out of filter housing.
Installing
- Install oil filter -3-
- Replace O-rings -2 and 4-.

Parking Brake Warning Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3762
Parts and Tools.
Note:
Always clean contaminants from both oil drain plug and oil pan drain hole threads. Never use air
tools to install the oil drain plug, as damage to the oil pan can occur.
Do not exceed the specified torque. Exceeding the specified torque may damage the oil pan or
bend the sealing washer, which can lead to leaks at the drain plug.
Oil pans with damaged threads will not be covered under Warranty.
Engine oil, filling
To prevent overfilling, for all engines:

^ Add approximately 1/2 quart (or liter) less than capacity.
^ Start engine and let run until engine operating temperature is approximately 60°C (140°F), switch
ignition off.
^ Wait about three minutes.
^ Check level on oil dipstick and fill to dipstick full mark. This may be even more or less than 1/2
quart (or liter), depending on engine.
Warranty
Information only
No special parts required. Always see ETKA for the latest part(s) information.
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 309
Brake Fluid Pump Relay: Diagnostic Aids
Page 999
Compressor/Pump Relay: Diagnostic Aids
Page 393
Part 1
Page 6593
Part 2
Page 63
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 173
Part 3
DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 3960
8 Oil Pump Sprocket
‹› Removal and Installation, refer to one of the following:
From MY 2008.
9 Oil Pump Drive Chain Guide Rail
10 Oil Pump Drive Chain

Page 111
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7441
Clutch Disc: Specifications Specifications - Clutch Pressure Plate Bolts
Sachs
Clutch, Pressure Plate Bolts, Sachs (M7)
First pass: Hand-tighten all bolts evenly by hand until bolt head makes contact on pressure plate
Final pass
................................................................................................................................................ 20 Nm
LuK
Clutch Pressure Plate Bolts, LuK (M6)
First pass: Hand-tighten all bolts evenly until bolt head makes contact on pressure plate Final pass
................................................................................................................................................ 13 Nm
Page 1887
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1507
Sunroof / Moonroof Switch: Service and Repair
Sunroof
Sunroof Automatic Rotary Switch
- Unclip trim - 1 - in - direction of arrow - and remove.
- Remove bolts - 1 - and carefully unhook retaining frame locking lugs of automatic preselector -
arrows -.
- Disconnect harness connector.

Page 1417
1 - Track Numbers

Page 2744
Part 2
Page 7457
Clutch Fluid: Service and Repair


Page 2494
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 2874
stops.

Page 3767
using the VAS 5051 The results and diagnostic log must be sent to the Volkswagen Technical
Assistance Center (TACS) before any repairs are performed.
4. Advise the customer that if the low oil level warning light comes on before the 630 mile (1014
km) test is completed, the vehicle must be taken
directly to the Dealership for part # 2 of the oil consumption test, regardless of the miles
accumulated. The customer should not add any oil.
Note:
Page 1714
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 2176
Final procedures

Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Locations

Page 871
NOTE
If a connection error is indicated for Seat Occupant Recognition Module not found", an "ERROR"
indicator on the VAS 5052 / VAS 6150 screen is highlighted.
^ Check all connections.
^ Restart application by pressing EXIT".
^ Switch ignition key ON and then OFF
^ Begin procedure again.

If error continues, try rebooting scan tool and re attempt to perform programming update.
After programming is complete or verified flash was already applied,
^ Disconnect VAS 6103/2 pods connector and VAS 6103 from scan tool.
^ Reconnect 5052/3 diagnostic cable to VAS 5052 I VAS 6150 tester and reconnect vehicle Data
Link Connector.
^ Reconnect and lock Seat Occupant Recognition Module 10 pin connector to body 10 pin
connector. Be sure that the connector snaps locked.
^ Switch ignition ON.

Page 7141
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7308
Page 981
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Acceleration/Deceleration Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6697
Checking wiring
terminal 1
45
28

- End diagnosis.
Final procedures
End diagnosis.
Page 42
- Antenna cables - double DIN (Premium VI) radio.
- Antenna cables - Phaeton 2004 > 2006
- Antenna cables - Satellite radio (Hard top vehicles)

Page 1850
Part 3
Page 2049
Ground (GND)

Page 1128
Ground (GND)

Page 5679
Page 3441
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6860
Checking wiring

Page 993
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7320
Ground (GND)

Locations
Neutral Safety Switch: Locations


Page 4748
Part 2
Specifications
Wheel Fastener: Specifications
Wheel Assembly, Tightening Specifications
Wheel bolt to wheel hub for all vehicles Tightening torque .................................................................
................................................................................................................................ 120 Nm
Page 1131
Part 1
Page 787
Ground (GND)

Page 7250
- Pull button - 2 - out of handle - 4 - until it stops - arrow -.
- Secure button from springing back e.g. using a wire bracket - 3 -.
- Remove selector lever handle.
Installing
- Pull button - 2 - out of handle - 4 - until it stops - arrow -.
- Secure button from springing back e.g. using a wire bracket - 3 -.
‹› Installation position: Button faces driver.
- Press handle onto selector lever up to stop.
- Remove wire bracket.
- Press button to secure pull lever - 5 - in pull-rod - 6 -. Button must now spring back to stop again.
- Rotate and slide sleeve - 1 - upward until tabs in sleeve engage and lock audibly into slots of
handle - 4 -.
- Move selector lever in position "P".
Selector Mechanism Cover and Circuit Board

Page 2837
legend.
wiring diagram.
harness.


question.)
19 - Legend




F125

Page 7085
- Install Multi-Function Transmission Range (TR) Switch (F125) => [ Multi-Function Transmission
Range Switch ] See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service
and Repair.
- Adjust Multi-Function Transmission Range (TR) Switch (F125) => [ Multi-Function Transmission
Range Switch, Adjusting ] See: Sensors and Switches - A/T/Transmission Position
Switch/Sensor/Adjustments.
Page 1610
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1568
WHAT ARE TRACKS?
15-28, and so on).
Page 50
WHAT ARE TRACKS?
15-28, and so on).
Page 6991
Page 3185
Brake Fluid: Service and Repair Brake and Clutch System, Changing Brake Fluid


Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Body - Door Lock Rotary Switch Diagnostic Aid
Door Module: Technical Service Bulletins Body - Door Lock Rotary Switch Diagnostic Aid
57 07 08
July 30, 2007
2015633 Supersedes T.B. Group 57 number 07-07 dated July 18, 2007 due to modified door ajar
switch testing procedure.
Condition
Vehicle Information
Door Lock Rotary Switch Diagnostic Aid
Instrument cluster display shows door ajar, anti-theft alarm may intermittently sound, Battery may
discharge and / or power door lock inoperative.
Information only, to assist with diagnosis of door lock rotary switch and / or door ajar switch.
Production Solution
Service
Tip:
When performing the following procedure, two keys will be required.
To Check Rotary Switch Function (all vehicles except Passat):
2. Insert key into lock cylinder.
3. Rotate key to lock position and hold, windows should roll up.
4. Rotate key to unlock position, windows should roll down.
If windows do not operate as stated above:
1. Verify rotary position via Measured Value Block with VAS 5051/5052.
a. Select Guided Functions.
b. Select Door Control Module.
c. Read measure value block 5, function 4, Drivers Side Key Switch.
d. Cycle the key cylinder back and forth several times while monitoring measure value block 5,
function 4.
Tip: Ensure door is closed during the key cycling procedure.

Page 3799
Page 5469
Page 1247
1 - Track Numbers

Page 6397
1 - Track Numbers

Page 7830
Page 7649
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6449
‹› Puller (T10112)
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Procedures
Oil Filter: Procedures
Engine oil, draining or extracting; changing oil filter and filling engine oil
Warning!
On engines with standing oil filter module, the oil filter should be changed before the oil
change.Removing the filter element will open a valve and oil in the filter housing will flow
automatically into the crankshaft housing. The oil drain plug is equipped with a permanent seal,
therefore the oil drain plug must always be replaced.
- Oil extractor V.A.G 1782
- Oil absorbent towel VAS 6204/1
Engine oil, draining or extracting
- Extract engine oil using old oil collecting and extracting unit V.A.G 1782.
or
- Drain engine oil.
- Fill motor oil.
Engine oil capacities, refer to Fluid Capacity Charts for appropriate model and year.
- The torque specifications are dependent on engine code
Warning!
Torque settings must not be exceeded A torque figure that is too high may lead to leaks or even
damage the oil pan.
Replacing oil filter, 1.8 L-, 2.0 L fuel injection engines

Page 1286
Page 7630
‹› Drive plate, removal and installation. Refer to => [ Drive Plate ] See: Drive Plate.
8 Sensor Wheel
‹› Removal and installation, refer to => [ Crankshaft Seal, Transmission Side ] See: Engine,
Cooling and Exhaust/Engine/Seals and
‹› Removal and installation, refer to => [ Control Housing Cover ] See: Engine, Cooling and
Exhaust/Engine/Camshaft, Lifters and Push
Rods/Variable Valve Timing Cover / Housing/Service and Repair.
11 O-ring
‹› Replace
12 Bolt, 25 Nm
14 Bolt, 5 Nm
16 Seal
‹› Replace
Page 2041
Brake Light Switch: Service and Repair Brake Light Switch, From 12.06
Brake Light Switch, from 12.06
‹› Use only new type brake light switches.
‹› The most visible distinguishing feature is the new lighter colored end of the push rod head- A -.
Removing
- Remove trim on driver's side
- If necessary remove footwell vent
- Pull connector off brake light switch.
The brake light switch may be removed only while operating rod is pressed in (brake pedal is not
operated), or the locking mechanism of the brake light switch will be damaged.
- Remove brake light switch by rotating 45 degrees toward left.
Installing, adjusting and locking
Before installing the brake light switch, grease the lighter colored end of the push rod head with
polycarbamide grease (G 052 142 A2).
‹› The brake light switch must not be operated while the brake light switch is being installed. The
brake pedal may only come into contact with the
push rod head of the brake light switch during the whole installation process.
- Guide the brake light switch through the assembly aperture - arrow 1 - and push it with the push
rod head against the brake pedal. Then turn the brake light switch through 45 degrees to the right -
arrow 2 - until it noticeably engages.
Page 982
Locations
9- Steering angle sensor -G85

^ Location: On steering column between steering wheel and steering column switch.
^ Observe installation instructions
^ When the steering angle sensor -G85- is replaced, a zero compensation must be performed
^ Introduce basic setting, perform display group number 060

Brake Fluid Level Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6251
Part 1
Page 4214
Page 720
Page 4816
Part 1
Page 7605
Installing
Pressing wheel bearing into wheel bearing housing
- Install securing ring.
‹› Make sure securing ring is correctly seated. Opening of securing ring must point downward.
Press wheel hub into wheel bearing
‹› If it should be necessary to move a vehicle whose drive axle has been removed, then before
doing so install an outer joint in place of the drive axle
and tighten it to 50 Nm, or else wheel bearing will be damaged.

Page 6225

Code.
Page 305
Part 2
Sender For Rotation Rate G202 and Sensor For
Transverse Acceleration G200, Removing and Installing,
Vehicles From 11.01
Yaw Rate Sensor: Service and Repair Sender For Rotation Rate G202 and Sensor For Transverse
Acceleration G200, Removing and Installing, Vehicles From 11.01
Sender for rotation rate G202 and Sensor for transverse acceleration G200, removing and
installing, Vehicles from 11.01
Note: ^
Removing and installing the sender for rotation rate G202 and the sensor for transverse
acceleration G200 is identical except for the mounting bracket for each component.
Removing
- Request radio code on vehicles with coded radio.
- Disconnect battery.
- Pry off cover caps - 1 - and remove screws - 2-.
- Remove switch mounting - 3 - from bracket.
- Release cover - 1 - from rear, off instrument panel and pull off.
- Remove screw - 2 - and screws - 3 -.
- Turn rotary knob - 1 - of lighting switch to position 0.
- Press rotary knob inward - arrow A - and then turn to the right - arrow B -.
- Disconnect switch out of instrument panel - arrow C - and disconnect electrical connections.
- Unclip headlight range control switch - 2 - and disconnect connector.

Page 1829
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4900

Code.
Page 1395
Page 1965
Part 1
Page 7856


Page 1664
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Wiring
Wheel Speed Sensor Wiring
‹› Wiring harness repair kit (VAS 1978)
Removing
- Note radio code (for vehicles equipped with coded anti-theft radio).
- Remove bolts - 3 -, - 4 - and - 5 -.
- Disengage connector - arrow 1 - and disconnect - arrow 2 - from control module.
- Loosen and remove cap of multi-pin connector using a screwdriver.

Page 4718
1 - Track Numbers

Page 2104
Part 1
Page 700
Control Modules

Removing

Page 2673
Steering Column Position Sensor: Diagnostic Aids
Page 4821
Page 2633
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1303
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 752
order)
Tip:
Page 1962
Ground (GND)

Page 4850
Part 2
Page 2338
WHAT ARE TRACKS?
15-28, and so on).
Page 2456
Final procedures

09.

Code.
Page 7593
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing, Hub and Inner Race, With Wheel Bearing Housing Installed
Front Wheel Bearing, Hub and Inner Race, with Wheel Bearing Housing Installed
‹› Hub puller (3283)
‹› Engine/transmission jack (V.A.G 1383 A) with universal transmission support (V.A.G 1359/2)
‹› Puller (Kukko 18/0 )
‹› Foot pump with high pressure hose (V.A.G 1389 A/1 )
‹› Wheel bearing tool (V.A.G 1459 B)
‹› Hollow piston cylinder (HKZ-15) with thrust piece (E-0-204-T) hydraulic
‹› Tie bolt (E-0-217+218)
‹› Special nut (E-8-214)
‹› Pressure bolt (E-15)
‹› Supplementary set (V.A.G 1459 B/2)
‹› Bell (E-40)
If there is a hand pump ( V.A.G 1389/1) available it can also be modified for use as a foot pump.
To do so, use conversion kit (V.A.G 1389/4 ).
Removing
- Remove wheel.
Page 3254
Fluid - M/T: Fluid Type Specifications
Transmission fluid
Type .....................................................................................................................................................
................................................. Refer to parts catalog
Transmission fluid
Type .....................................................................................................................................................
......................... G50 SAE 75w-90 Synthetic Gear oil
Transmission fluid
Type .....................................................................................................................................................
Page 1007
WHAT ARE TRACKS?
15-28, and so on).
Page 2468
Part 3
Page 3006
- If necessary, correct the existing difference.
At the front axle, it can be compensated by applying weights on to corresponding suspension strut
dome in engine compartment.
At the rear axle, it can be compensated by applying weights in luggage compartment on the
corresponding vehicle side.
For example, sand bags of approximately 10 kg are suitable as weights.

Page 5934
Recall 10V621000: Fuel Supply Line Replacement
Fuel Supply Line: Recalls Recall 10V621000: Fuel Supply Line Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Volkswagen/Jetta 2006-2010
Volkswagen/Jetta Sportwagen 2009
Volkswagen/New Beetle 2006-2010
Volkswagen/New Beetle Convertible 2006-2010
Volkswagen/Rabbit 2007-2009
MANUFACTURER: Volkswagen of America, Inc.
MFR'S REPORT DATE: December 14, 2010
NHTSA CAMPAIGN ID NUMBER: 10V621000
NHTSA ACTION NUMBER: N/A
COMPONENT: Fuel System, Gasoline: Delivery: Hoses, Lines/Piping, and Fittings
POTENTIAL NUMBER OF UNITS AFFECTED: 377,286
SUMMARY: Volkswagen is recalling certain model year 2006-2010 Jetta, New Beetle, New Beetle
Convertible, model year 2009 Jetta Sportwagen and model year 2007-2009 Rabbit vehicles
equipped with 2.5L engines. The Jetta, Jetta Sportwagen, and Rabbit vehicles may have a small
plastic tab located on the windshield washer fluid reservoir that may chafe against an underhood
fuel supply line. The New Beetle and the New Beetle Convertible vehicles may have a fastening
clamp on a hydraulic hose of the power steering system that may be located in an improper
position which could cause chafing against an underhood fuel supply line.
CONSEQUENCE: If chafing occurs, there is the potential for a fuel leak to develop. Fuel leakage,
in the presence of an ignition source, could result in a fire.
REMEDY: Dealers will inspect and if necessary replace the underhood fuel line. Additionally,
depending on the vehicle model, dealers will either remove the plastic tab from the windshield
washer fluid reservoir, or inspect the position of the fastening clamp and adjust the related
fastening clamp into the correct position. This service will be performed free of charge. The safety
recall is expected to begin on or before January 31, 2011. Owners may contact Volkswagen at
1-800-822-8987.
NOTES: Volkswagen safety recall No. 20I4/U1. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.

Page 551
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7225
Part 1
Locations
Outside Temperature Sensor G17

Page 5302
Information Bus: Electrical Diagrams
IMPORTANT NOTE:
IMPORTANT NOTE:
Locations

Page 6494
1 - Track Numbers

Page 598
1 - Track Numbers

Page 770
Technical Data
Technical Data
Page 4771
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 2503
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3795
Page 2916
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 126
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5624
Ground (GND)

Locations
Fuel Rail: Locations
Fuel Rail and Injectors Assembly Overview

1 Bolt, 3.5 Nm
2 Fuel Rail
3 Fuel Supply Line
4 O-ring
‹› Replace
‹› Lubricate with clean engine oil.
5 Retaining Clip
‹› Make sure the clip is correctly seated on the fuel injector and rail.
6 Fuel Injector (N30, N31, N32, N33, N83)
‹› Removal and installation, refer to => [ Fuel Injectors ] See: Fuel Injector/Service and Repair/Fuel
Injectors.
‹› Checking, refer to => [ Fuel Injectors, Checking Injection Quantity and for Leaks ] See: Fuel
Injector/Testing and Inspection/Fuel Injectors,
Checking Injection Quantity and For Leaks.
7 Intake Manifold
8 Protective Cap
Page 1217
WHAT ARE TRACKS?
15-28, and so on).
Page 4393
Part 2
Page 992
WHAT ARE TRACKS?
15-28, and so on).
Page 6254
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 722
stop:
Checking resistance
Page 5798
Air Injection Pump: Service and Repair
Secondary Air Injection Pump Motor
Removing
‹› Secondary Air Injection (AIR) pump motor (V101) is removed together with bracket.
- Remove the left front wheel housing liner.
- Disconnect the intake pipe - 2 - and pressure pipe - 1 -. To do so, compress the securing ring.
- Disengage and disconnect the connector - 3 -.
- Unclip the harness connector - 4 - from the bracket.
- Remove the bolt - 3 - for the double signal horn bracket.

Page 1067
Page 4839
Final procedures

Page 548
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1908
Solar Sensor: Diagnostic Aids
Page 2339
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 892
WHAT ARE TRACKS?
15-28, and so on).
Page 3345
Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 3265
Warranty
Page 6861
circuit.
- End diagnosis.
Final procedures
Page 5804
Page 4448
Ground (GND)

Page 930
Charging System Relay: Diagnostic Aids
Page 6883
Tip:
Page 2758
Part 1
Electronic Throttle Actuator: Locations Accelerator Pedal Module Assembly Overview

1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
5 Bracket

Fluid - M/T: Customer Interest M/T - Humming Noise When Turning at Low Speeds
34 06 02
June 12, 2006
2011899
Affected Vehicles
under load.
Production Solution
Service
model years.
Page 2908

- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
resistance.

Page 1936
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6128
Fuel Gauge Sender: Diagnostic Aids
Page 412
Global Positioning System Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1454
Part 2
Page 6885
Warranty
Information only.
removal.
Page 5153
Throttle Position (TP) Actuator V60

Control Module: Customer Interest A/T - Won't Shift Out of PARK/DTC's U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 1654
Part 2
Page 5341
1 - Track Numbers

Page 3534
‹› Arbor 50 mm dia. (VW432)
‹› Thrust pad (VW442)
‹› Thrust pad (VW 447 i)
‹› Press appliance (VW 459/2)
‹› Box wrench (46 mm) (3252 A)
‹› Wheel bearing assembly set (3253)
Removing
Pressing wheel hub out of wheel bearing housing
Pulling bearing inner race off of wheel hub

Page 7461
Parking Brake Warning Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1377
Part 2
Page 7678
‹› Taper roller bearing puller (V.A.G 1582)

‹› Attachment (V.A.G 1582/3)
‹› Thrust Disc (VW 412)

Page 5293
Ground (GND)

Page 2941
Power Window Safety Switch: Diagnostic Aids
Page 4178
Page 6480
Installing

Page 359
Ground (GND)

Page 7325
Part 3
Page 4236
Page 1666
Terminal assignment of harness connector (T25) wiring harness/ABS control module (J104).
ABS/EDL/ASR/ESP Mark 20 IE Harness Connector ( T47)
ABS/EDL/ASR/ESP Mark 60 Harness Connector ( T47)
- Using a prodding tool from wiring harness repair kit (VAS 1978 ), poke out the relevant terminals.
Page 3431
‹› By briefly pressing on the scroll bar - 2 - right of the cursor, the number value is increased by one
number.
‹› By briefly pressing on the scroll bar - 3 - left of the cursor, the number value is decreased by one
number.
‹› The adaptation value in the upper line shows the maximum distance that can be driven to the
next service event (15 = 15 000 km, 30 = 30 000 km,
50 = 50 000 km).
50 LongLife Service 4-cylinder diesel engines: engine oil conforming to VW standard 506 00 (TDI)
or VW standard 506 01 (PD TDI)
30 LongLife Service for gasoline engines: engine oil conforming to VW standard 503 00
15 Time- or distance-dependent service: no engine oil according to VW-Norm 503 00 (gasoline

engines), 506 00 (TDI) or 506 01 (pump injector TDI)
By selecting the adaptation value 15, the instrument panel insert is coded "non-flexible", i.e. "time
or distance dependent ".
‹› If the instrument panel insert is to be coded to "flexible" (LongLife service), the adaptation value
30 must be selected for gasoline engines and/or
the adaptation value 50 must be selected for diesel engines.
- Press the Save button - 4 - on display.
Page 2191
Final procedures

09.

Code.
Page 4361
‹› Remove pin (T03000/1) from (T03000).
‹› Install the (T03000) to the cylinder block with pin - 3 - and tighten the bolts - 1 and 2 - hand tight.
‹› Then install pin (T03000/1) and tighten to 20 Nm.
‹› Then tighten bolts - 1 and 2 - to 25 Nm.
- Place the (T03000) on the (VAG 1383A) and lift the engine/transmission assembly slightly.
- Remove the engine mount bolts - arrows - from above and remove.
‹› Use (VAS 5085) to remove the bolts.
- Remove both front bolts from the holding fixture.
- Remove the transmission mount bolts - arrows - from above.

Page 2696
Ground (GND)

Page 448
Part 3
Page 115
Part 1
Page 6239
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2156
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5824
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 216
Memory Positioning Module: Diagnostic Aids
Heater
Heater
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 5512
Final procedures

Page 2440
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4349
Thermostat: Service and Repair
Coolant Thermostat
‹› Drip tray (VAG 1306) or drip tray for VAS 6100 (VAS 6208)
Removing
- Remove the intake manifold. Refer to => [ Intake Manifold ] See: Engine/Intake Manifold/Service
and Repair/Intake Manifold.
- Install the guide tube for the oil dipstick into the cylinder block again and secure it tightly so that
no escaping coolant can run into the engine.
- Place a suitable container under the coolant thermostat housing to catch coolant flowing out.
- Remove the bolts - arrows -, disconnect the connecting piece - A - and remove the thermostat.
Installing
‹› Replace the seal - item 17 - in => [ Seal ] See: Service and Repair/Removal and
Replacement/Cooling System Components, Engine Side and
O-ring - item 15 - in => [ O-ring ] See: Service and Repair/Removal and Replacement/Cooling
System Components, Engine Side.
‹› Note the installed position of the thermostat - 1 -. Valve - 2 - must point upward.
Page 5762
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3917
- Lightly move the knurled bolt of the (VAS 5161/8) back and forth, this causes the valve keepers to
be pressed apart and captured in the (VAS 5161/8).
- Release the (VAS 5161/2).
- Remove the (VAS 5161/8), valve spring retainers and valve springs.
- Remove the valve stem seal using (3364).
- In the event the (3364) cannot be used due to limited space constraints, drive out the spring
dowel sleeve - arrow - using a drift and remove the impact device.
- Place the lower part of the (3364) onto the valve stem oil seal.
Page 5696
Part 1
Specifications
Firing order
1-2-4-5-3
Page 4156
Part 3
Locations

Page 3578
Page 1961
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1799
Part 1
Acceleration Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4572
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
30) to Ground.

Page 593
Headlamp Alignment Control Module: Service and Repair
HID Headlamp
Headlamp Range Control Module
The Headlamp Range Control Module (J431) is installed in the left front wheel housing.
Removing
- Remove the left front wheel housing liner.
- Remove the screws - 1 - on the Headlamp Range Control Module (J431).
- Disconnect the connector - 2 - on the Headlamp Range Control Module (J431).
Installing
- Make sure the headlamp is working correctly.
Coding the Headlamp Range Control Module (J431).
- Perform basic setting of headlamp, refer to => [ HID Headlamp, Basic Setting ] See: Lighting and
Horns/Headlamp/Service and Repair/Procedures/HID Headlamp, Basic Setting.
Page 7144
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 556
Page 2225
Ground (GND)

Page 5760
Ground (GND)

Page 2253
Page 7114
- Multimeter
- Wiring diagram
Test procedure
Start diagnosis
1 -.
Checking wiring

A/C - Insufficient Heater Output at Idle
Coolant Reservoir: Customer Interest A/C - Insufficient Heater Output at Idle
Condition
80 07 05
Sept. 14, 2007
2011762 Supersedes T.B. Group 80 number 07-01 due to addition of coolant reservoir and
warranty table information change.
Customer States Heater Output is Sufficient while Driving But is Reduced When Idling
While driving heat output from HVAC will warm cabin area sufficiently when setting is at high, med,
or low, but when idling, heat output greatly diminishes.
For example, output temperature from center vent while driving is approximately 160°F (71°C), but
while sitting at idle, output temperature decreases to approximately 90°F (32°C).
May be caused by a small amount of air in cooling system.
Production Solution
Improved coolant reservoir as of VIN:
1C_7M 518233
1Y_7M416166
Service
Install improved coolant reservoir Part No. 1C0121407 E, see Repair Manual Group 19 Engine -
Cooling system, in ElsaWeb.
After installation:
^ Purge the air from coolant system using the VAS 6096 "Cooling System Charge Unit" as follows.
WARNING
Prior to working on any cooling system, always review and follow all Notes, Tips, and Warnings in
Group 19 - Engine - Cooling system.
Tip:
Illustrations used in this Bulletin are from documentation included with the VAS 6096 "Cooling
System Charge Unit".
Procedure:
^ Install the VAS 6096 onto the Cooling System using the appropriate adapters (fig. 1).
Page 1540
Brake Booster Vacuum Sensor: Diagnostic Aids
Page 5666
Part 2
Page 6592
Part 1
Page 7502
Repair/Clutch, Sachs
‹› Check spring connections and rivet connections => [ Check Spring Connections and Rivets ]
See: Service and Repair/Clutch, Sachs
‹› Only replace together with clutch disc
4 M7 bolt, 20 Nm

Page 2024
Part 2
Locations
Brake Light Switch: Locations
3- Brake light switch -F
^ The brake light switch is open in the rest position

Page 3502
Page 224
WHAT ARE TRACKS?
15-28, and so on).
Page 5792
Final procedures

Page 5686

Page 2745
Part 3
Page 6123
Part 1
Page 948
Part 1
Page 2507
Part 1
Page 4373
Ground (GND)

Page 4068
- Carefully lower the engine with transmission only as far downward - arrow 2 - until pin - 4 - of
transmission mount bracket can be slid toward the left - arrow 3 - out from under the transmission
mount.
- Slide the engine/transmission assembly until it stops at left longitudinal member.
- Rotate the pulley so that arrow - A - (relative to engine axis) points upward vertically.
- Remove the coolant pump bolts - arrows -.
- Pull the coolant pump - A - out of the cylinder block.

Page 4169
1 - Track Numbers

Page 7565
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7488
Otherwise, the clutch pedal switch will be destroyed.
Positions of stops - A - and - C - must be corrected:
- Press in plunger until it stops - arrow 1 -.
- At the same time, rotate upper part of clutch pedal switch in direction of - arrow 2 - until stop.
- Before installing clutch pedal switch (F36), pull out plunger completely.
- Insert clutch pedal switch (F36) into assembly hole.
- To engage, turn clutch pedal switch (F36) at housing 45 degrees toward right.
- Connect connector on clutch pedal switch (F36 ).
- Install cover in driver's side footwell.

Page 6951
ATF Level, Checking

ATF Level, Checking
The ATF temperature should not be more than approximately 30°C at start of test. ^
Transmission not in emergency running mode; ATF temperature not above approximately 30°C
^ Vehicle must be standing level
^ Selector lever in "P".
- Connect tester and continue switching until it is ready for operation Vehicle Diagnosis, Testing
and Information System VAS 5051, Connecting and Selecting Functions.
- Press right Guided Functions.
- Press ->.
- Start engine.
- Raise vehicle.
- Press.
If a test temperature between 35°C and 45°C is displayed:

Page 4493
Installing
Functions".
Tightening torques:
Component Nm

Page 786
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7599
^ Wheel bearing tool V.A.G 1459 B
^ Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T hydraulic
^ Tie bolt E-0-217+218
^ Special nut E-8-214
^ Thrust piece E-5
^ Thrust piece E-10
^ Thrust sleeve E-13-1
^ Pressure bolt E-15
^ Supplementary set V.A.G 1459 B/2
^ Bell E-40
Removing
- Remove 12-point nut.
- Remove wheel.
- Mark installation position of ball joint - 1 - to control arm - 2 -.

Procedures
Drive Belt: Procedures
- Crank engine at vibration damper/belt pulley using a socket wrench.
- With vehicle elevated, check ribbed belt - 1 - from below for:
‹› Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
‹› Layer separation (top layer, cord strands), base break-up
‹› Wear at flanks (material wear, frayed flanks, hardening or glazing of flanks, surface cracks)
‹› Replace the belt if any damage is found. By replacing, failures and/or disturbances can be
avoided. Replacing the belt is a repair procedure.
Ribbed Belt, Without Automatic Tensioner, Adjusting Tension

Ribbed Belt, without Automatic Tensioner, Adjusting Tension
‹› Clamping Lever (3297)

Page 325
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2429
Page 6177
WHAT ARE TRACKS?
15-28, and so on).
Tools and Equipment
Fan Clutch: Tools and Equipment
32mm Fan Clutch Wrench
AST tool# 8032
32mm x 380mm long wrench used for the R and R of any 32mm fan clutch nuts. This tool is
applicable to VW, Audi and BMW models with 32mm fan clutch nuts.
- Used for R and R of Fan Clutch
- Steel Construction
- Easy-Grip Handle
- Applicable to VW, Audi and BMW

Page 4421
Exhaust Manifold: Service and Repair Exhaust Manifold Assembly Overview
Exhaust Manifold Assembly Overview

1 Gasket
‹› Replace
2 Nut, 25 Nm
‹› Replace
3 Exhaust Manifold
‹› Coat the stud bolts on the cylinder head with hot bolt paste (G 052 118 A3).
‹› Remove downward.
4 Clip
5 Heat Shield
6 Bolt, 10 Nm
7 Heated Oxygen Sensor (HO2S) (G39), 55 Nm
‹› Use ring spanner 7 piece set (3337) for removal and installation.
‹› Threads of the new oxygen sensor are coated with assembly paste.
Page 3414
Relay Box: Application and ID Relay Arrangements on Thirteen Position Auxiliary Relay Panel,
Above Relay Panel, From July 2005
Page 5316
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis
Checking wiring
Page 6776
SVM can provide a response code with a repair suggestion or after a successful repair. The
response code will appear in the diagnostic log.
Warranty
Information only.
Checking for Internet Connectivity:

With the tester connected to the internet, go to Guided Functions >> All remaining vehicles >>
Immobilizer I & II >> Online System Test.
Technical Helpline Contact Requirements:
Contact the Technical Helpline via the Volkswagen Technical Assistance (VTA) system in ElsaWeb
or phone in cases where there is a clear technical issue with the vehicle or response from the SVM
system. Always include the following information in the VTA contact.
^ SVM Action Code attempted
^ Control Module(s), affected part numbers and software levels, Address word(s) that are in
question
^ The complete tester diagnostic log from the GFF session attached to the VTA helpline ticket
Further Tester Assistance:
Page 4823
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 2010
Part 3
Page 4098
these reasons, the cooling system must be filled with radiator freeze and corrosion protection fluid
all year round.
‹› Especially in countries with tropical climates or when vehicle is driven under heavy load, the
coolant improves the engine reliability by its
increased boiling point.
‹› The coolant concentration must not be reduced by adding water, even during the warmer
season. The coolant additive ratio must be at least 40%.
Freeze protection table
- Check freeze protection ratio once more after road test.

Page 7328
Page 5325
legend.
wiring diagram.
harness.


question.)
19 - Legend



Adjustments
Shift Interlock Cable: Adjustments
Locking Cable, Adjusting
CAUTION! Locking cable adjustment must always be performed as described in the following.
Adjustment requirements:
‹› Locking cable in installation position
‹› Center console removed.
‹› Selector lever in position "P".
‹› Ignition key in removal position.
Adjusting procedure:
‹› Steering wheel in position fully extended and downward toward floor.
- Loosen bolt - 3 - on mounting bracket.
- Insert Adjustment Pin For Shiftlock 3 (3352A) between locking lever - 1 - and locking cable eyelet
- 2 -.
- To compensate for play, pull cable sleeve in direction of - arrow - until it stops.
- Hold cable sleeve firmly in this position.

- It must be possible to remove and insert Adjustment Pin For Shiftlock 3 (3352A) in this position.
- Tighten bolt - 3 - at mounting bracket to 10 Nm.

Page 1715
Part 1
Page 7006
Part 2
Page 3062
‹› Puller (T40039)

Page 5548
1 - Track Numbers

Page 7597
nut - 5 -.
1 Wheel bearing
2 Thrust piece (E-13-1)
Wheel Hub, Installing
1 Wheel hub
- Tighten bolts for control arm and ball joint on to old marks.
Page 7135

Service Precautions
Relay Box: Service Precautions
Page 1849
Part 2
Page 650
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1237
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5924
1 - Track Numbers

Page 5858
- Remove the bolts - 1 and 2 -.
- Remove the Evaporative Emission (EVAP) canister with the Leak Detection Pump (LDP) (V144).
Removing the LDP
- Disconnect the connecting hose from the LDP.
- Remove the three bolts.
- Remove the LDP from the EVAP canister
Installing
‹› Connect ventilation lines until they engage audibly.
‹› Make sure lines and EVAP canister are locked securely.
Page 1630
WHAT ARE TRACKS?
15-28, and so on).
Page 6488
End diagnosis.
Page 574
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3307
Refrigerant: Fluid Type Specifications
A/C Refrigerant ....................................................................................................................................
..................................................................... R134a
Locations
Canister Purge Control Valve: Locations

7 Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 (N80)
Page 7774
Page 373
1 - Track Numbers

Page 4067
‹› Remove pin (T03000/1) from (T03000).
‹› Install the (T03000) to the cylinder block with pin - 3 - and tighten the bolts - 1 and 2 - hand tight.
‹› Then install pin (T03000/1) and tighten to 20 Nm.
‹› Then tighten bolts - 1 and 2 - to 25 Nm.
- Place the (T03000) on the (VAG 1383A) and lift the engine/transmission assembly slightly.
- Remove the engine mount bolts - arrows - from above and remove.
‹› Use (VAS 5085) to remove the bolts.
- Remove both front bolts from the holding fixture.
- Remove the transmission mount bolts - arrows - from above.

Page 4247
1 - Track Numbers

Page 7539
Part 2
Page 5799
- Remove the bolt - 1 - and nut - 2 - and remove the bracket with the AIR pump motor.
Installing
‹› Make sure that pressure pipe and intake pipe lock securely to AIR pump motor.
Page 2216
for resistance.

Page 1759
Ground (GND)

Page 3223
- Top off ATF => [ ATF, Filling ] See: Service and Repair/09G Transmission/ATF, Filling.
Page 673
WHAT ARE TRACKS?
15-28, and so on).
Page 4656
Part 3
Page 6650
Part 2
Page 2759
Part 2
Page 4341
Part 2
Page 7527
Page 1800
Part 2
Page 7782

Page 1802
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2648
1 - Track Numbers

Locations

Page 3877
Page 3539
18 Circlip
‹› Check for proper seating
19 Wheel bearing
‹› Pressing out => [ Pressing out wheel bearing from wheel bearing
housing ] See: Wheel Bearing Housing
‹› Replace, destroyed during pressing out
‹› Pressing in => [ Pressing wheel bearing into wheel bearing housing ] See: Wheel Bearing
Housing
For vehicles:
‹› With gasoline engine from 110 kW

Page 1553
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5725

Page 5739
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5133
Data Link Connector: Locations ABS Mark 60
18- Data Link Connector (DLC)
^ Location- on left below drivers stowage compartment

Page 4375
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5605
Part 3
Page 4330
Page 2137
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7872
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3741
1 - Track Numbers

Page 2484
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1324
Ground (GND)

Page 5553
Part 1
Page 7140
1 - Track Numbers

Page 5930
Part 2
Page 1483
Part 1
Page 2368
Ground (GND)

Locations
Page 3348
Warranty
Information only.
removal.
Page 1322
1 - Track Numbers

Steering Angle Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1555
Part 2
Page 7458
the strainer).

Page 464
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7923
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 379
Part 2
Page 6358
The removed parts remain at the dealer and must be destroyed, not re-used.

Parts are vehicle specific.
Review repair manual procedure in ElsaWeb for special tools.
Page 1935
Part 3
Page 1010
Part 2
Page 3184
CAUTION! If brake fluid level is below MIN mark, check brake system " repair procedure", before
adding brake fluid.
Page 677
Part 3
Page 5067
Part 1
Page 7868
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1994
Fuel Gauge Sender: Service and Repair Removal and Installation
Fuel Level Sensor
Removing
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and
Replacement/Removal and Installation/Fuel Delivery Unit.
- Disengage the connector prongs for wires - 3 and 4 - and disconnect.
- Pry up the retaining tabs - 1 and 2 - using screwdriver and remove the sensor downward in the -
direction of the arrow -.
Installing
- Insert the sensor into the guides on the fuel delivery unit and press up until engagement.
- Insert the connector prongs for the wires and engage.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] See: Powertrain Management/Fuel
Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Removal and
Installation/Fuel Delivery Unit.
Page 6570
Final procedures
End diagnosis.
Page 830
Part 3
Page 3291
Page 2825
Page 4031
Fuel Filter
Removing
connection.
Installing

Page 4299
Checking wiring
Final procedures

09.

Code.
Page 2725
‹› M8 x 12
7 Hex bolt
‹› M8 x 12

8 Heat shield
Page 7257
‹› Replace the frame if the retaining tabs are damaged.
- Remove upper section of frame - 1 -.
- Remove cover strip - 2 - from lower section of frame - 3 -.
Assembling
- Check whether magnets - arrows - are secured to cover strip - 2 -.

37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 2153
Part 1
Page 7913
Checking wiring
terminal 1
45
28

- End diagnosis.
Final procedures
End diagnosis.
Page 3503
Tire Pressure Sensor: Diagnostic Aids
Page 1937
Page 7137
strip - 2 -.
Page 6287

Page 7202
Install clip from above. Angled ends of clip point toward steering lock.
- Check that clip engages.
- Adjust locking cable => [ Locking Cable, Adjusting ] See: Adjustments.
- Ignition key removal lock, checking function => [ Ignition Key Removal Lock, Checking Function ]
- Install left trim below instrument panel.
- Install steering column trim.
- Tighten bolts - 1 - for steering column - 2 - height and longitudinal adjustment handle.
Page 7961
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
Page 5635

Page 6006
Fuel Filter
Removing
‹› Observe the safety precautions. Refer to => [ Safety Precautions ] See: Fuel Tank/Description
and Operation.
‹› Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] See: Fuel
connection.
Installing
and Operation.

- Press the <- key.

Page 6292
Final procedures

Page 6246
1 - Track Numbers

Page 5274
Start diagnosis
Checking voltage
terminals.
terminals.
Checking activation


Page 5723
Page 3990
Specifications
Fuel Pressure
At idle speed ........................................................................................................................................

....................................................................................................................................... at least 3.0
bar
Page 5914
Part 1
Page 4580
Page 3488
Module Components, Adapting ] See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection.
Removing

Installing
[ Comfort System Central Control Module, Coding ] See: Body and Frame/Body Control
Systems/Body Control Module/Testing and Inspection.
Page 6634
Page 1727
Ground (GND)

Specifications
Fuel Pressure
At idle speed ........................................................................................................................................

....................................................................................................................................... at least 3.0
bar
Specifications


Page 2226
WHAT ARE TRACKS?
15-28, and so on).
Page 1951
Part 3
Page 4868
Page 4350
‹› Fill with coolant. Refer to => [ Draining and Filling ] See: Service and Repair/Procedures/Draining
and Filling.
Page 2958
Part 3
Page 206
1 - Track Numbers

Page 4533
order)
Tip:
Page 5842
Part 2
Control (EPC)) G188

Page 3005
Alignment: Service and Repair Wheel Alignment, Preparing to Measure
The present lateral run-out of the rims must be balanced (compensated). Otherwise, measurement
will result in incorrect readings.
If compensation for wheel run-out is not performed, it will not be possible to obtain a correct toe-in
adjustment!
For this purpose, observe notes of alignment equipment manufacturer.
- Perform wheel run-out compensation.
- Insert brake pedal depressor (V.A.G 1869/2 ).
- Operate brake pedal using brake pedal depressor.
Vehicle Transverse Inclination Neutral Position
Always applies!
When one measured value is not within tolerance, vehicle transverse inclination must be checked
before the adjustment.
When measured values lie outside tolerance range of specified values, the cause for this may be
an off-center vehicle.
Right-hand drive vehicles or e.g. vehicles with automatic transmission may be slightly off-center.
This is due to the installation position of the assemblies and the corresponding weight transfer and
is normal.
- Then, always check dimension - a - at left and right side from rear.
The 0-line on roof symbolizes the horizontal position (zero position) of the vehicle.
Page 2285


Door Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2560
Impact Sensor: Service and Repair
Driver/Front Passenger Airbag Crash Sensor G283 and G284 Assembly Overview
Airbag
1 - Driver Front Airbag Crash Sensor (G283) and Front Passenger Front Airbag Crash Sensor
(G284)
‹› In the front longitudinal member
2 - Combination Nut
‹› 6 Nm
3 - Connector
Airbag
Page 6058
supply line - 2 -.
and Operation.
- Check the delivery quantity of the fuel pump. Refer to => [ Delivery Quantity, Checking ] See: Fuel
Page 1099
Part 1
Page 1152
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6587
1 - Track Numbers

Page 2975
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6917

Page 3475
1 - Track Numbers

Page 438
Warranty

Page 6704
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1776
1 - Track Numbers


Page 589
Part 3
Power Window Safety Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2020
Ground (GND)

Page 5272
- Multimeter.
- Wiring diagram.
Test requirement
- A/C switched off.
Test procedure
Function
control modules.
Start diagnosis
step.
Checking wiring
for resistance.

ABS Mark 60
Lateral Accelerometer: Locations ABS Mark 60
4- Sender for rotation rate -G202

^ Location: Under instrument panel next to steering column
^ Checked by OBD
^ Can be checked via read measured value block
5- Sensor for transverse acceleration -G200
^ Location: Under instrument panel next to steering column
^ Checked by OBD
^ Can be checked via read measured value block
^ When the sensor for transverse acceleration -G200- is replaced, a zero compensation must be
performed
6- ESP-Sensor unit -G419-, vehicles from my 12.01
^ Combined sensor for transverse acceleration -G200- and sender for rotation rate -G202
^ Assembled together in one housing
^ Checked by OBD
^ When the ESP-sensor unit -G419- is replaced, a zero compensation must be performed

Page 1781
Part 1
Page 7479
7 Connecting plate
9 Bearing bushing
10 Pivot pin
11 Clutch pedal
‹› Removing and installing => [ Clutch Pedal ] See: Clutch Pedal.
12 Retainer
‹› Removing and installing => [ (Item 4) Retainer ] See: Clutch Hydraulic System/Service and
‹› For master cylinder and mounting bracket to bulkhead
14 Clutch master cylinder
‹› Removing and installing => [ Master Cylinder ] See: Clutch Hydraulic System/Clutch Master
15 Supply hose
16 Over-center spring
‹› Removing and installing => [ Over-Center Spring ] See: Over-Center Spring.
17 Over-center spring mounting
‹› Insert in mounting bracket
‹› To replace, remove and install master cylinder => [ Master Cylinder ] See: Clutch Hydraulic
System/Clutch Master Cylinder/Service and
Repair.
18 Clutch pedal switch (F36)
‹› Removing and installing, adjusting => [ Clutch Pedal Switch ] See: Clutch Switch/Service and
Repair.
19 Stop bracket
‹› For clutch pedal
‹› Installed position => [ Installation Position ] See: Clutch Hydraulic System/Clutch Master
20 Hex nut, 25 Nm
Page 257
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4928
Part 3
Locations
Engine Coolant Level (ECL) Sensor G32

Page 1203
Page 979
Part 2
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 769

Page 2703
Page 922
Ground (GND)

Page 4312
Part 3
Page 6731
want the Update Programming installed in their vehicle.
Updated ECM software that addresses:
^ Speed regulation of the camshaft adjuster.
^ Incorrect algorithm used in ECM software.
^ Exhaust popping noise is an exhaust resonance that becomes more audible under certain RPM
and load ranges during the catalyst heating phase of cold start.
^ Engine Control Modules Affected:
Production Solution
Update software addressed in production as of:
Service
PROCEDURE:
Tip:
Update programming procedure has been revised for vehicles equipped with the higher speed
diagnostic CAN bus.
Note:
The programming for this procedure is designed to work with the diagnostic CAN-BUS. The New
Beetle and New Beetle Convertible is an older platform which does not support the use of
CAN-BUS, instead, the New Beetle and New Beetle Convertible relies on the K-line for
communication. BEFORE attempting to flash these vehicles, remove Pin 6 from the Data Link
Connector (T-16) using special tool VAS 1978A. After the programming procedure has completed,
re-install Pin 6 into the Data Link Connector.
Engine Control Module Update - Programming (Flashing)
Tip:
diagnostic CAN bus.
When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs
linked to Guided Fault Finding function tests will be
Page 2103
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4860
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1184
Part 1
Page 6732
lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update
programming procedure first.
The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM
programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the
normal parameters and specifications approved by Volkswagen of America, Inc.
If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming"
(flashing) procedure:
^ Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to
have been tuned, and that any damage caused by the tuning of the ECM (including any adverse
^ For any repair requested by the owner under warranty or outside warranty that requires update
programming, which will automatically wipe out the "Tuning" program, your Dealership should
advise the owner of the above and get Owner's written consent (see Control Module Tuning form)
to the update programming procedure.
Page 6250
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7594
‹› Be sure there is sufficient room when pulling out drive axle.
CAUTION! Place engine/transmission jack (V.A.G 1383 A) underneath (danger of accident if parts
Wheel Hub, Removing

Page 443
Ground (GND)

Page 4996
11 Air Duct
13 Intake Tube

Page 4994
11 Air Duct
13 Intake Tube

Computers/Controls - Software Version Management
Info.
PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls -
Software Version Management Info.
01 10 05
April 1, 2010
2014603 Supersedes T.B. Group 01 number 08-36 dated Dec. 10, 2008 due to additional SVM
function information and to include Response Codes with explanation.
Vehicle Information
Condition
Software Version Management
This Technical Bulletin details the general process for carrying out a Software Version
Management (SVM) software update for any Technical Bulletin/RVU.
Troubleshooting information is included in the Additional Information Section.
SVM is a function within GFF with the options illustrated in Figure 1.
SVM is a process to update the programming in flashable (re-programmable) control modules

and/or to document changes in software levels in Volkswagen vehicles. This system uses the VAS
5051B, VAS 5052, VAS 5052A or VAS 6150 diagnostic tools to send vehicle-specific data to the
SVM database, to download instructions from the SVM database, and to program control modules
for identified software updates.
The technician must first diagnose the condition in the vehicle and find a Technical Service Bulletin
that describes that condition. This conditional bulletin specifies the appropriate Unit Code (Action
Code) for the programming update. SVM eliminates the need to wait for Flash CDs to be sent to
the dealer and problems such as scratched or missing discs, and allows the updates to be
performed faster and more efficiently at the dealership.
Note:
An Update Programming procedure (flash) may overwrite any "TUNED" ECM or TCM
programming. A "TUNED" ECM or TCM is described as any ECM or TCM altered so as to perform
outside the normal parameters and
specifications approved by Volkswagen Group of America, Inc.
Current Tuned ECM or TCM requirements:
If you encounter a vehicle with a "Tuned" ECM or TCM, your dealership must do the following
before performing any procedure that updates ECM or TCM programming:
^ Notify the owner that their ECM or TCM was found to have been tuned
^ Notify the owner any damage caused by the tuning of the ECM or TCM (including any adverse
Page 3577
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 680
Power Distribution Relay: Diagnostic Aids
Page 1667
- Disconnect harness connector from wheel speed sensor wire and wheel speed sensor.
- In addition, disconnect harness connector - 1 - on vehicles with brake pad wear indicator.
- Unclip wire - 2 - from bracket.
- Remove malfunctioning wheel speed sensor wire.
Installing
- Thread new wheel speed sensor wire.
- Clip in wheel speed sensor wire - arrows -.

Page 4653
Track 1-14
named Track 1-14.
Track 169-182
reference box.

PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls -
DTC's 00545/00638 Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 1782
Part 2
Page 7929
Page 4193
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7655
Page 7460


Page 1991
‹› To the fuel rail.
23 Vent Line
‹› White
‹› Clipped in at the top of the fuel tank.
‹› To the EVAP canister purge regulator valve (N80 ).
24 Seal
‹› Replace
‹› To install, place into the opening of the fuel tank dry.
‹› Only coat the inner part with fuel when installing the fuel delivery unit.
‹› Note the installed position in the fuel tank, refer to => [ Fuel Delivery Unit Installed Position ].
‹› Removal and installation, refer to => [ Fuel Delivery Unit ] See: Powertrain Management/Fuel
Delivery and Air Induction/Fuel Tank/Service
and Repair/Removal and Replacement.
‹› Fuel pump checking, refer to => [ Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank) ]
See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel Pump/Testing and Inspection/Fuel Pump Checking, Engine Code BPS
(Plastic Fuel Tank).
‹› Clean the strainer if contaminated.
26 Locking Ring, 110 Nm
‹› Ensure the ring is securely seated.
‹› Use wrench (T10202) for removal and installation.
27 Supply Line
‹› Black
‹› To the fuel filter.
‹› To disconnect from the flange and fuel filter, press in the securing ring on the connecting piece.
‹› Clipped to the side of the fuel tank.
28 Return Line
‹› Blue

Page 3141

Page 2978
Rain Sensor: Electrical Diagrams
IMPORTANT NOTE:
IMPORTANT NOTE:
Page 2820
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5282
Page 5693
Ground (GND)

Page 2601
Ground (GND)

Page 3467
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1422
Part 1
Page 3687
Piston: Locations
Piston and connecting rod, assembly overview
1 - Connecting rod bolt 30 Nm plus an additional 1/4 turn (90°)
^ Replace
^ Lubricate threads and contact surface
^ Tighten to 30 Nm to measure radial play, do not turn further
2 - Pressure relief valve, 27 Nm
^ Opening pressure 1.3 to 1.6 bar positive pressure
3 - Oil spray jet
^ For piston cooling
4 - Connecting rod bearing cap
^ Note installation position
^ Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position
and only on to respective connecting rod.
^ Affiliation to cylinder mark - B -
^ Installed location: Markings - A - point to belt pulley side
5 - Bearing shell
^ Do not interchange used bearing shells
^ Axial play new: 0.10 to 0.35 mm
- Wear limit: 0.4 mm
^ Measure radial clearance with Plastigage(R):
- New: 0.02 to 0.06 mm
- Do not turn crankshaft when measuring radial play.
6 - Connecting rod
^ With cracked bearing cap

Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 2444
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3559
Wheel Fastener: Service and Repair Wheel Bolts, Tightening Specifications
Wheel Bolts, Tightening Specifications
Removing and installing wheel bolt covers
‹› Depending on vehicle equipment, the wheel bolts may be covered by the following components:
‹› Wheel bolt cover caps
‹› Center wheel cover
‹› Full wheel cover
- Remove the corresponding wheel bolt cover, if present.
‹› The pulling hook for removing the cover caps or center wheel cover is located in the vehicle tool
kit.
Example, removing center wheel cover
- Insert removal hook into one of the holes of the wheel center cap and pull in - direction of arrow -.
Installation notes
‹› Cover caps protect the wheel bolts and should be reinstalled after final tightening of the wheel
bolts.
‹› Note that the center wheel cover tab must engage into rim recess for some rims.
‹› Place adapter and extractor in vehicle tool kit after completing work.
- On vehicles with full covers, install full wheel cover by guiding the tire inflating valve through the
designated recess - arrow -.
Page 1406
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4125
removal.
Page 2518

Page 1656
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet

Page 3676
‹› Drive plate, removal and installation. Refer to => [ Drive Plate ] See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Drive Plate.
8 Sensor Wheel
‹› Removal and installation, refer to => [ Crankshaft Seal, Transmission Side ] See: Seals and
Gaskets/Crankshaft Main Bearing Seal/Service and
Repair/Crankshaft Seal, Transmission Side.
‹› Removal and installation, refer to => [ Control Housing Cover ] See: Camshaft, Lifters and Push
Rods/Variable Valve Timing Cover /
Housing/Service and Repair.
11 O-ring
‹› Replace
12 Bolt, 25 Nm
14 Bolt, 5 Nm
16 Seal
‹› Replace
Page 2907

‹› Removing and installing => [ Wiring Harness with 8-Pin Connector ] See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Wiring Harness/Service and Repair/Wiring Harness With 8-Pin Connector

Front Wheel Alignment
Alignment: Specifications Front Wheel Alignment
Front Wheel Alignment Specifications
Note: Camber is not adjustable. Only slight corrections are possible by moving the subframe.
Adjustment range approx. 10' to 15'
Page 7468
Installation Position
The holder - arrow - points to master cylinder - B -.
- Bleed clutch system after installing clutch master cylinder => [ Clutch System, Bleeding ] See:
Service and Repair/Procedures.
Page 1746
Part 1
Page 3344
Page 2127
- Turn the rotary handle to "0" - arrow 2 -, let it go and engage the Headlamp Switch (E1).
Page 7525
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 664
Page 100
Part 2
Page 5485
Ground (GND)

Page 1185
Part 2
Page 7924
Part 1
Page 839
stop:
Checking resistance
Page 2074
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5931
Part 3
Page 3321
the strainer).

Page 2337
Ground (GND)

Page 7791
Final procedures
Page 815
- Multimeter.
- wiring diagrams.
Test requirements
- Fuse SB42 OK.
- The generator OK.
Test procedure
Start diagnosis
Ground (GND).
- Crank the engine.
16/MOT 65

Page 411
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4940
Page 2084
WHAT ARE TRACKS?
15-28, and so on).
Page 4632
Final procedures

Page 1480
Ground (GND)

Page 4541
- Multimeter.
- Wiring diagram.
Test requirement
- A/C switched off.
Test procedure
Function
control modules.
Start diagnosis
step.
Checking wiring
for resistance.

Specifications
Valve Clearance

Page 5144
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7519
Ground (GND)

Procedures
Oil Filter: Procedures
Engine oil, draining or extracting; changing oil filter and filling engine oil
Warning!
On engines with standing oil filter module, the oil filter should be changed before the oil
change.Removing the filter element will open a valve and oil in the filter housing will flow
automatically into the crankshaft housing. The oil drain plug is equipped with a permanent seal,
therefore the oil drain plug must always be replaced.
- Oil extractor V.A.G 1782
- Oil absorbent towel VAS 6204/1
Engine oil, draining or extracting
- Extract engine oil using old oil collecting and extracting unit V.A.G 1782.
or
- Drain engine oil.
- Fill motor oil.
Engine oil capacities, refer to Fluid Capacity Charts for appropriate model and year.
- The torque specifications are dependent on engine code
Warning!
Torque settings must not be exceeded A torque figure that is too high may lead to leaks or even
damage the oil pan.
Replacing oil filter, 1.8 L-, 2.0 L fuel injection engines

Locations

Locations

Audio Control Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1167
WHAT ARE TRACKS?
15-28, and so on).
Page 4719
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6957
- Drain ATF.
- Finally, check ATF level and top off => [ ATF Level ] See: Testing and Inspection/ATF Level.
Page 5074


Page 2249
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5955
Ground (GND)

Page 1009
Part 1

Page 7421
Page 5585
Checking wiring
Final procedures

Page 3632
Start in the area of the alignment bushings - arrows -.
‹› Make sure the sealing surfaces are not damaged.
- Drive out the seal with the control housing cover removed.
Installing
- Remove the remainder of the sealant from the cylinder block, upper oil pan and control housing
cover using a rotating plastic brush.
- Clean the sealing surfaces of the cylinder block, upper oil pan and control housing cover, they
must be free of oil and grease.
- Replace the seals - 1 and 2 -.

Page 7554
Part 2
Page 7377
Valve Body: Service and Repair Valve Body Assembly Overview
Valve Body Assembly Overview

1 ATF inspection plug, 27 Nm
‹› Always replace seal => [ (Item 2) Oil seal ]
‹› ATF level, checking and topping off => [ ATF Level ] See: Fluid - A/T/Testing and Inspection/ATF
Level
2 Oil seal
3 Overflow tube, 2 Nm
‹› Remove to drain ATF
‹› ATF level, checking and topping off => [ ATF Level ] See: Fluid - A/T/Testing and Inspection/ATF
Level
4 Oil pan
‹› Removing and installing => [ Oil Pan ] See: Fluid Pan/Service and Repair
5 Bolt, 7 Nm
‹› Tighten bolts for oil pan in several stages in diagonal sequence

Ignition Coil: All Technical Service Bulletins Emissions - Interim Repair For Recall 28F3
28 10 02
May 10, 2010

Vehicle Information

Page 2582
Part 3
Page 3148
Page 6126
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2793
Suspension Mode Switch: Diagnostic Aids
Page 7247
1 Selector lever handle
‹› Removing and installing => [ Selector Lever Handle ] See: Selector Lever Handle
2 Sleeve
‹› Engages in selector lever handle
‹› Locks the removal of selector lever handle
3 Cover
‹› With circuit board and frame
‹› Assembly overview => [ Selector Mechanism Frame Assembly Overview ] See: Selector
Mechanism Frame Assembly Overview and => [
Selector Mechanism Cover Assembly Overview ] See: Selector Mechanism Cover Assembly
Overview
4 Bolt, 10 Nm
‹› For locking cable adjustment
5 Locking cable
‹› Removing and installing => [ Locking Cable ] See: Shift Interlock/Shift Interlock Cable/Service
and Repair
6 Nut, 23 Nm
‹› For selector mechanism to body
7 Floor plate/body
Page 5670
Page 2323
Final procedures
09.

Code.
Page 1544
Brake Booster Vacuum Sensor: Service and Repair Brake Booster Pressure Sensor
Brake Booster Pressure Sensor
Removing
- Remove plenum chamber cover.
- Remove brake booster pressure sensor ( G294).
Installing
Installation is performed in reverse order of removal.

Locations
9- Steering angle sensor -G85

^ Location: On steering column between steering wheel and steering column switch.
^ When the steering angle sensor -G85- is replaced, a zero compensation must be performed
^ Introduce basic setting, perform display group number 060

Page 6956
- Drain ATF until it drips.
If no ATF drips out:
- Add another liter => [ ATF, Filling ] See: ATF, Filling.
CAUTION! An ATF level which is too low or too high will impair the function of the transmission. But
if the transmission was 2 liters low, it must be carefully inspected. There is probably a "major" leak.


Page 5256
Page 6630
Part 2
Specifications
Fuel Pressure
At idle speed ........................................................................................................................................

....................................................................................................................................... at least 3.0
bar
Page 2785
Ground (GND)

Page 6453
Spark Plug Pliers
AST tool# H 1849
- Spark Plug Pliers

Page 2175
Page 3387
Page 4781
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4643
Final procedures

Page 5217
Page 5850
- Remove the bolts - 1 and 2 -.
- Remove the Evaporative Emission (EVAP) canister with the Leak Detection Pump (LDP) (V144).
Removing the LDP
- Disconnect the connecting hose from the LDP.
- Remove the three bolts.
- Remove the LDP from the EVAP canister
Installing
‹› Connect ventilation lines until they engage audibly.
‹› Make sure lines and EVAP canister are locked securely.
Page 170
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1257
Parking Assist Switch: Diagnostic Aids
Page 1757
1 - Track Numbers

Page 4731
2.
Checking wiring

Page 4466
Control Modules
‹› Body

Page 1587
Part 3
Page 5645

- Start the engine.

Page 6118
1 - Track Numbers

Page 255
Ground (GND)

Page 5551
WHAT ARE TRACKS?
15-28, and so on).
Page 7522
Part 1
Page 678
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1407
Part 1
Page 1572
Part 3
Power Distribution Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7601
1. Thrust piece E-5 2. Thrust sleeve E-65-1 3. Hollow piston cylinder HKZ-15 4. Special nut
E-8-214 and tie bolt
Pull bearing inner race off hub
Pressing in wheel bearing
Molykote grease G 052 723 A2

Page 3416
Specifications
Engine Oil Pressure: Specifications
Engine Oil Pressure at 2000 RPM, oil temperature 80° C (176° F)
.................................................................................................................. 2.7 to 4.5 bar
Page 5969

Page 6012
1 - Track Numbers

Control (EPC)) G188

Specifications
Crankshaft Main Bearing: Specifications
Crankshaft Main Bearing Cap Bolts

........................................................................................... 40 Nm Final pass .....................................
................................................................................................................................... Tighten 90°
Crankshaft
Axial play
New .....................................................................................................................................................
............................................ 0.07 to 0.21 mmm Wear limit ..................................................................
.................................................................................................................................... 0.30 mm
Radial clearance
New .....................................................................................................................................................
........................................... 0.023 to 0.043 mm Wear limit ..................................................................
.................................................................................................................................... 0.07 mm
Identification of Top Crankshaft Bearing Shells
thickness. Colored spots serve to identify the bearing thicknesses.
The letters marked on the lower sealing surface of the cylinder block identify which bearing
thickness must be installed in which location.
G Yellow B Blue W White
If colored marks can no longer be seen, use the blue bearing shell.
The lower crankshaft bearing shells are always shipped as replacement part with a "yellow" colored
mark.
(Dimensions in millimeters (mm))

Page 7702
Fluid - M/T: Fluid Type Specifications
Transmission fluid
Type .....................................................................................................................................................
................................................. Refer to parts catalog
Transmission fluid
Type .....................................................................................................................................................
Transmission fluid
Type .....................................................................................................................................................
Page 1482
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7551
WHAT ARE TRACKS?
15-28, and so on).
Page 6403
Part 2
Page 7255
‹› With integrated Tiptronic Switch ( F189)
‹› Can be tested in "Guided Fault Finding" using Vehicle Diagnosis, Testing and Information system
(VAS 5051)
‹› Removing and installing => [ Selector Mechanism Cover and Circuit Board ] See: Removal and
Replacement/Selector Mechanism Cover and
Circuit Board
5 Frame
‹› With cover strips
‹› Assembly overview => [ Selector Mechanism Frame Assembly Overview ] See: Removal and
Replacement/Selector Mechanism Frame
Assembly Overview
‹› Disassembling and assembling => [ Selector Mechanism Frame ] See: Selector Mechanism
Frame
6 Bracket
‹› With clip for selector lever cable
7 Locking plate
‹› For selector lever cable to selector mechanism housing
8 Selector lever cable
‹› Do not bend or kink
‹› If protective sleeve is damaged, the selector lever cable must be replaced
‹› Checking and adjusting => [ Selector Lever Cable, Checking and Adjusting ] See: Shift
Linkage/Shift Cable/Testing and Inspection
‹› Removing and installing => [ Selector Lever Cable ] See: Shift Linkage/Shift Cable/Service and
Repair
‹› Do not grease cable eyelet and ball socket
9 Self-locking nut, 10 Nm
‹› For cover at selector mechanism housing
‹› 4x
10 Cover
‹› For selector mechanism housing
‹› With bonded seal
11 Selector mechanism housing

‹› Removing and installing => [ Selector Mechanism ] See: Removal and Replacement/Selector
Mechanism
12 Bolt
13 Locking washer
‹› For pivot pins => [ (Item 15) Pivot pin ] of pawl => [ (Item 14) Pawl ]
14 Pawl
‹› For shift lock solenoid

Removal and Replacement
Shifter A/T: Removal and Replacement
Selector Mechanism
Selector Mechanism
Removing
- First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Remove selector lever handle => [ Selector Lever Handle ] See: Selector Lever Handle.
Board ] See: Selector Mechanism Cover and Circuit Board.
- Carefully pry off frame at four corners - arrows - and remove.
- Disengage locking cable - 1 - on selector mechanism from locking lever => [ Locking Cable ] See:
Shift Interlock/Shift Interlock Cable/Service and Repair.
Page 2804
Part 1
Page 7004
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6174
1 - Track Numbers

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 707

Page 4772
voltage.
Checking wiring
Page 4964
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Battery Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 588
Part 2
Page 3929
Ground (GND)

Page 824
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5537
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2774
Part 2
Page 3756
Engine Oil Pressure: Testing and Inspection
Oil Pressure and Switch, Checking
‹› Oil pressure gauge (VAG 1342)
‹› Voltage tester (VAG 1527B)
‹› Engine oil level OK.
‹› Engine oil temperature at least 80° C (176° F) (radiator fan must start up once)
540/1A) and a M8 x 100 bolt - A -.
- Remove the oil pressure switch (F1) and install it into the (VAG 1342).
- Install the (VAG 1342) into the oil filter bracket in place of the oil pressure switch.
- Connect the brown wire of the (VAG 1342) to ground (GND).
- Connect the (VAG 1527B) using adapter cables from (VAG 1594C) to B+ and the oil pressure
switch.
Page 908
WHAT ARE TRACKS?
15-28, and so on).
Page 2399
1 - Track Numbers

Page 4479
Ground (GND)

Page 6659
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 4115
^ Install the VAS 6096 onto the fill tank using the appropriate adapter (fig. 2).
^ Install air compressor hose (fig. 4).
^ Verify both valves are in the closed position (fig. 5).
^ Open valve on air hose side (fig. 6)

Page 3537
‹› Welding and straightening work on supporting or wheel bearing components of the front
suspension is not permitted.
‹› Always replace self-locking nuts.
‹› Always replace corroded bolts/nuts.
1 Drive axle
‹› Pressing drive axle out and in from wheel hub => [ Drive Axle with CV Joint and Triple Roller
Joints AAR 2000 and AAR 2900 ] See:
Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and
Repair/Removal and Replacement/Drive Axle with CV Joint and Triple Roller Joints AAR 2000 and
AAR 2900.
2 ABS wheel speed sensor
3 Socket head bolt
‹› M6 x 16
‹› Tightening specification => [ Wheel Bearing Housing ] See: Steering and

4 Strut
5 Hex bolt
‹› Hex bolt point must face in direction of travel
6 Tie rod end

After-Run Coolant Pump: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2354
Page 7120
1 - Track Numbers

Page 1329
Part 3
Service and Repair
Oil Filter Housing: Service and Repair
Oil Filter Housing, Draining
‹› When installing the oil drain adapter (T40057), a valve in the oil filter housing is opened. If the
(T40057 ) is removed, the valve is closed again.
- Remove the dust cap - 1 - from the oil filter housing - 2 -.
- Hold the hose for the (T40057) in a container and install the (T40057) to the oil filter housing - 2 -
until seated.
- Let the engine oil drain.

Page 3592
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Specifications
Firing order
1-2-4-5-3
Page 1520
Part 2
Page 2259
‹› Multimeter.
Test requirements
Function
Test procedure
Start diagnosis
- Start the engine.

misdiagnosis.
G182, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking wiring
Page 3538
7 Self-locking nut
‹› M12 x 15

‹› Never less than 90 degrees
‹› Torque angle tolerance 90 degrees to 120 degrees
8 Self-locking nut

For vehicles:
‹› With gasoline engine up to and including 85 kW
‹› With TDI engine
10 Ball joint
‹› Removing and installing => [ Ball Joint ] See: Steering and Suspension/Suspension/Ball
Joint/Service and Repair.
11 Self-locking nut
‹› M12 x 15
‹› Tightening specification => [ Front Suspension Tightening Specifications ] See: Steering and
Suspension/Suspension/Specifications/Front
Suspension.
12 Cover plate
13 Hex bolt
‹› M6 x 10

‹› Tightening => [ Tightening Specifications ] See: Transmission and Drivetrain/Drive Axles,

Bearings and Joints/Axle Shaft Assembly/Service
and Repair/Removal and Replacement/Drive Axle with CV Joint and Triple Roller Joints AAR 2000
and AAR 2900.
16 Vented brake rotor
17 Wheel hub with rotor for speed sensor
‹› Rotor is welded to wheel hub
Page 1271
Page 7127
Part 3
Page 5472
- Multimeter.
- Wiring diagram.
Test requirement
- A/C switched off.
Test procedure
Function
control modules.
Start diagnosis
step.
Checking wiring
for resistance.

Page 2917
Ground (GND)

Locations
Alarm Horn Relay: Locations
Page 5736
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4941
Final procedures

Procedures
Air Bag Control Module: Procedures
Airbag Control Module -J234-, Coding (Function 07)
NOTE:
- The coding is carried out with the code reader V.A.G 1551 or with the Vehicle diagnostic, testing
and information system VAS 5051.
- New coding numbers have been added especially for the New Beetle convertible. Airbag Control
Module -J234- current coding numbers can be found in the Vehicle Diagnosis, Testing and
Information System VAS 5051.
- In the guided fault finding you can choose the code number list using the "Go to" button
(Function/component selection).
Coding is only possible when a new control module is used.
- Connecting V.A.G 1551 or VAS 5051 and initiating On Board Diagnosis (OBD).
- Switch on printer with Print button (warning lamp in button lights up) if using V.A.G 1551 or print
via the print menu when using VAS 5051, if necessary.
The Airbag Malfunction Indicator Lamp (MIL) -K75- lights up continuously.
- Press buttons -1- and -5- (the address word of the vehicle system to be tested "Airbag" is entered
with 15).
Rapid data transfer Q 15 Airbag
Indicated on display of scan tool V.A.G 1551 (see Parts Catalog for actual control module version):
GQ0909G05E 04 AIRBAG VW7 0518 -> Coding 0012340 WSC12345
- -> Press button
- Press buttons -0- and -7- (with 07 the function "Code control module" is selected).
Rapid data transfer Q 07 Code control module
Code control module Enter code number XXXXX (0--32000)
- Enter code number according to table:
NOTE: Airbag Control Module -J234- current coding numbers can be found in the Vehicle
Diagnosis, Testing and Information System VAS 5051.
>1999 MY Coding
Index Code number F
00070
AQ 16721
Index letter is the same as part number suffix. For example: Part no. 1 JO 909 608 AQ; Index is
"AQ".
Page 391
WHAT ARE TRACKS?
15-28, and so on).
Page 2150
Ground (GND)

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6193
Removing
Injection.
- arrows -.
Page 102
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6083
‹› Multimeter.
Test conditions
Test procedure
Start diagnosis
pressure.

Page 1005
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5595

Page 5211
WHAT ARE TRACKS?
15-28, and so on).
Page 3480
Part 1
Page 2205
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7553
Part 1
Page 5210
Ground (GND)

Page 920
1 - Track Numbers

Page 6210
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2615
Otherwise, the clutch pedal switch will be destroyed.
Positions of stops - A - and - C - must be corrected:
- Press in plunger until it stops - arrow 1 -.
- At the same time, rotate upper part of clutch pedal switch in direction of - arrow 2 - until stop.
- Before installing clutch pedal switch (F36), pull out plunger completely.
- Insert clutch pedal switch (F36) into assembly hole.
- To engage, turn clutch pedal switch (F36) at housing 45 degrees toward right.
- Connect connector on clutch pedal switch (F36 ).

Page 7612
- Install brake disc.
- Drive in dust cap.
‹› Always replace dust caps.
‹› Damaged dust caps allow moisture to enter. Therefore, always use the tool shown.
- Install wheel and tighten => [ Wheel Bolt Tightening Specifications ] See: Maintenance/Wheels
and Tires/Wheel Fastener/Specifications.
Wheel Bearing Assembly Overview

Valve Guide: Testing and Inspection
Valve Guides, Checking
‹› Dial gauge holder (MP 3-447)
‹› Dial gauge
- Insert a new valve into the guide. The valve stem tip must seal with the guide. Due to differences
in valve stem diameters, make sure that only intake valves are used to check the intake valve
guides, and only exhaust valves are used to check the exhaust valve guides.
- Determine tilt clearance.
Wear limit: 0.8 millimeter (mm)
If tilt clearance is exceeded:
- Replace the cylinder head.

Page 1145
legend.
wiring diagram.
harness.


question.)
19 - Legend



Mode
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 2802
WHAT ARE TRACKS?
15-28, and so on).
Page 1388
Ground (GND)

Page 5221
Checking wiring

Page 3446
Part 2
Page 7
Page 6632
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3938
Oil Pressure Sender: Testing and Inspection
540/1A) and a M8 x 100 bolt - A -.
switch.
Page 1281
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 156
Part 1
Page 2446
Page 5567
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4583
- End diagnosis.
Final procedures
End diagnosis.
Page 4152
WHAT ARE TRACKS?
15-28, and so on).
Page 1919
Part 2
Page 2116
Headlamp Alignment Sensor: Service and Repair Left Front Level Control System Sensor
Overview
Sensors and Switches - Steering and Suspension/Sensors and Switches - Suspension/Ride Height
Sensor/Service and Repair/Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
1 Bracket
2 Hex nut

Suspension.
Page 459
WHAT ARE TRACKS?
15-28, and so on).
Page 2712
Ground (GND)

Page 1780
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5234
Page 1353
1 - Track Numbers

Page 5040

Page 3989
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6186
terminals.
Checking activation
Final procedures


Page 3428
Adaptation channel 44 adapts the time to the next interval.
- Confirm entry by pressing "Q" button on display number block.
‹› The adaptation value is the max. time until the next service is due (365 = 365 days = 12 months).
‹› If the instrument panel insert must be coded to "flexible" (LongLife service), the adaptation value
730 is to be entered.
By selecting the adaptation value 365, the instrument panel insert is coded "non-flexible", i.e. "time
or distance dependent ".
- Press the "Save" button - 2 - on display.

Page 2141
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4372
legend.
wiring diagram.
harness.


question.)
19 - Legend



Service and Repair
Fan Shroud: Service and Repair
Fan Shroud with Coolant Fan
Removing
540/1A) and a M8 x 100 bolt - A -.
- Disconnect electrical connector - A -.
- Remove the bolts - arrows - for the fan shroud.

Page 2286
2.
Checking wiring

Page 7182
5 38
6 50
- End diagnosis.
Final procedures
End diagnosis.
Page 5654
accessible.
‹› Multimeter.
Test requirements
box B is OK.
Test procedure
Start diagnosis

Page 1028
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1306
Ultrasonic Sensor: Testing and Inspection
Anti-Theft Alarm System and Interior Monitoring
Passenger Compartment Monitoring Switch, Checking
- Using the Go To button, select "Functions/Component selection" and the following menu options
in sequence:
‹› Body
‹› Convertible interior monitoring
‹› Electrical Components
‹› Passenger compartment monitoring switch

NOTE:
J217.
Procedure
0301
Removal
J217.
Installation
Page 872
^ Navigate to Vehicle Self Diagnosis 15- Airbag, interrogate fault memory and erase fault codes.
Page 2681
WHAT ARE TRACKS?
15-28, and so on).
Page 2836
1 - Track Numbers

Page 2118
Headlamp Alignment Sensor: Service and Repair Left Rear Level Control System Sensor Overview

Sensors and Switches - Steering and Suspension/Sensors and Switches - Suspension/Ride Height
Sensor/Service and Repair/Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
4 Bracket
5 Axle beam
Page 5351
Page 4422
‹› When using an old oxygen sensor again, only use hot bolt paste (G 052 112 A3) on the threads;
do not let the paste get onto the slits of the
oxygen sensor body.
‹› If the sealing ring is leaking cut it off and replace it.
‹› Color of harness connector: Black.
8 Brace
9 Nut, 25 Nm
‹› Replace
10 Bolt, 25 Nm
Page 7714
- Pull out flanged shaft with compression spring.
Seal and Sleeve are Designed as Two Parts
- Pry out seal using screwdriver - A -. Support screwdriver with assembly tool (3253/2).
‹› Do not damage sleeve, otherwise there is the risk of leaks.
‹› Replace sleeve if damaged => [ Pry out sleeve using
screwdriver ] See: Service and Repair/Overhaul/Transmission and Clutch Housing
Seal and Sleeve are Designed as One Part
- Pull out seal and sleeve together.
A ridge is located on inner diameter of sleeve.
- Position puller hooks pulling hook (VW 771/37 ) directly behind ridge in sleeve.
Page 823
1 - Track Numbers

Page 2609
Seat Sensor/Switch: Diagnostic Aids
Page 5353
Ground.
Ground.
Final procedures
Page 5529
1 - Track Numbers

Page 363
Part 2
Traction Control Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1256
Page 1096
Ground (GND)

Page 601
WHAT ARE TRACKS?
15-28, and so on).
Page 2771
WHAT ARE TRACKS?
15-28, and so on).
Page 354
19 - 5 Nm
Page 1032
Installing

Owner's Manual
General Information
Page 4335
1 - Track Numbers

Page 566
1 - Track Numbers

Page 6724
Response Codes
Page 2650
Ground (GND)

Page 7383
- Disconnect harness connectors - 2 - and - 5 -.
- Remove bolts - 3 - for bracket.

‹› If harness connector is damaged, replace the wiring harness or Transmission Input Speed (RPM)
Sensor (G182) or Transmission Output Speed
(RPM) Sensor ( G195).
Page 7970
1 - Track Numbers

Page 7459
Page 4822
- Multimeter
- Wiring diagram
Requirements
- Fuse SB28 OK.
Test procedure
Start diagnosis
connector - 2 -.
Checking voltage
Page 3904
Crankshaft Main Bearing Seal: Service and Repair Sealing Flange and Drive Plate/Flywheel
Assembly Overview
‹› Quantity: 5
‹› Replace
3 Bolt, 10 Nm
‹› Removal and installation, refer to => [ Sealing Flange, Belt Pulley Side ] See: Cylinder Block
Assembly/Sealing Flange, Engine Front/Service
and Repair/Sealing Flange, Belt Pulley Side.
5 Cylinder Block
‹› Replace
Page 7418
Page 5569
WHAT ARE TRACKS?
15-28, and so on).
Page 1932
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Specifications

............................................................................................................................................. 9.0 to
13.0 bar Wear limit ..............................................................................................................................
..............................................................................................................................................................
.... 3.0 bar
Engine - Measurement Of Oil Consumption
Engine Oil: Technical Service Bulletins Engine - Measurement Of Oil Consumption
17 11 01
March 25, 2010
2017813 Supersedes T.B. V171003 dated July 12, 2010 to include additional model year
applicability and special tool purchase information.
Vehicle Information
Condition
Oil Consumption Measurement
Customer states oil consumption is higher than the Volkswagen oil consumption standard of up to
0.5 quarts per 600 miles, or 0.5 liters per 1000 km.
In order to provide effective lubrication and cooling of internal engine components, all internal
combustion engines consume a certain amount of engine oil. Oil consumption varies from engine
to engine and may change significantly over the life of the engine.
Typically, engines with specified break-in periods consume more oil during the break-in period, and
the oil consumption will stabilize after the break-in period. Refer to the Owners Manual for specific
break-in procedures.
Under normal conditions, the rate of oil consumption depends on the quality and viscosity of the oil,
the RPM at which the engine is operated, the ambient temperature and road conditions.
Further factors are the amount of oil dilution from water condensation or fuel residue and the
oxidation level of the oil.
Production Solution
Not applicable.
Service
If the customer complains that their engine is apparently consuming oil in excess of the
Volkswagen oil consumption standard above, an oil consumption test must be performed using the
test plan in the VAS 5051 B, 5052/A, 6150 tester, before any repair is carried out.
Tip
Using the VAS tester, navigate to the Oil consumption measurement using one of the provided
methods below:
^ GFF- Function/Component Selection: Powertrain >> Engine >> Systems capable of self
diagnosis >> Motronic engine control >> Functions >>
General functions» Oil consumption measurements.
^ GFF- Function/Component Selection: Drivetrain >> Engine >> Lubrication >> Sub-systems,
marginal conditions >> Oil consumption measurements.
1. Follow VAS 5051B, 5052/A, 6150 test protocol exactly, and document all information on oil
measurement sheets.
2. Archive the VAS 5051B, 5052/A, 6150 diagnostic log and oil measurement test sheet (attached)
in the dealership vehicle service file.
3. When the customer returns the vehicle to the dealership after a minimum of 630 miles (1014
km), complete part # 2 of the oil consumption test plan
Page 2869
End diagnosis.
09G, 6 Speed A/T
Fluid - A/T: Service and Repair 09G, 6 Speed A/T
ATF Level, Checking and Topping Off
ATF Level, Checking and Topping Off, 09G, 6 Speed A/T
Observe these notes as well. ^
About filler tube
^ Torque wrench V.A.G 1331
^ Used oil collection and extraction unit V.A.G 1782
^ Vehicle diagnosis, testing and information system VAS 5051
^ Drip tray for workshop hoist VAS 6208
^ Adapter for filling oil VAS 6262
^ Adapter VAS 6262/2
If ATF must be added, use only ATF listed.

Page 4407
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1468
Part 1
Page 2817
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 82
Vehicle Information
Production Solution
Service
Symptoms
Warranty
removal.
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6356
Note
Tip:
Warranty
Page 68
Part 2
Page 2265
Safety Precautions
connection.

components.
Module DTC Memory, Checking and Erasing ] See: Powertrain Management/Computers and
Control Systems/Engine Control Module/Testing and Inspection/Reading and Clearing Diagnostic
Trouble Codes.
Page 54
Part 3
Page 6241
Fuel Flow Sensor: Diagnostic Aids
Page 4659

Engine Code BPS
Injection.
replaced.
Injection.
connection.
Page 7072
WHAT ARE TRACKS?
15-28, and so on).
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Page 1181
Ground (GND)

Page 2580
Part 1
Page 2309
Ground.
Ground.
Final procedures
Page 5927
WHAT ARE TRACKS?
15-28, and so on).
Page 778
guided function.
Removing
Installing

Page 1810
1 - Track Numbers

Page 1239
Parking Assist Distance Sensor: Diagnostic Aids
Page 3834

Page 2936
Part 1
Page 2213
Page 5646
Final procedures

Page 5065
WHAT ARE TRACKS?
15-28, and so on).
Page 6523
Page 1731
Part 2
Page 6293

Page 1846
WHAT ARE TRACKS?
15-28, and so on).

Page 2139
Part 2
Page 2352

Page 6037
Part 2
Page 5735
1 - Track Numbers

Page 2067
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7371
Checking wiring
terminal 1
45
28

- End diagnosis.
Final procedures
End diagnosis.
Page 6450

Page 4762


Page 1094
1 - Track Numbers

Page 3639
Connecting Rod: Locations
Piston and connecting rod, assembly overview
1 - Connecting rod bolt 30 Nm plus an additional 1/4 turn (90°)
^ Replace
^ Lubricate threads and contact surface
^ Tighten to 30 Nm to measure radial play, do not turn further
2 - Pressure relief valve, 27 Nm
^ Opening pressure 1.3 to 1.6 bar positive pressure
3 - Oil spray jet
^ For piston cooling
4 - Connecting rod bearing cap
^ Due to the way the separated connecting rod breaks (cracks), the cap fits only in one position
and only on to respective connecting rod.
5 - Bearing shell
^ Do not interchange used bearing shells
^ Measure radial clearance with Plastigage(R):
- New: 0.02 to 0.06 mm
- Do not turn crankshaft when measuring radial play.
6 - Connecting rod
^ With cracked bearing cap

Page 6904

Page 4455
Page 925
Part 1
Page 2055
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5304
Information Bus: Description and Operation
Instrument clusters from 06.99 are integrated into the vehicle CAN Data Bus network (may also be
known as "CAN-Bus" or "Data-Bus ").
The data bus on board diagnostic interface (J533 ) (which is integrated into the instrument cluster)
enables data to be exchanged between the vehicle CAN Data-Bus network and the Data Link
Connector (DLC) "K-wire".
The data bus on board diagnostic interface (J533 ) has specific On Board Diagnostic (OBD)
capabilities and requires a separate address word.
On replacement instrument clusters, the data bus on board diagnostic interface (J533) must be
coded according to vehicle market version and equipment level variables.
Diagrams
Windshield Washer Switch: Diagrams
Windshield Wiper/Washer Switch and Multifunction Display Connector Assignments
Connecting.
4-pin connector A, 4-pin
1. not used
2. not used
3. not used
4. not used
5. Windshield Wiper Intermittent Regulator (E38 ) for the Wiper/Washer Intermittent Relay (J31 )
6. Windshield Wiper Intermittent Regulator (E38 ) -> terminal 31
8-pin connector B, Windshield Wiper/Washer Intermittent Switch (E22)
1. Terminal 53
2. Terminal 31
Page 1838
Cabin Temperature Sensor / Switch: Diagnostic Aids
Brake Caliper and Wheel Bearing Housing Component
Overview
Wheel Bearing: Service and Repair Brake Caliper and Wheel Bearing Housing Component
Overview
Front Brakes, FS III
operating position.
2 Brake disc
Page 6742
- Click on "Continue" to proceed and follow the prompts to update ECM to the software level in the
table shown.
After Pass - Thru Vehicle Programming has been completed:
- Vehicle readiness code must be set.

Page 2605
Part 2
‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 3523
22 Bolt
Page 2773
Part 1

Page 1394
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
High Pressure Sensor / Switch: Description and Operation
A/C Refrigerant System Component Description
High Pressure Sensor
‹› Depending on engine type, refrigerant systems have either an A/C Pressure Switch (F129) or
High Pressure Sensor (G65) installed. Refer to
appropriate wiring diagram.
High Pressure Sensor (G65) - B -, transmits a square wave signal to Coolant Fan Control (FC)
Control Module (J293) at a rate which varies according to the refrigerant system pressure. The
signal is processed as follows:
Based on the signal transmitted by High Pressure Sensor (G65), Coolant Fan Control (FC) Control
Module (J293) determines the A/C refrigerant system pressure and controls A/C Clutch (N25) and
Coolant Fan functions accordingly. For example:
‹› Switches the Coolant Fan (V7) to the next higher speed when pressure in the refrigerant circuit
increase.
‹› Switches off A/C Clutch (N25) when pressure is excessive (for example when engine cooling is
insufficient).
‹› Switches off A/C Clutch (N25) off when pressure is too low (for example with low/no refrigerant).
The High Pressure Sensor (G65) signal is also input to the Motronic Engine Control Module (ECM).
As the amount of torque needed to drive the A/C compressor varies according to refrigerant system
pressure, the ECM processes this signal in order to enhance engine performance.
High Pressure Sensor (G65) signal, checking => [ High Pressure Sensor, Function ] See: Heating
and Air Conditioning/Description and Operation/High Pressure Sensor, Function.
Page 4213
Page 2606
Part 3
Page 6156
Page 3354
Page 6735
Warranty
removal.
Page 3003
Alignment: Service and Repair Wheel Alignment Test Prerequisites
Wheel Alignment Test Prerequisites
‹› Check suspension, wheel bearing, steering and steering linkage for excessive play and damage
‹› Tread depth difference of no more than 2 mm on an axle
‹› Tires inflated to prescribed pressure
‹› Curb weight of vehicle
Fuel tank must be full
Spare tire and vehicle tools are installed in appropriate position in vehicle
The water container for the windshield/headlight cleaning system must be full.
‹› Be sure that the sliding plates and turn tables are not touching the end stop when checking
wheel alignment
‹› Test equipment must be properly adjusted and attached to the vehicle (see equipment
manufacturer's instructions)!
If necessary, contact the manufacturer for familiarization with the proper use of the equipment.
After a certain period, wheel alignment platforms and computer equipment can lose their original
leveling setting and adjustments.
Wheel alignment platforms and wheel alignment analyzer/computer should be serviced and
calibrated at least once a year.
- Precision equipment of this type should be treated with due care and knowledge.
Page 2229
Part 2
Page 2028
Page 4177
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6734
^ Reset readiness code.
Page 7155
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 5651
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 1031
Control Modules

Removing

Page 7919
1 - Track Numbers

Page 6451
Removing

Page 4890
Page 7628
- Remove the drive plate again and install shim - 2 -. Tighten bolts - 3 - to 30 Nm again and repeat
the measurement.
If the specified value is OK:
- Tighten the bolts to 60 Nm + 90° (1/4) additional turn, the additional turn may occur in several
stages).
following:
‹› Remove the (T40069) from the cylinder block and install the locking bolt (30 Nm).
Page 2512
Page 4642
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 5538
Page 1566
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1233
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3142
Page 2960
Page 7122
Ground (GND)

Page 3709
- Tighten the cylinder head cover bolts in sequence - 1 through 16 -.
- Observe the tightening sequence when installing the AIR connecting pipe - A -. Refer to => [
Connecting Pipe- Tightening Sequence ] See: Powertrain Management/Emission Control
Systems/Air Injection/Service and Repair/Removal and Replacement.
Page 6232
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5137
legend.
wiring diagram.
harness.


question.)
19 - Legend



Specifications
Valve Clearance

Page 6986
Part 1
Page 7303
Part 1
Page 1100
Part 2
Page 6348

Page 5187
Part 1
Page 6253
Part 3
Page 2967
1 - Track Numbers

‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 6852
Shift Lock Solenoid
Removing
- Raise vehicle.

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 3936
Page 6775
Response Codes
‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 1427
Power Mirror Switch: Diagnostic Aids
Page 3131
- Loosen oil filter -arrow- from below using tension strap or oil filter wrench VAS 3417 as an aid.
- Clean sealing surface on oil cooler.
- Lightly oil rubber gasket on new filter. This achieves the best possible seal when tightening the
filter.
- Tighten filter by hand.
Replacing oil filter, TDI - Diesel engines:

Page 1171
Part 3
Page 1797
WHAT ARE TRACKS?
15-28, and so on).
Page 3042
- For fuel filter
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2741
WHAT ARE TRACKS?
15-28, and so on).
Locations
Headlamp Alignment Sensor: Locations

2 Left rear level control system sensor (G76) on rear axle
‹› General notes => [ Vehicle Level Sensor with Automatic Headlight Vertical Aim Control ] See:
Sensors and Switches - Steering and
Suspension/Sensors and Switches - Suspension/Ride Height Sensor/Service and Repair/Vehicle

Level Sensor With Automatic Headlight Vertical Aim Control.
‹› Component location: => [ Left Rear Level Control System Sensor Overview ] See: Sensors and
Switches - Steering and Suspension/Sensors
and Switches - Suspension/Ride Height Sensor/Service and Repair/Left Rear Level Control
System Sensor Overview.
3 Left front level control system sensor (G78) on front axle
‹› General notes => [ Vehicle Level Sensor with Automatic Headlight Vertical Aim Control ] See:
Sensors and Switches - Steering and
Suspension/Sensors and Switches - Suspension/Ride Height Sensor/Service and Repair/Vehicle

Level Sensor With Automatic Headlight Vertical Aim Control.
‹› Component location: => [ Left Front Level Control System Sensor Overview ] See: Sensors and
Switches - Steering and Suspension/Sensors
and Switches - Suspension/Ride Height Sensor/Service and Repair/Left Front Level Control
System Sensor Overview.
Locations

Page 2443
Part 3

F125

Page 608
Headlamp Control Module: Diagnostic Aids
Page 2748
Steering Angle Sensor: Diagnostic Aids
Page 5127
Checking wiring


Page 1120
Heated Glass Control Module: Diagnostic Aids
Page 6443
Ground.
Final procedures


Page 2415
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 192
Voice Activation Module: Diagnostic Aids
Page 342
Ground (GND)

Tire Pressure Monitoring System Control Module, Coding
Body Control Module: Testing and Inspection Tire Pressure Monitoring System Control Module,
Coding
Control Modules
‹› Chassis
‹› Tire pressure monitoring indicator
‹› Functions
‹› Coding the TPMS control module

Antitheft - No Start Condition Below 40 Degrees F.
Instrument Panel Control Module: All Technical Service Bulletins Antitheft - No Start Condition
Below 40 Degrees F.
90 08 03
February 6, 2008
2011326, Supercedes T.B. Group 90 number 05-08 dated November 18, 2005 due to Service
Action M4 expiring.
Affected Vehicles
Condition
Immobilizer Activated If Ambient Temperature Is Below 4°C (40°F)
An intermittent No Start condition may exist in ambient temperatures below 4°C (40°F):
^ The vehicle cranks but does not start after sitting for long periods or over night
^ The electronic immobilizer light is flashing
^ The vehicle cannot be started with any of the keys
When the concern can be reproduced the following fault codes may be present:
^ P1570 in 01 - Engine Electronics
^ 01176 in 25 - Immobilizer
N/A
Production Solution
N/A
Service
^ Verify if instrument cluster has already been updated:
^ Tilt steering wheel down in order to see white label on bottom of instrument cluster.
If a letter "C" is printed on the label, part has already been updated.
If a letter "C" is not on label, a new instrument cluster has to be ordered for the vehicle based on
the Vehicle Identification Number (VIN).
Page 4411
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Adjustment Overview
Differential: Adjustments Adjustment Overview
Adjustment Overview
‹› If repairs have been performed on the transmission, it is only necessary to adjust the input shaft,
output shaft or differential if components have
been replaced which have a direct effect on the adjustment of the transmission. Refer to the
following table to avoid unnecessary adjustments:
Page 6252
Part 2
Page 5333
Page 7228
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1268
Part 2
Page 2608
Page 2083
Ground (GND)

Page 3205
Coolant: Fluid Type Specifications
Coolant System
Type .....................................................................................................................................................
................... Phosphate-free coolant G 012 A8F A4
Color ....................................................................................................................................................
.............................................. lilac or violet (purple)
Specification ........................................................................................................................................
............................................................. TL VW 774F
Use phosphate-free coolant G 012 A8F A4 G12+ (purple), Valvoline G12 (purple) is really G12+.
Note the following mixing combinations:
G11 (green) & G12 (pink) NO G11 & Valvoline G12 OK G11 & G12+ OK G12 & Valvoline G12 OK
G11 & G12 & G12+ NO G11 & G12 & Valvoline G12 NO
Frost protection is required down to approx. -25°C (-13°F). In countries with arctic climates, frost
protection is required down to approx. -35°C (-31° F). The anti-freeze ratio must be a minimum of
40%, otherwise frost protection is reduced. The recommended mixture ratio is 50:50. If greater frost
protection is required (very cold climates), the amount of G 012 A8F A4 can be increased, but only
up to 60%. This provides frost protection to approx. -40°C (-40°F). Do not reduce the coolant
concentration by adding water, even in warmer seasons/countries, as cooling effectiveness will be
reduced.
Page 2658
Steering Angle Sensor: Diagnostic Aids
Page 5387
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2495
Page 883
^ Verify all connections are properly secure.
^ Insert CD, Part No: W42DTC02511014-2, into CD drive of VAS 5052 / VAS 6150.
^ Go to "My computer" to access the CD-ROM
^ Double click on the file named PODS- B_VW_Action_695606.exe"
The following text will appear when programming is successful.
Trying to find Seat Occupant Recognition Module
Press ■EXIT" to cancel if software update has been performed successfully, the following screen
will appear in VAS 5052 / VAS 6150 display.
Check System
- Power?
- Connection to VAS Tester
- Connection to Seat
Seat Occupant Recognition Module found and connected to System
Apply Action 695606
This can take a minute, please wait
"Action 695606 applied successfully".
TIP
Page 461
Part 1
Page 3658
7 - Cylinder block
Identification of top crankshaft bearing shells
thickness. Colored spots serve to identify bearing thicknesses.
The letters marked on lower sealing surface of cylinder block identify which bearing thickness must
be installed in which location.
G - Yellow B - Blue W - White
Note: ^
^ If color markings can no longer be read, use blue bearing shell.
^ The lower crankshaft bearing shells are always shipped as replacement part with "yellow" color
marking.
Page 3175
‹› M8
6 Hex bolt
‹› M8 x 28

7 Bracket
‹› Bolted to bolt for starter

P0716/P0740
Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 5048
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 1801
Part 3
Page 5386
Part 3
Page 4339
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4675
Part 3
Page 5208
1 - Track Numbers

Page 6504
Page 1215
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6153
Part 3
Page 1148
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4174
Part 1
Page 4285
1 - Track Numbers


F125

Page 4465
Control Modules
Procedure
‹› Body

Page 5116
Ground (GND)

Page 7810
Part 3
Engine - Oil Filler Cap Separation
Engine Oil Filler / Breather Cap: All Technical Service Bulletins Engine - Oil Filler Cap Separation
Condition
17 07 04
Mar. 2, 2007
2010384 supersedes Technical Bulletin Group 17 number 05-06 dated Oct. 18, 2005 due to
inclusion in ElsaWeb and additional models.
Cap, Oil Filler, Comes Apart When Removing Engine Cover
Oil filler cap separates when engine cover is improperly removed.
See Repair Group 24 - Multiport Fuel Injection (MFI), Engine cover with air filter, removing and
installing.
Note:
Oil filler cap can be repaired. Do not replace oil filler cap!
Production Solution
N/A
Service
If oil filler cap has separated:
Tip:
Make sure that the symbol on oil filler cap is facing in the correct direction.
Page 816
If the fault does not return: Repair complete, Generate readiness code. See: Powertrain
- End diagnosis.
Final procedures
Systems/Testing and
End diagnosis.
Page 1424
Part 3
Page 4571

Page 3775
AC-Bu
Page 176
Parking Assist Control Module: Diagnostic Aids
Page 5814
1 - Track Numbers

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2593
- Remove plastic cover - 2 - by unhooking at the lower part of seat - 3 -.
- Remove the bolt - arrow -.
Page 2843
Part 3
Page 615
1 - Track Numbers

Page 3312
CAUTION! Part numbers are for reference only. Always check with for Parts Department for latest
parts information.
Page 6906
Function
Page 1252
Part 1
Page 4668
1 - Track Numbers

Page 2353
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 1899
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1030
Page 6394
Ignition Coil: Locations

Page 1338
1 - Track Numbers

Page 6854
Installing

Oil Filter Adapter Assembly
Oil Filter Adapter Assembly
Page 914
Page 5819
Part 1
Page 5769
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage

wiring diagram.
Page 6862
End diagnosis.
Page 4672
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4324
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Electrical / Mechanical Repair
Wheel Bearing: Electrical / Mechanical Repair
Rear Wheel Bearing Press for VW/Audi
AST tool# 3420
VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle
2008 suggested user price: 25.92
Assenmacher Specialty Tools 1 800 525 2943

Page 3413
Page 7412
Warranty

Page 1558
Page 7152
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 3169
‹› On power steering pump
4 Intake hose mount
5 Intake hose mount
‹› On right longitudinal member
6 Return hose mount
‹› On longitudinal member
7 Ribbed line cooler
On manual transmission 0A4
‹› Assembly notes => [ Pressurized Line Mount Overview ] See: Pressurized Line Mount Overview.
On automatic transmission 09G
‹› Assembly notes => [ Pressurized Line and Return Hose Overview ] See: Pressurized Line and
Return Hose Overview.
Page 2862
Part 2
Page 2362


Page 6988
Part 3
Page 5224
Installing
Functions".
Tightening torques:
Component Nm

Page 5488
Part 1
Page 5765
Part 3
Locations

Page 659
Power Distribution Module: Diagnostic Aids

Page 5003
- For fuel tank
17 - Lock washer
Replace
21 - Fuel filter -
22 - Supply line -
Black
- To fuel rail
23 - Vent line -
White
24 - Seal -
Replace
- Check fuel pump.

27 - Supply line -
Black
- To fuel filter
28 - Return line -
Blue
- To fuel filter

Page 4652
WHAT ARE TRACKS?
15-28, and so on).
Page 5118
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7180
3 51
4 39
- End diagnosis.
Final procedures
End diagnosis.
Page 5655
wiring diagram.
Final procedures

Page 5303
Page 6934
Part 2
Actuation) G187
Page 550
WHAT ARE TRACKS?
15-28, and so on).
Page 3530
^ Wheel bearing tool V.A.G 1459 B
^ Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T hydraulic
^ Tie bolt E-0-217+218
^ Special nut E-8-214
^ Thrust piece E-5
^ Thrust piece E-10
^ Pressure bolt E-15
^ Supplementary set V.A.G 1459 B/2
^ Bell E-40
Removing
- Remove 12-point nut.
- Remove wheel.

Page 2553
Left Front Crash Sensor - G283, Right Front Crash Sensor - G284
Page 2370
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Service and Repair
Heater Core: Service and Repair
Heater Core Bulkhead Seal, Installation Position
The seal between the heater core and the bulkhead has a positioning mark.
- Install the seal - 1 - so that the notches on the seal and the base plate - 2 - align - 3 -.
Page 6938
Technical Service Bulletin # 9105-01 Date: 050502
Group: 91
Number: 05-01
Date: May 2, 2005
Subject: Radio, Reception Diagnosis
Model(s): All with Premium V and VI Radio
1998 > 2006
Condition
Poor radio reception.
Service Procedure
For concerns of poor radio reception:
- Use the following as a guide for trouble shooting.
Tip:
This Technical Bulletin is divided into four sections:
^ Section 1: Includes antenna systems by vehicle.
^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using
internal radio diagnostics.
^ Section 3: Includes antenna lead diagnosis.
^ Section 4: Antenna cables
Tip:
^ Perceived reception issues may be a result of environmental factors.
^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses.
^ Aftermarket window tint may interfere with reception.
^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is
same, condition may be normal).
Section 1 - Antenna systems by vehicle
Tip:
For more detail see Repair Manual Group 91- Communication of the vehicle you are working on.
Passat (W8 only)

Page 807
Final procedures

09.

Code.
Page 2687
Page 3167
4 Intake hose mount
5 Intake hose
6 Intake hose mount
7 Pressurized line
‹› Assembly notes => [ Pressurized Line and Intake Hose to Power Steering Pump Overview ] See:
Pressurized Line and Intake Hose to Power
Steering Pump Overview.
9 Return hose mount
‹› Assembly notes => [ Pressurized Line and Intake Hose to Power Steering Pump Overview ] See:
Pressurized Line and Intake Hose to Power
Steering Pump Overview.
10 Return hose
2.5L
I - Vehicles with manual transmission
II - Vehicles with automatic transmission

Page 3983
Ground (GND)

Page 1921
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1947
WHAT ARE TRACKS?
15-28, and so on).
Page 710
1 - Track Numbers

Locations

Wheel Alignment General Information
Alignment: Description and Operation Wheel Alignment General Information
Wheel Alignment General Information
Always measure wheel alignment using VW approved wheel alignment equipment.
It is recommended to align the front and rear axles for every vehicle alignment.
Otherwise, proper vehicle driveability cannot be ensured.
‹› Wheels should not be aligned until the vehicle has been driven 1,000 - 2,000 km, since it takes
this long for the coil springs to settle.
‹› When making adjustments the specifications must be adhered to as close as possible.
Steering wheel may be crooked if installation position of rear axle and driving direction of vehicle
are not taken into account.
Steering wheel and steering column are marked.
A Line marking on steering wheel B Punch indentation on steering column
Do not change this position.
Otherwise centering of toothed shaft cannot be guaranteed.
If steering wheel is offset, basic setting of steering angle sensor (G85) must be checked! perform
basic setting using See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column.
Steering columns that are delivered as replacement parts do not have punch indentations.
These steering columns must be marked after vehicle alignment and a subsequent road test.
Page 3895
- Remove the intake manifold upward at an angle.
Make sure that no bolts fall out.
- Seal the intake passages in the cylinder head using clean cloths.
- Reinsert the guide tube for oil dipstick into the cylinder block and secure it.
If the manifold must be replaced:
- Remove the fuel rail with injectors. Refer to => [ Fuel Injectors ] See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Fuel Injectors.
- Disconnect the vacuum hose for the Leak Detection Pump (LDP) (V144).
- Remove the Manifold Absolute Pressure (MAP) sensor (G71).
Installing
‹› Replace the seals between the intake manifold and cylinder head.
‹› Tighten the bolts for the intake manifold starting inside working toward the outside and in a
diagonal sequence.
‹› Replace the oil dipstick guide tube O-ring.
- Bleed the fuel supply system. Refer to one of the following:
‹› Engine code BPS, refer to => [ Fuel System, Bleeding ] See: Powertrain Management/Fuel
Delivery and Air Induction/Fuel Tank/Description and
Operation.
‹› Engine code BPR, refer to => [ Fuel System, Bleeding ] .
- Connect the battery.
Page 6935
Part 3
Page 504
Explain to the Customer, the reasons for the margin of error as listed above.
Warranty
Information only.

Page 6777
If any of the listed troubleshooting procedures and/or checks result in errors or yield no solution
and further assistance is required, please follow these steps:
1. Utilize the information contained in the Function Description button in the tester at the point of
the error
2. Report the problem to the shop network administrator for further investigation
3. Contact the responsible support team for further assistance:
^ Service Department Applications: (this includes: GeKo, ElsaWeb, Hotline Channel,

Telediagnosis, and Service Net)
^ VAS 5051/5052 Software Subscriptions
^ VAS 5051/5052 Software Support
Page 240
Condition
Page 1208
Global Positioning System Switch: Service and Repair
Telematics Control Head -E264-, Removing And Installing
Removing
Before beginning repairs on the electrical system, disconnect battery.
- Remove Interior rear view mirror
CAUTION: Telematics control head buttons cannot be removed, dismantled or serviced separately.
Should malfunctions occur, replace complete control head.
Installing Install in reverse order of removal.
- Check Telematic system coding and recode if necessary.

Specifications
Valve Clearance

Page 3560
Loosen anti-theft wheel bolts and tighten
‹› The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.
‹› If the adapter to loosen/tighten the anti-theft wheel bolts is not present in the vehicle, use Master
Wheel Bolt Key Set ( T10101).
‹› If adapter has been lost, a new replacement adapter can be obtained only via the code number.
‹› Master Wheel Bolt Key Set (T10101)

Page 4670
Ground (GND)

Page 4887
Part 2
Page 6452
Installing
audibly.

Actuation) G187
Page 2976
Page 7558
Page 3355
Fuse: Locations Fuse Arrangements on Thirteen Position Auxiliary Relay Panel, Above Relay
Panel, From July 2005
Fuse Arrangements On Thirteen Position Auxiliary Relay Panel, Above Relay Panel, E-J
Page 7103
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 479
Part 1
Page 1661
10 Circlip
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Driver/Front Passenger Airbag Crash Sensor G283 and
G284 Assembly Overview
Impact Sensor: Service and Repair Driver/Front Passenger Airbag Crash Sensor G283 and G284
Assembly Overview
Airbag
1 - Driver Front Airbag Crash Sensor (G283) and Front Passenger Front Airbag Crash Sensor
(G284)
‹› In the front longitudinal member
2 - Combination Nut
‹› 6 Nm
3 - Connector
Crash Sensor For Side Airbag, Driver's Side G179
Crash Sensor For Side Airbag, Driver's Side G179

Page 1391
Part 1
Page 2898
5 38
6 50
- End diagnosis.
Final procedures
End diagnosis.
Page 5660
1 - Track Numbers

Page 880
See Repair Manual, Repair Groups 69 and 72, for detailed information.
The following software program will address the topic concern, using the procedure below.
^ Connect the Midtronics IN-Charge-940 to battery to ensure a constant voltage between 12.5 and
14.5 volts during flash procedure.
^ Connect VAS 5052 or VAS 6150 tester to OBD connector.
^ Verify airbag indicator light is illuminated and that code 02511 014-Seat Occupant Recognition
Control Module Faulty is stored in Air Bag -15-.
^ Switch the ignition OFF.
^ Remove OBD Cable from vehicle and scan tool.
^ Connect VAS 6103 cable to serial port RS-232 as shown.
^ Connect cable VAS 6103/2 to Cable VAS 6103.
^ Connect remaining OBD connector on VAS 6103/2 to the vehicles OBD diagnostic port.
Page 253
1 - Track Numbers

Page 4950
WHAT ARE TRACKS?
15-28, and so on).
Page 152
legend.
wiring diagram.
harness.


question.)
19 - Legend



Coding
Control Modules
‹› Chassis
‹› Functions

Page 6964
Fluid Pan: Service and Repair
Oil Pan
Removing
- Observe general repair notes => [ General Repair Information ] See: Description and
Operation/09G Transmission/General Repair Information.
- Remove ATF drain plug - B -.
- Drain ATF.
- Remove ATF inspection plug - A -.
- Remove overflow tube - C - and drain remaining ATF.

Page 1916
WHAT ARE TRACKS?
15-28, and so on).
Page 3933
Part 2
Page 1027
Part 3
Page 6931
WHAT ARE TRACKS?
15-28, and so on).
Page 2455

Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool
Testing and Procedures/Diagnostic Modes 01 - 09
Generate readiness code. Refer to => [ Readiness Code ] See: Powertrain

Page 1537
Part 3
Page 524
NOTE:
If condition exists, and instrument cluster has been updated, follow normal distonic procedures.
^ Replace instrument cluster with one of the selections from Required Parts table below.
^ See Repair Manual Group 90-Instruments for replacement procedure.
Tip:
Updated clusters will have the same part number as the old part, however they will be marked with
the letter "C" as mentioned above.
Make note of the odometer mileage of the vehicle.
^ Adapt instrument cluster using the GFF plan.
^ Verify correct odometer mileage setting of new instrument cluster after replacement.
NOTE:
It mat take up to 6 attempts to program the instrument cluster. If after 6 attempts instrument cluster
does not program, contact technical assistance or selecting the "Technical Assistance" tab in
ElsaWeb and follow the instructions to obtain a 6 digit access code.
Warranty
Information only.
Page 5694
WHAT ARE TRACKS?
15-28, and so on).
Page 2572
Right Front Seat Belt Micro Switch F141

Page 1154
Wiper Control Module: Diagnostic Aids
Page 2697
WHAT ARE TRACKS?
15-28, and so on).
Page 1643
Left Rear ABS Wheel Speed Sensor G46

Page 2301
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Heated Glass Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 573
Part 3
Page 4204
1 - Track Numbers

Page 5326
Ground (GND)

Restraints - Air Bag Lamp ON/DTC 02511 014 Stored
Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Restraints - Air Bag
Lamp ON/DTC 02511 014 Stored
69 11 01
February 17, 2011
2010347 Supersedes T.B. V010807 dated January 29, 2008 to update scan tool applicability used
during procedure.
Vehicle Information
Condition
Airbag Monitoring Light ON, Passenger Occupant Detection System, DTC 02511 014 Stored in
Memory
Note
The passenger airbag system operates according to manufacturer specifications during the
following key-ON cycles, however, the Airbag Monitoring" indicator light in the instrument cluster
remains illuminated indicating a DTC stored in DTC memory.
"PASSENGER AIRBAG OFF" indicator light, in the center of the instrument panel, will stay
illuminated during the first key-ON cycle.
Airbag control module will disable the passenger airbag module during the first key-ON cycle when
this DTC is stored to memory, and the "PASSENGER AIRBAG OFF" indicator will alert occupants
that the airbag has been disabled.
Page 6836
1 - Track Numbers

Page 230
Page 6124
Part 2
Page 3717
3365 - Valve Seal Installer
VW 541-1 A - Valve Spring Compressor
Page 223
Ground (GND)

Page 1278
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6052
Fuel Injector: Service and Repair Fuel Injectors
Fuel Injectors
Removing
Injection.
- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.
- With ignition switched off, disconnect the battery ground (GND) cable.
connection.
- Disconnect the ventilation line - 2 - and fuel supply line - 3 -. Catch any draining fuel with a clean
cloth.
‹› Press the securing ring to disengage the lines.
- Disconnect all connectors - 1 - from the fuel injectors as well as connectors - 2 and 6 -.
Page 6910
Checking
- Multimeter.
- Wiring diagram.
Requirements
- Fuse SA6 OK.
- Fuse SB28 OK.
- Fuse SC14 OK.
Test procedure
Start diagnosis
Checking voltage


Page 6694

Page 3202
Note:
Cooling system flushing due to coolant mixing or incorrect coolant is not covered by warranty.
Warranty Information Only.
Page 7976
Part 2
Page 4133
1 - Track Numbers

Page 3149
Oil Filter: Tools and Equipment
VW Oil Filter Housing Drain
AST tool# T 40057


Page 4942

Page 2186

Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool
Testing and Procedures/Diagnostic Modes 01 - 09
Generate readiness code. Refer to => [ Readiness Code ] See: Powertrain

Page 5312
Information Bus: Service and Repair
Wiring Harnesses and Connectors, Repairing
Safety Precautions
CAUTION! When performing repairs on airbag and seat belt tensioner wiring harness, use only
terminals, connectors and wires designated for it.
CAUTION! Be sure to read the information regarding repairing the wiring harnesses for the airbag
and pretensioner.
Observe country-specific regulations.

Pay attention to decals designating high voltage components. When performing repairs, residual
voltage must be discharged.
The wiring harnesses for the airbag and the pretensioner may be repaired only with the (VAS 1978
B). Refer to => [ Airbag and Belt Tensioner Wires, Repairing ]. See: Power and Ground
Distribution/Wiring Harness/Service and Repair/Procedures/Wiring Harnesses and Connectors,
Repairing/Airbag and Belt Tensioner Wires, Repairing
Refer to => User's instructions of (VAS 1978 B)
CAN Bus Wires, Repairing
‹› Unshielded two-strand wiring - 1 - and - 2 - with a cross section of 0.35 mm2 or 0.5 mm2can be
used as CAN-Bus wiring.
‹› CAN bus wires have the following color coding:
‹› Perform wiring harness repairs using only yellow wiring. Repaired areas are to be marked with
yellow tape.
‹› When repairing Bus leads, both wires must be of the same length. When twisting together wires -
1 - and - 2 -, length of lay of - A -: 20 mm must
be observed.
‹› While doing this, no section of the wire, e.g. in area of crimp connectors - arrow -, may be greater
than - B -: 50 mm without twisting of the
wires.
Page 4077
1 - Track Numbers

Page 1804
Page 241
Vehicle Information
Production Solution
Service
Symptoms
Warranty
removal.
Page 3476
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5720

Page 6937

Page 2969
Ground (GND)

Page 4269
Part 1
Page 4797

Page 6018
Part 2
Page 7009
Page 2653
Part 1
Page 5138
Ground (GND)

Page 1539
Page 6651
Part 3
Page 7793
Removing
arrow 2 -.
"learning" process.
Installing

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 1285
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4227
1 - Track Numbers

Locations

Page 3356
Fuse: Locations Fuse Arrangements in Fuse Panel, Instrument Panel, Left, From July 2005
Fuse Arrangements in Fuse Panel, Instrument Panel, Left
Page 7025
Page 4388
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3744
WHAT ARE TRACKS?
15-28, and so on).
Page 7698
funnel.

Page 4153
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1645
Wheel Speed Sensor: Locations Electrical and Electronic Component Locations, From MY 2006

9 Right rear ABS wheel speed sensor (G44)/left rear ABS wheel speed sensor (G46)
11 Wheel hub with rotor for front speed sensor
‹› Rotor and left and right front speed sensor are identical
12 Wheel hub with rotor for rear speed sensor
‹› Rotor and left and right rear speed sensor are identical
Locations


Page 1559
Brake Fluid Level Sensor/Switch: Diagnostic Aids
Page 672
Ground (GND)

Page 4936

Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/DTC's P0300-P0312 Stored
28 10 01
March 31, 2010
2023121
Page 3525
‹› Be sure there is sufficient room when pulling out drive axle.
CAUTION! Place engine/transmission jack (V.A.G 1383 A) underneath (danger of accident if parts
Wheel Hub, Removing

Page 1985
Page 3241
Tip:
Tip:
Page 3871
Track 1-14
named Track 1-14.
Track 169-182
reference box.


Page 6802
Shift Lock Solenoid
Removing
- Raise vehicle.

Page 4683
Overview
1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
5 Bracket

Locations


Page 2636
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2841
Part 1
Page 4061
Example
- Only suspect coolant pump leak, and consider replacement if the following conditions occur
- Vehicle arrives with excessive coolant leak.
- Vehicle arrives with coolant light ON.
- Vehicle arrives with the temperature warning at its highest level.
- Pressure drops in the coolant pump during Pressure test, see Group 19, Cooling System,
Checking for Leaks in ElsaWeb.
Warranty
Information Only.
Page 5941
supply line - 2 -.
and Operation.
Page 5474
Start diagnosis
Checking voltage
terminals.
terminals.
Checking activation


Page 1451
WHAT ARE TRACKS?
15-28, and so on).
Page 1442
Page 2558
Impact Sensor: Service and Repair Driver/Front Passenger Side Airbag Sensor Assembly
Overview
Airbag
2 - Bolt
‹› 9 Nm
3 - Connector
4 - Carpet
Page 7252
Installing
‹› When installing circuit board, make sure that the terminals are not damaged and circuit board is
not bent.
- Install circuit board on to mounts on frame - arrows -.
- Connect harness connector - 1 - of circuit board.
- Clip harness connector into hole - arrow - in bracket - 2 -.
- Carefully place cover on shift mechanism and lock with retaining tabs - arrows - (qty. 4).
Page 4135
Ground (GND)

Page 5704
End diagnosis.
Page 2006
WHAT ARE TRACKS?
15-28, and so on).
Page 3168
1 Refill tank
‹› Assembly notes => [ Power Steering Reservoir Assembly Overview ] See: Steering and
Suspension/Steering/Power Steering/Power Steering
Fluid Reservoir/Service and Repair.
‹› Checking delivery pressure => [ High Mount Power Steering Pump, Checking Delivery Pressure ]
See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Testing and Inspection/High Mount

‹› Before installing, fill with power steering fluid => [ High Mount Power Steering Pump ] See:
Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and Repair/High Mount Power Steering Pump.

Page 4888
Part 3
Page 7071
Ground (GND)

Page 4573
- Start the engine.
If the LED was ON:
Checking wiring

Page 2328
Final procedures
09.

Code.
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4171
Ground (GND)

Page 3132
- Loosen sealing cap -1- using oil filter wrench 3417.
- Replace O-rings -2- and -3- as well as oil filter element -4-.
- Tighten sealing cap -1- using oil filter wrench 3417.
- Tightening torque of sealing cap: 25 Nm
Replacing oil filter, 2.5L fuel injection engines
- Oil drain adapter T40057
- Torque wrench V.A.G 1331/ Needle-nose pliers
Warning!
Oil filter housing must be drained before it is removed.

Page 4594
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5367
Final procedures


Page 5330
Part 2
Page 144
‹› Query/erase the DTC memory
- Switch the ignition off and wait several minutes.
‹› Body
‹› Query/erase the DTC memory
No malfunctions may be present in the memory.
The green Telematics Control Lamp (K186) must illuminate in the Telematics Control Head (E264).
- Disconnect the (VAS 5051B) from the Telematics control module.
Configuration
- Drive the vehicle to an open space without buildings and roofs.
- Press OnStar button. A sequence of tones is heard.
- Press the OnStar button again during the sequence of tones.
- When the OnStar Call Center responds, identify yourself as VW Service and report that you
replaced the Vehicle Communications Interface Unit (VCIM).
- Give the OnStar Call Center the ESN and STID of the new Telematics control module as well as
the VIN and customer data (if necessary).
- The OnStar Call Center will guide you through the configuration and update the customer data.
- When the configuration is complete, press the OnStar button.
- Wait 10 minutes and press the OnStar button again to confirm the configuration. Inform the
OnStar Call Center that VW Service conducts a quality check after replacement of the VCIM and
the configuration.
- To end the connection, press the OnStar button.
‹› Normal connection time is 10 to 15 seconds. However, connection time can be up to three

minutes, depending on reception conditions. Be patient.
‹› If message: "Unable to contact OnStar" is heard, drive vehicle to open area and try to connect
again. Depending on local conditions, it is possible -
and normal - that several connection attempts are necessary.
‹› If message: If "OnStar request ended" is heard, connection was interrupted before it was
completed. Wait for a short period of time before
repeating connection attempt.
‹› If you are still unable to connect, call OnStar Customer Care at: 1-888-390-4050. Advisor will
verify whether customer account is active.
Page 6761
Your Service Center should place the vehicle owner on notice in writing, that their ECM or TCM
was found to have been tuned, and that any damage caused by the tuning of the ECM or TCM
(including any adverse emissions consequences) will not be covered by Volkswagen of America,
Inc. warranties.
For any repair requested by the owner under warranty or outside warranty that requires Pass -
Thru Vehicle Programming, which will automatically wipe out the "Tuning" program, your Service
Center should advise the owner of the above and get Owner's written consent (see Control Module
Tuning form shown) to the flashing procedure.
^ Battery MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update
process can lead to ECM/TCM failure)
^ Battery voltage must be maintained throughout procedure (always use an approved battery
Charger / Maintainer).
Page 3295
Engine Oil, Filling
General Information
Page 3284
Engine Oil: Fluid Type Specifications
Engine Oil Gasoline engines: Only oils meeting VW oil quality standard:
............................................................................................................................. VW502 00 Use oil
viscosity ...............................................................................................................................................
............................................................ 5W-40 if not available, 5W30 or 0W40.
Do not overfill! Overfilling engine oil can cause misfire DTCs to be stored in ECM (J220). To
prevent overfill, add approx. 0.5L less than capacity, start engine and let run until engine operating
temp is appox. 60°C (140°F), turn OFF ignition, wait approx. 3 minutes, check dipstick, then fill to
MAX. See Repair Manual for details. Turbo engines only: After changing oil and filter, start and run
engine at idle until oil pressure light goes out. DO NOT rev engine, this could cause damage/failure
of the turbocharger.
Page 5871
Part 3
Page 7863
WHAT ARE TRACKS?
15-28, and so on).
Page 3700
‹› Feeler gauge
- Before measuring, clean the ring groove.
Pistons, Checking
‹› External micrometer 75 to 100 mm
- Take the measurement approximately 10 millimeter (mm) from the lower edge of the piston skirt
and offset 90° to the piston axis.
Deviations from nominal dimension: Max. 0.04 mm
Cylinder Bore, Checking

Page 6855
- Check selector mechanism => [ Selector Mechanism, Checking ] See: Shifter A/T/Testing and
Inspection.

Page 1362
Page 1690
1 - Track Numbers

Page 3085
Drive Belt: Removal and Replacement
Ribbed Belt Routing
Ribbed Belt Routing
5-Cylinder Engine with Power Steering Pump and A/C Compressor
2 - Ribbed Belt - Power steering pump, a/c compressor, tensioner roller, coolant pump and
generator
3 - Idler roller
5 - Ribbed Belt - Crankshaft/vibration damper and a/c compressor
6 - Pulley - Crankshaft/vibration damper
7 - Tensioner
8 - Tensioner
9 - Pulley - Coolant pump
4-Cylinder TDI Engine with Power Steering Pump and A/C Compressor
2 - Ribbed Belt - Power steering vane pump, idler roller, a/c compressor, crankshaft/vibration
damper, tensioning roller and generator.
3 - Idler roller
4-Cylinder TDI-PD Engine with Power Steering Pump and A/C
Compressor
Page 1969
Page 1798
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1221
Part 3
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Specifications
Power Steering Fluid: Specifications
Power steering fluid
Hydraulic oil .........................................................................................................................................

.................................................................. G002 000
Do not use ATF

Page 1787
540/1A) and a M8 x 100 bolt - A -.
switch.
Page 6022
Page 2729
Ride Height Sensor: Service and Repair Left Front Level Control System Sensor Overview

Vehicle Level Sensor With Automatic Headlight Vertical Aim Control.
1 Bracket
2 Hex nut

Suspension.
5 Control arm
Page 4505
removal.
Fluctuation
Condition
Production Solution
Service
the driver has
position.
Warranty
Information only.
required.
Page 7524
Part 3
Page 256
WHAT ARE TRACKS?
15-28, and so on).
Page 761
removal.
Page 7090
- Remove right noise insulation.
- Turn steering to right to full lock.
- Mark installation position of ball joint bolts - arrows - on control arm.
- Remove coupling rod - A - from control arm.
‹› This work step is necessary so that the right drive axle must not be disconnected from the wheel
bearing (wheel hub).
‹› Right drive axle must only be disconnected from the transmission.
- If installed, remove protective cover - A - for inner right constant velocity joint from engine - arrows
-.
Page 4909
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1495
Ground (GND)

Service and Repair
Spare Tire: Service and Repair
Vehicles with flat tire kit
The New Beetle Convertible is equipped with a flat tire kit.

The flat tire kit is located in luggage compartment, where the spare wheel is stored. The kit
contains a bottle of tire sealant next to the compressor.
Tire sealant
Tire sealant in the bottle has a limited shelf life.
Therefore the minimum shelf life date - arrow - is marked on the bottle.
In this example, the minimum shelf life date 05/2003 has expired, the bottle must then be replaced.
If the bottle was opened, e.g. for a flat tire, it must also be replaced.
Page 2217
Checking wiring


Page 6143
Page 4727
Hood Sensor/Switch (For Alarm): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6614
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4599
Page 7712
Installing
- Drive in new sealing ring to stop. Do not distort oil seal.
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Install flange shaft, secure with countersunk bolt and tighten to 25 Nm.
- Install drive axle.
- Bolt on wheel
- Checking and filling up gear oil => [ Gear Oil, Checking and Filling ] See: Fluid - M/T/Service and
Repair.
- Install center and left sections of sound insulation below engine/transmission.
Page 2783
1 - Track Numbers

Page 7213


Page 7548
1 - Track Numbers

Page 7448
Check Spring Connections and Rivets
- Check spring connections between pressure plate and cover for cracks and rivets for secure fit.
‹› A pressure plate with damaged spring connections or loose rivets - arrows - must be replaced.

Page 5219
‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis
Page 2105
Part 2
Page 2754
legend.
wiring diagram.
harness.


question.)
19 - Legend



Service and Repair
Timing Belt: Service and Repair
Camshaft Drive Toothed Belt, Checking
Toothed Belt, Checking Condition
- Open fasteners of upper toothed belt cover and remove cover.
- Check condition of toothed belt for:
‹› Cracks, cross-sectional breaks
‹› Separation (cover layer, belt cords)
‹› Wear-through on cover layer
‹› Surface cracks (plastic shroud)
‹› It is essential to replace toothed belt if malfunctions are found. By replacing, failures and/or
disturbances can be avoided. Replacing the belt is a
repair procedure.
While checking the condition, take notice of the following defects:
A - Tears (cover side)
B - Lateral movement
C - Fraying
D - Tears (in teeth)

Page 997
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5275
Final procedures

Page 2366
1 - Track Numbers

Page 3574
Part 1
Page 5719

Page 6224
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 2719
Page 3230
Fluid - A/T: Service and Repair 09G Transmission
ATF, Filling
ATF, Filling
- With engine "running", install adapter for filling oil (VAS 6262/2) hand-tight.
- Add 1 l of ATF.
- Pull off adapter for oil filling (VAS 6262) at quick-release connection and check:

Locations
Locations


Page 7406
Page 1954
Dimmer Switch: Diagnostic Aids
Page 890
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1864
Part 2
Page 906
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3521
2 Brake disc
3 Brake pads
‹› Vehicles until model year 2000
Replacement.
4 Retaining spring
‹› Insert in both holes of brake caliper housing
5 Brake carrier
Page 6236
Part 1
Page 1232
WHAT ARE TRACKS?
15-28, and so on).
Page 7691
Warranty

Page 2896
3 51
4 39
- End diagnosis.
Final procedures
End diagnosis.
Relay and Fuse Arrangements on Relay Panel, From July
2005
Power Distribution Relay: Locations Relay and Fuse Arrangements on Relay Panel, From July
2005
Page 4553
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 215
Engine - Oil Drain Plug Thread Cleaning
Engine Oil Drain Plug: Technical Service Bulletins Engine - Oil Drain Plug Thread Cleaning
Condition
17 07 05
Mar. 2, 2007
2010621 supersedes Technical Bulletin Group 17, number 04-04 dated Dec. 3, 2004 due to
additional models and inclusion in ElsaWeb.
Oil Pan Drain Plug, Cleaning Threads on Plug and Oil Pan When Changing Oil
Engine oil leaks are found after engine oil is changed.
This condition may be caused by contaminants on the threads of the oil drain plug or the oil pan (if
both are not cleaned before installing and tightening the oil drain plug to the proper torque).
Production Solution
N/A
Service
After draining engine oil:
^ Clean any contaminants from both oil drain plug and oil pan drain hole threads.
^ Carefully inspect drain plug and oil pan threads for damage.
^ If drain plug is damaged, replace it along with drain plug seal.
^ Replace either drain plug with seal, or drain plug seal only (if available separately), as necessary.
Tip:
Always see ETKA for the latest part(s) information.
Note:
In some cases the drain plug comes with an integral (permanent) seal and must be replaced as a
unit.
Never install a drain plug sealing ring from another application (always consult ETKA for the
appropriate drain plug / sealing washer combination).
^ Install oil drain plug and hand-tighten first. Then, using a torque wrench, tighten to the proper
specification as listed in the table below. See Required
Page 1766
Page 3984
WHAT ARE TRACKS?
15-28, and so on).
Page 36
^ Location: Behind rear section of molded headlining.
Antennas
All models use four antennas items -2-, 4- (qty. 2) & -7-.
^ Antennas (R130, R131) are integrated into rear hatch glass.
^ Antenna R11 in left rear side glass.
^ Antenna R93 in right rear side glass.
Antenna amplifiers
All models use four antenna amplifiers items -1-, -3-, -5- & -6-.
^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window.
^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid.
^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window.
Phaeton
Page 3656
Crankshaft: Specifications Crankshaft Dimensions
(Dimensions in millimeters (mm))

Page 376
WHAT ARE TRACKS?
15-28, and so on).
G182, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking wiring
Locations
Clutch Pedal Position (CPP) Switch F194

Page 2187
Final procedures

09.

Code.
Page 5913
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4342
Part 3
Page 2688
Telescoping Wheel Switch: Diagnostic Aids
Page 1153
Page 1425
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4901
Final procedures

Page 3730
Drive Belt: Removal and Replacement
Ribbed Belt Routing
Ribbed Belt Routing
5-Cylinder Engine with Power Steering Pump and A/C Compressor
2 - Ribbed Belt - Power steering pump, a/c compressor, tensioner roller, coolant pump and
generator
3 - Idler roller
5 - Ribbed Belt - Crankshaft/vibration damper and a/c compressor
6 - Pulley - Crankshaft/vibration damper
7 - Tensioner
8 - Tensioner
9 - Pulley - Coolant pump
4-Cylinder TDI Engine with Power Steering Pump and A/C Compressor
2 - Ribbed Belt - Power steering vane pump, idler roller, a/c compressor, crankshaft/vibration
damper, tensioning roller and generator.
3 - Idler roller
4-Cylinder TDI-PD Engine with Power Steering Pump and A/C
Compressor
Page 5389
Page 4322
Ground (GND)

Page 3619
WHAT ARE TRACKS?
15-28, and so on).
Page 1434
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5869
Part 1
Page 5823
Page 5344
WHAT ARE TRACKS?
15-28, and so on).
Page 2082
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2230
Part 3
Page 7190

Service and Repair
Valve Cover: Service and Repair
Cylinder Head Cover
Removing
- Disconnect the air hose for the crankshaft housing ventilation - arrow -.
- Remove the Secondary Air Injection (AIR) connecting pipe - A -.
- Remove the ignition coils - 1 through 5 -. Refer to => [ Ignition Coils with Power Output Stages ]
See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair.
- Remove the cylinder head cover bolts in sequence - 16 through 1 -.
Installing
Install in reverse order of removal. When doing this note the following:
‹› Replace the cylinder head cover if damaged or leaking.
- Clean the sealing surfaces so they are completely free of any oil or grease.
Page 5107
Page 2087
Part 2
Page 6306
Part 3
Page 4914
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6609
Part 1
Page 7044
Warranty
Information only.
removal.
Page 6355
Note
Production Solution
Service
Procedure
Note
bulletin.
Page 1828
1 - Track Numbers

Page 5603
Part 1
Page 5268
Technical Data
Technical Data
Page 7673
- Insert shim under outer race.
- Support transmission housing directly beneath bearing mount using press support (3144 ).
Removing and installing roll pin for differential bevel gear axle
- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of
shavings.
- Drive out roll pin using chisel. Place chisel in surrounding groove, to do so.
- Drive into differential housing until stop.
On some transmissions the thrust washer union was made with a ridge - A - in area of holes.
In conjunction with this, the differential housing had a circumferential groove - B -.
- Insert thrust washer union with gear oil.
- Install thrust washer union so that it engages into groove - B - of differential housing.
Installing differential planetary gears

Page 3146
Removing
Installing
Page 1110
1 - Track Numbers

Page 7123
WHAT ARE TRACKS?
15-28, and so on).
Page 2297
1 - Track Numbers

Page 6859
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
Page 211
Part 1
Intake Manifold
Intake Manifold: Service and Repair Intake Manifold
Intake Manifold
‹› Socket and extended bit (T10107A)
Removing
- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.
- With the ignition switched off, disconnect the battery ground (GND) cable.

connection.
Vehicles through Model Year (MY) 2009
- Remove the vacuum line - 1 -, ventilation line - 2 - and fuel supply line - 3 - and catch any leaking
fuel with a clean cloth.
Vehicles from MY 2010
- Remove the ventilation line - 2 - and fuel supply line - 3 -. Catch any leaking fuel with a clean
cloth.
‹› Press the securing ring to disengage the lines.
- Disconnect all connectors - 1 - from the fuel injectors as well as connectors - 2 and 6 -.
Service and Repair
Clutch Slave Cylinder: Service and Repair
Slave Cylinder
Removing
- Disconnect intake air duct - 1 - and connector - 2 - Mass Air Flow (MAF) sensor (G70).
- Remove locking washer - arrow 1 - for shift cable from transmission shift lever - A -.
- Remove locking washer - arrow 2 - for selector cable from actuator lever - B -.
- Remove selector cable and shift cable from pins.
- Remove locking washer - arrow 3 - from actuator lever - B - and remove actuator lever.
- Remove transmission shift lever - A -. To do so, remove nut - arrow 4 -.

Page 362
Part 1
Page 6560
Tip:
Page 5310
=> [ Display Group 125, Evaluating ]
=> [ Display Group 126, Overview ]
=> [ Display Group 126, Evaluating ]
Display Group 125, Overview
‹› Display fields in display groups 125 and 126 provide the CAN Data Bus function status codes of
various control modules connected to the vehicle
CAN Data Bus network.

‹› If a vehicle is not equipped with control module(s) or components listed in the following display
groups, the applicable display field remains
blank.
‹› Display fields may vary depending on instrument cluster manufacturer (VDO or MMO).
Display Group 125, Evaluating
Display Group 126, Overview

Page 2218
Checking wiring
Final procedures

09.

Code.
Page 4392
Part 1
Page 5724
Final procedures

Page 2505
WHAT ARE TRACKS?
15-28, and so on).
Page 2058
Combination Switch: Connector Views
Steering Column Switches, Multi-Pin Connector Assignments
Steering Column Switches, Multi-Pin Connector Assignments
Windshield Wiper and Washer System Switches, 6-Pin Connector - A -
1 - 4 - Open
5 - Windshield wiper intermittent regulator to automatic intermittent washer/wiper relay
6 - Windshield wiper intermittent regulator - terminal 31
Windshield Wiper and Washer System Switches, 8-Pin Connector - B -
1 - Windshield wiper switch - terminal 53
2 - Windshield wiper switch - terminal 31
3 - Windshield wiper switch - terminal 53e
4 - Windshield wiper switch - terminal 53c
5 - Windshield wiper switch - rear window wiper
6 - Windshield wiper switch - terminal 53b
7 - Windshield wiper switch - intermittent operation
8 - Windshield wiper switch - terminal 53a
Turn Signals, High and Low Beam, Headlamp Dimmer/Flasher and Parking Light Switches, 12-Pin
Connector - C -
1 - Headlamp dimmer/flasher switch - terminal 30 (B+)
2 - Headlamp dimmer/flasher switch - terminal 30 (B+)
3 - Turn signal switch - terminal L
4 - Parking light switch - terminal P
5 - Turn signal switch - terminal 49a
6 - Horn plate - terminal 71

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2642
Page 5691
1 - Track Numbers

Page 4600
Page 5652
voltage.
Checking wiring
Page 689
Page 7654
Page 1655
Part 3
Page 5692
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7650
Part 1
Luggage Compartment Light W3, Removing and
Installing
Trunk Lamp Switch: Service and Repair Luggage Compartment Light W3, Removing and Installing
Luggage Compartment Light W3, Removing And Installing
Removing
CAUTION:
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Insert screwdriver behind lens and carefully pry lens out.
- Remove lens with bulb holder.
- Disconnect electrical connection.
- Replace 12V/3W bulb.
Installing
- Connect electrical connection.
- Insert lens with bulb holder into mounting and engage properly.
After working on the luggage compartment light a functional check of the switch must be carried
out.
With trunk lid closed, the light must not come on.
Oil Pressure Sender: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 131
Part 2
Page 1726
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 319
Do not tighten bolts completely. It will be easier to attach the various brake lines to the hydraulic
unit.
- Tighten hydraulic unit after tightening brake lines.
- Rest of installation is in reverse order of removal.
- Remove brake pedal actuator (V.A.G 1869/2 ).
- Bleed brake system => [ Brake System Bleeding General Information ] See: Brakes and Traction
Control/Brake Bleeding/Service and Repair/Brake System Bleeding General Information.
- Code radio.
- Code control module.

Page 3173
7 From power steering pump
8 Pressurized line
9 Hex bolt
‹› M8 x 28
‹› Tightening specification => [ Pressurized Line to Automatic Transmission
09G ] See: Specifications/Pressurized Line Mount to Transmission Tightening Specifications.
10 To steering gear
2.5L With Automatic Transmission 09G
Pressurized Line and Return Hose Overview

Page 569
WHAT ARE TRACKS?
15-28, and so on).
Page 2003
1 - Track Numbers

Page 5491
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Maintenance Required Lamp/Indicator: Description and Operation
Service Interval Display
Function:
The Service Reminder Indicator electronics include:
‹› A time counter
and
‹› Two odometers
The electronics evaluate the contents of the counters, so that the consumer is either
‹› After a specific time span has run out
or
‹› After reaching a specific distance
via Service Reminder Indicator (SRI), that a service is required (whichever is due first).
Only the total distance driven and the daily distance driven is displayed in the speedometer - 2 -
between services.
When a Service comes due, the type of service will blink in the speedometer after the ignition is
turned on - 2 -. For the Service Tables, refer to => [ Service Table ].
‹› By pressing button - 1 -, the display can be switched back to driven "daily distance."
‹› The display switches back to the "daily distance driven" after 1 minute after the engine is started.
=> [ Service Table ]
=> [ Service Interval Display Resetting from 04.1999 ]
=> [ Service Interval Display from 05.1999 ]
=> [ Service Interval Display Resetting from 05.1999, ]
Service Table
Page 2762
Page 1718
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Service and Repair
Lock Cylinder
Connecting.
Removing
1. Position "Off"
2. Position "Run"
3. Position "Start"
Page 3657
Crankshaft: Locations
Crankshaft, assembly overview
1 - 40 Nm plus an additional 1/4 turn (90°)
^ Replace
^ Fully threaded
^ Tighten to 40 Nm (but not any further) to measure radial play in crankshaft.
2 - Bearing cap
^ Bearing cap 1: Belt pulley side
^ Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
3 - Bearing shell for bearing cap
^ Without lubricating groove
^ Do not interchange used bearing shells (mark)
4 - Crankshaft
^ Measure radial clearance with Plastigage(R)
- New: 0.023 to 0.043 mm Wear limit: 0.07 mm
^ Do not turn crankshaft when measuring radial play
5 - Thrust washers
^ For bearing 3
^ Side lubricating grooves face outward
6 - Bearing shell for cylinder block
^ With lubricating groove
^ Classification for replacement part ordering
^ Do not interchange used bearing shells (mark)

Page 1535
Part 1
Page 7786
Final procedures
Systems/Testing and
End diagnosis.
Engine Controls - MIL ON/DTC's P001, P000A Set
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P001, P000A Set
Number: PT01-07-48
Date: May 15, 2007
Subject: Updated Programming, MIL ON P0011, P000A Stored in ECM Fault Memory
Model(s): See Model Table Below
2006-2007
Condition
MIL ON, DTC P0011, P000A stored in ECM fault memory.

Model Table
Service
Tip:
The "Pass - Thru Vehicle Programming" process may overwrite any "TUNED" ECM/TCM
programming.
A "TUNED" ECM or TCM is described as any ECM or TCM altered so as to perform outside the
normal parameters and specifications approved by Volkswagen of America, Inc..
If you encounter a vehicle with a "Tuned" ECM or TCM, prior to performing the "Pass - Thru
Vehicle Programming" procedure:
Page 3096
11 Air Duct
13 Intake Tube

Page 480
Part 2
Page 2714
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5467

Page 1313
Active Spoiler Switch: Service and Repair
Rear Spoiler Switch
The Rear Spoiler Switch (E127) " manually" extends and retracts the rear spoiler.
The Rear Spoiler Switch (E127) - arrow - is located under the instrument panel near the steering
column.
The rear spoiler will extend all the way out when the ignition is turned on and the switch is in
position - 1 -.
The rear spoiler will extend in steps all the way out when the ignition is turned on and the switch is
in position - 2 -.
CAUTION! Danger of injury!
Make sure there is enough clearance when "manually" extending or retracting the spoiler using the
switch.
Actuation) G187
Page 3477
Ground (GND)

Page 6839
WHAT ARE TRACKS?
15-28, and so on).
Page 3493
1 - Track Numbers

Page 5213
Part 1
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 649
1 - Track Numbers

Page 7300
Ground (GND)

Service and Repair
Variable Valve Timing Cover / Housing: Service and Repair
Control Housing Cover

Removing
‹› Engine removed, transmission disconnected from flange.
- Remove the chain compartment cover. Refer to => [ Chain Compartment Cover ] See: Timing
Components/Timing Cover/Service and Repair.
- Remove the cylinder head. Refer to => [ Cylinder Head ] See: Cylinder Head Assembly/Service
and Repair/Removal and Replacement/Cylinder Head.
- Disengage the wiring harness - arrow - and remove the engine speed (RPM) sensor (G28) - 1 -
and vacuum pump - 2 -.
- Pry off the control housing cover - 1 - from the cylinder block - 2 - or from the upper oil pan - 3 - at
the positions designated at the top and bottom using a suitable screwdriver - A -.
Page 3930
WHAT ARE TRACKS?
15-28, and so on).

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 2504
Ground (GND)

Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 3818
- oil filter insert -2-
- oil filter housing sealing ring -3-
- oil filter housing center tube -4-
Pumpe Duse PD-TDI Diesel
- oil filter -3-
- O-rings -2 and 4-
Page 5148
Page 3449
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3783
SW-Wu
Page 4514
order)
Tip:
Removal and Replacement
Differential: Removal and Replacement
Table of Contents
=> [ Left Drive Flange Shaft Oil Seal ] See: Seals and Gaskets/Service and Repair/Left Drive
Flange Shaft Oil Seal
=> [ Right Drive Flange Shaft Oil Seal ] See: Seals and Gaskets/Service and Repair/Right Drive
Flange Shaft Oil Seal
Differential Assembly Overview
Differential Assembly Overview
‹› Heat inner race/tapered roller bearing to approximately 100° C before installing.
‹› Always replace both taper roller bearings together as a set.
‹› Adjust differential => [ Differential, Adjusting ] See: Adjustments/Differential, Adjusting, when

replacing tapered roller bearing, differential
housing, transmission housing and clutch housing.
2 Shim
‹› For differential
‹› Determining thickness => [ Differential, Adjusting ] See: Adjustments/Differential, Adjusting.

Page 7428

Page 4654
Part 1
Page 715
Part 1
Page 2344
Page 2883
Warranty

Page 3274
Ch-Fu
Bleeding Without Brake Filler/Bleeder Unit
Brake Bleeding: Service and Repair Bleeding Without Brake Filler/Bleeder Unit
Bleeding without Brake Filler/Bleeder Unit
- Build pressure in brake system by pumping brake pedal.
- Open bleeder screw with bleeder bottle hose attached.
- Close bleeder screw with pedal depressed.
- Repeat procedure until no more air exits.
Bleeding sequence => [ Bleeding Sequence ] See: Bleeding With Brake Filler/Bleeder Unit VAS
5234.
Pre-bleeding the brake system when one chamber of the brake fluid reservoir is completely empty
(e.g. due to a leak in brake system).
Bleeding sequence => [ Bleeding Sequence ] See: Bleeding With Brake Filler/Bleeder Unit VAS
5234.
Change brake fluid=> 14.1

Page 869
^ With connector in both hands, slide locking clip rearward and separate connector halves. It may
be necessary to use a small hook tool to pull back the spring clip.
^ Move passenger seat to full reverse position and access connector panel.
^ Release lock on 10 pin connector under black connector panel. It may be necessary to use a
small hook tool to pull back the spring clip. Care must be taken not to damage surrounding
connectors and wiring.
^ Connect 10 pin connector of VAS 6103/02-1 to 10 pin seat harness connector as shown.
Page 5417
Page 6412
Installing
- Insert all ignition coils loosely into the spark plug holes.
- Align the ignition coils to the recesses in the cylinder head cover and connect all connectors in
reverse order of removal onto the ignition coils.
- Press the ignition coils evenly onto the spark plugs by hand.
Page 1253
Part 2
Page 6590
WHAT ARE TRACKS?
15-28, and so on).
Page 7245
- Remove tunnel bridge - B - beneath exhaust system.
- Remove selector mechanism from body - arrows B -. Do not loosen nuts - arrows A -.
- Remove selector mechanism with selector lever cable downward.
Installing
- Reconnect exhaust system and install tunnel bridge. Component location and removing and
installing.
- Do not bend or kink selector lever cable.
- Do not grease ball socket of selector lever cable.
- Carefully insert selector lever cable in support bracket/transmission and press on to lever/selector
shaft. Do not bend lever/selector shaft when doing this, otherwise shifting can no longer be
adjusted precisely.
Page 1403
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2859
WHAT ARE TRACKS?
15-28, and so on).
Page 3527
Wheel Bearing, Installing
- Put wheel bearing - 1 -, pressure piece - 2 - (put collar into bearing), and hollow piston cylinder - 3
- with tie bolt on wheel bearing housing.
Control (EPC)) G188

Page 3290
Page 7607
7 Self-locking nut
‹› M12 x 15

‹› Never less than 90 degrees
‹› Torque angle tolerance 90 degrees to 120 degrees
8 Self-locking nut

For vehicles:
‹› With gasoline engine up to and including 85 kW
‹› With TDI engine
10 Ball joint
‹› Removing and installing => [ Ball Joint ] See: Steering and Suspension/Suspension/Ball
Joint/Service and Repair.
11 Self-locking nut
‹› M12 x 15
‹› Tightening specification => [ Front Suspension Tightening Specifications ] See: Steering and
Suspension/Suspension/Specifications/Front
Suspension.
12 Cover plate
13 Hex bolt
‹› M6 x 10

‹› Tightening => [ Tightening Specifications ] See: Axle Shaft Assembly/Service and

Repair/Removal and Replacement/Drive Axle with CV
Joint and Triple Roller Joints AAR 2000 and AAR 2900.
16 Vented brake rotor
17 Wheel hub with rotor for speed sensor
‹› Rotor is welded to wheel hub
Page 6952
Install new seal to plug and tighten to 15 Nm. This completes the ATF check.
If no ATF drips out of inspection hole: -
Top off ATF Topping Off ATF.
Topping Off ATF

Topping Off ATF, 09G, 6 Speed A/T
Alarm Module: Testing and Inspection

Anti-Theft Immobilizer Control Module, Adapting
Replacement of instrument cluster with integrated immobilizer control module functions requires
replacement unit to be adapted to the vehicles Engine Control Module (ECM). The following OBD
program steps initiate this procedure:
- Vehicle Diagnostic Testing and Information System VAS 5051 / VAS 5052
- Adapter cable VAS 5051/1 or VAS 5051/3
- Appropriate VAS 5052 adapter cable
Adapting
- Switch off all electrical consumers.
- Engage parking brake.
- Automatic transmission: Selector lever in "N" or "P" position.
- Manual transmission: Selector lever in "Neutral" position.
- With ignition switched off, connect Vehicle Diagnostic Testing and Information System VAS 5051 /
VAS 5052 with adapter cable to Data Link Connector (DLC) located under the instrument panel,
left.
- Switch on ignition
- Select mode "Guided Fault Finding"
- Enter appropriate model, equipment and model year information and press ">" to confirm.
After all Control Modules have been registered and DTC memories checked,
- Select "Go to"
- Select "Function / Component Selection"
- Select "Body"
- Select Electrical System
- Select "01-Systems capable of self-diagnosis"
- Select "Anti-theft immobilizer" where indicated
- Select "Functions"
- Select Adapt instrument cluster to Engine Control Module (ECM).
- Forward with -> button
- Follow/perform selected OBD program steps as prompted by tester.

Page 960
Ground (GND)

Page 5269
Page 5336
terminals.
Checking activation
Final procedures


Page 974
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5896

Page 6928
1 - Track Numbers

Page 2215
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 6795
Active Exhaust System Actuator: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3138
Oil Filter: Removal and Replacement

1 Bolt, 25 Nm
‹› Removing:
- Drain the coolant. Refer to => [ Draining and Filling ] See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair/Procedures/Draining and Filling.
- Remove the intake manifold. Refer to => [ Intake Manifold ] See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold.
- Drain the oil filter housing, refer to => [ Oil Filter Housing, Draining ] See: Engine, Cooling and
Exhaust/Engine/Engine Lubrication/Oil Filter Housing/Service and Repair, and remove.
3 Gasket
Page 154
WHAT ARE TRACKS?
15-28, and so on).
Clutch Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1241
- Disconnect the connector - arrow - in removed condition.
Installing
CAUTION! ‹› Do not bend the coupling ring.
‹› Using a damaged coupling ring can cause malfunctions.
‹› Replace damaged coupling rings.
‹› Sensor brackets are designed in different shapes and must be matched to the respective
component location in the bumper cover.
‹› Pay attention to the connectors when installing the sensors.
Parking Aid Sensor Allocation Inside The Rear Bumper Cover:

Page 5126
for resistance.

Page 2545
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7509
Check Spring and Rivet Connections
- Check spring connections - arrows A - for damage and rivet connections- arrows B - for secure
seating.
of burnt clutches.

Page 1953
Locations


Page 7327
Locations


Page 5879
1 - Track Numbers

Page 4537
Technical Data
Technical Data
Page 6905

Page 7074
Part 1

Page 3277
No-Po
Coolant: Capacity Specifications
Cooling system
Coolant Capacity .................................................................................................................................

................................................. 9.0 liters (9.5 quarts)
Page 1717
Part 3
Page 4231
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7060

Page 7921
Ground (GND)

Page 4248
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6157
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 2142
DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Rear Suspension
Axle Nut: Specifications Rear Suspension
Axle nut
Use a new 12-point nut - A - and tighten.
Wheel Bearing to Stub Axle - M20 x 1.5 ...... 175 Nm

Page 634
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2088
Part 3
Page 3955
8 Oil Pump Sprocket
‹› Removal and Installation, refer to one of the following:
From MY 2008.
10 Oil Pump Drive Chain

Page 7849
Page 5104
Part 2
Page 5086
Removing

Installing
Page 6562
Warranty
Information only.
removal.
Fuel Gauge Sender: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Hood Sensor/Switch (For Alarm): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1598
Connect VAS5051 and select function.
Torque settings:
Torque settings
Page 44
- Antenna cables - Touareg 2004 > 2006
Tip:
Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the
latest parts information.
Page 2423
Page 2520
Final procedures
1. Check the DTC memory => [ Diagnostic Mode 03 - Read DTC Memory ] See: Powertrain
Management/Computers and Control Systems/Testing
and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09.

Code.
Page 141
Global Positioning System Module: Testing and Inspection Deactivating the Transport Mode
Telematics
Deactivating The Transport Mode
Telematics system is not functioning when Transport Mode is activated. This is necessary when
vehicles are transported over long distances or stored for longer periods of time.
When delivered to dealership, Transport Mode of Telematics system is activated.
In the case of newly installed Telematics Control Modules (J499), the Transport Mode is also
switched on. After installation, the Transport Mode must also be switched off.
Transport Mode must be deactivated before delivery to customer. This takes place using the
Vehicle Diagnosis, Testing And Information System (VAS 5051B) in the "On Board Diagnostic
(OBD) " function, address word "75 - Telematics", function " 10 - adaptation".
Specifications

............................................................................................................................................. 9.0 to
13.0 bar Wear limit ..............................................................................................................................
..............................................................................................................................................................
.... 3.0 bar
Page 5379
1 - Track Numbers

Page 4710
Safety Precautions
connection.

components.
Module DTC Memory, Checking and Erasing ] See: Computers and Control Systems/Engine
Control Module/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes.
Page 5480
Page 5956
WHAT ARE TRACKS?
15-28, and so on).
Page 1197
WHAT ARE TRACKS?
15-28, and so on).
Page 4661
for resistance.

Page 554
Part 3
Page 1519
Part 1
Page 7792
Removing
Note: ^
arrow 2 -.
Note: ^
Installing

Control (EPC)) G188

Trunk / Liftgate Closer Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1616
Parking Brake Warning Switch: Diagnostic Aids
Page 3106
- Press tabs of filter housing in direction of - arrow -.
- Remove filter element with frame in upward direction - arrow A -.
Installing
- Guide frame - 1 - into first slot on left and right sides of new filter element.
- Press frame with filter into housing - 2 - and engage retainers.

Page 5709
stops.

Page 7573
Page 6133
23 Vent Line
‹› White
‹› Clipped in at the top of the fuel tank.
‹› To the EVAP canister purge regulator valve (N80 ).
24 Seal
‹› Replace
‹› To install, place into the opening of the fuel tank dry.
‹› Only coat the inner part with fuel when installing the fuel delivery unit.
‹› Note the installed position in the fuel tank, refer to => [ Fuel Delivery Unit Installed Position ].
‹› Removal and installation, refer to => [ Fuel Delivery Unit ] See: Service and Repair/Removal and
Replacement.
‹› Fuel level sensor removal and installation, refer to => [ Fuel Level Sensor ] See: Service and
‹› Fuel pump checking, refer to => [ Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank) ]
See: Fuel Pump/Testing and Inspection/Fuel
‹› Clean the strainer if contaminated.
26 Locking Ring, 110 Nm
‹› Ensure the ring is securely seated.
‹› Use wrench (T10202) for removal and installation.
27 Supply Line
‹› Black
28 Return Line
‹› Blue
29 Gravity Valve
‹› To remove the valve, unclip upward out of the support.

Page 6801

Page 5866
Ground (GND)

Page 5884
Part 1
Page 4007
1318).
Checking Injection Quantity and for Leaks ] See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Testing and Inspection/Fuel Injectors, Checking Injection Quantity and For
Leaks.
disconnected.
Check Valve, Checking ] See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Page 3193
Clutch Fluid: Service and Repair


Page 2649
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2018
1 - Track Numbers

Page 1360
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5796
Air Injection Pump: Testing and Inspection
Secondary Air Injection Pump Motor, Checking
‹› Multimeter.
Test requirements
‹› The Secondary Air Injection (SAI) Pump Relay (-J299- ) fuse is OK.
‹› The Motronic Engine Control Module (ECM) Power Supply Relay (J271) fuse OK.
Test procedure
Start diagnosis
- Disconnect the Secondary Air Injection (SAI) Pump Motor (-V101-) electrical harness connector.
and ambient temperature are within 3° C of each other.
Checking voltage
- Connect a multimeter to the Secondary Air Injection (SAI) Pump Motor (-V101-) electrical harness
connector terminals 1 to 2.
- Start the engine and read the voltage on the multimeter.
- Replace Secondary Air Injection (SAI) Pump Motor (-V101-).
- Using a multimeter, check the Secondary Air Injection (SAI) Pump Motor (-V101-) electrical
harness connector terminal 1 to Ground.
Specified value: 0.5 ohms or less.

- Check the ground circuit for an open or high resistance. Refer to Wiring Diagrams.

Page 6200
Final procedures

Page 1029
Page 6033
Ground (GND)

Page 7606
‹› Welding and straightening work on supporting or wheel bearing components of the front
suspension is not permitted.
‹› Always replace self-locking nuts.
‹› Always replace corroded bolts/nuts.
1 Drive axle
‹› Pressing drive axle out and in from wheel hub => [ Drive Axle with CV Joint and Triple Roller
Joints AAR 2000 and AAR 2900 ] See: Axle
Shaft Assembly/Service and Repair/Removal and Replacement/Drive Axle with CV Joint and Triple
Roller Joints AAR 2000 and AAR 2900.
2 ABS wheel speed sensor
3 Socket head bolt
‹› M6 x 16

4 Strut
5 Hex bolt
‹› Hex bolt point must face in direction of travel
6 Tie rod end

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1404
Ground (GND)

Page 315
Electronic Brake Control Module: Locations Electrical and Electronic Component Locations, From
MY 2006
2 ABS control module (J104)
‹› Location: At hydraulic unit on left side of engine compartment

Page 4590
1 - Track Numbers

Page 7142
Ground (GND)

Page 4488
‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 964
Part 2
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2763
Suspension Control Pressure Sensor/Switch: Diagnostic Aids
Page 1728
WHAT ARE TRACKS?
15-28, and so on).
Page 1283
Part 2
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 7829
Page 7054
- End diagnosis.
Final procedures
Systems/Testing and
End diagnosis.
Page 3903
- Remove the (T10122/1).
- Install the (T10122/2) with seal - A - onto the crankshaft.
- Press in the seal all around evenly and flush using the (T10122/3).
following:
‹› Remove the (T40069) from the cylinder block and install the locking bolt
Page 6300
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3360
Page 4009
Final procedures

09.

Code.
Page 1287
Tow Sensor: Diagnostic Aids
Page 947
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4254
Part 3
Locations
Firing order
1-2-4-5-3
Specifications
Crankshaft Gear/Sprocket: Specifications

......................................................................................................................................... 50 Nm plus
Page 2977
Rain Sensor: Diagnostic Aids
Page 1741
1 - Track Numbers

Page 5676

Page 1188
Page 5540
connector.
‹› Multimeter.
‹› jumper wire.
Test requirements
‹› Engine COLD.
Test procedure
Start diagnosis

Page 1952
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5438
Page 3768
Warranty
Page 1269
Part 3
Page 3090
- Rotate the belt tensioner - 2 - using a 15 mm box end wrench - A - in the - direction of the arrow -
and secure using (T10060A).
- Remove the ribbed belt for the generator, power steering and coolant pumps.
Installing
- Place the ribbed belt for the generator, power steering and coolant pumps onto the pulleys, then
lastly onto the idler pulley - 3 -.
- Before tensioning the ribbed belt for the generator, power steering and coolant pumps, rotate the
A/C compressor belt tensioner and check the belt for correct seating in the pulley.
- Before installing the ribbed belt for the A/C compressor, secure the tensioner using (T10060A).
‹› When installing the belt, note the direction of rotation of the belt and be sure that it is seated
correctly on the pulley.
- Start the engine and check the belt running.

Page 6317
Removing
Injection.
- arrows -.
Page 1471
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2246
Part 1
Page 5258
Page 6146
1 - Track Numbers

Page 3258
- While pressing down shift rod, rotate bracket - A - upward in - direction of arrow 2 - and
Gear Oil, Draining
Use a clean container (3.0 liters capacity) with scale to collect gear oil.
‹› Shift rod is secured.
- Drain gear oil by removing oil drain plug - arrow 1 - and then removing journal - arrow 2 -.
- Install journal - arrow 2 - with new O-ring => [ (Item 7) Bolt, 25 Nm ] See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Housing and Shift Mechanism Assembly Overview.
- Install oil drain plug - arrow 1 - => [ (Item 17) Oil drain plug, 30 Nm ] See: Transmission and
Drivetrain/Manual Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission and Clutch Housing Assembly Overview.
- Now rotate angle - A - back into initial position - direction of arrow - to let shift rod move freely
again.
Page 462
Part 2
Page 5193
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 7666
Adjustment Shim, Determining

The specified bearing preload is obtained by adding a constant preload figure of (0.40 mm) to the
reading obtained.
Example
- Remove transmission housing and pull tapered roller bearing outer race from transmission
housing.
A Support, e.g. ( Kukko 22/2) B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
- Insert shims of the correct thickness, the thickest shim first.
The following shims are available:
If size of shim required is larger than that listed in the table, two shims totalling the correct value
can be installed.
Different tolerances make it possible to measure the required shim thickness exactly.
- Press in outer race again and tighten transmission housing.

Page 7229
Page 7001
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2356
09.

Code.
Page 775
6 (Can_Bus Low) 58
- End diagnosis.
Final procedures
Systems/Testing and
End diagnosis.
‹› Multimeter.
Test requirements
Test procedure
Page 5105
Part 3
Page 6364
Page 2531
Ground.
Final procedures
09.

Code.
Page 7942
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1104
Page 6384

Page 2069
WHAT ARE TRACKS?
15-28, and so on).
Page 1265
WHAT ARE TRACKS?
15-28, and so on).
Page 1098
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6179
Part 1
Page 2742
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7332
Requirements:

Work procedure:
Brake Booster Vacuum Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Locations
Exhaust Pipe: Locations
Front Exhaust Pipe With Catalytic Converter And Attachments (engine Code BPS), Assembly
Overview,
1 - Exhaust manifold -
Coat stud bolts with hot bolt paste.
2 - Gasket -
Replace
- Note installation position:
- Gasket recess - arrow A - must be located at exhaust manifold recess - arrow B -.
3-
25 Nm -
Replace
4 - Front exhaust pipe -
With catalytic converter
- Protect from shocks and impact stress
- With flex joint
- Flex joint must not be bent more than 10 degrees - otherwise it may be damaged
- Install exhaust system free of stress.
5 - Double clamp -
Before tightening, ensure exhaust system is tension-free.
- Installed location
- Tighten bolts evenly
6 - 25 Nm
7-
23 Nm
8 - Front cross member
9 - Oxygen sensor (O2S) behind three way catalytic converter (TWC) G130, 55 Nm -
Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body
10 - Connector -
Brown, 4-pin
- Installed location
11 - 25 Nm
12 - Suspended mount
Fluctuation
Condition
Production Solution
Service
the driver has
position.
Warranty
Information only.
required.
Page 5574
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1834
Part 2
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 867
See Repair Manual, Repair Groups 69 and 72, for detailed information.
The following software program will address the topic concern, using the procedure below.
^ Connect the Midtronics IN-Charge-940 to battery to ensure a constant voltage between 12.5 and
14.5 volts during flash procedure.
^ Connect VAS 5052 or VAS 6150 tester to OBD connector.
^ Verify airbag indicator light is illuminated and that code 02511 014-Seat Occupant Recognition
Control Module Faulty is stored in Air Bag -15-.
^ Switch the ignition OFF.
^ Remove OBD Cable from vehicle and scan tool.
^ Connect VAS 6103 cable to serial port RS-232 as shown.
^ Connect cable VAS 6103/2 to Cable VAS 6103.
^ Connect remaining OBD connector on VAS 6103/2 to the vehicles OBD diagnostic port.
Headlamp Switch
Headlamp Switch: Service and Repair Headlamp Switch
Headlamp Switch
The Fog Lamp Switch (E23) is integrated in the Headlamp Switch (E1).
Removing
- Turn the Light Switch (E1) rotary knob to the "0" position.
- Press the Headlamp Switch (E1) knob in - arrow 1 - and turn it slightly to the right - arrow 2 -.
- Hold rotary handle in this position and pull Light Switch (E1) on rotary handle out of instrument
panel - arrow 3 -.
- Disconnect the connector on the Headlamp Switch ( E1).
Installing
- Connect the connector to the Headlamp Switch ( E1).
- Hold the Headlamp Switch (E1), push the rotary handle in and turn slightly to the right.
- Hold the rotary handle in this position and insert the Headlamp Switch (E1) into the instrument
panel - arrow 1 -.
Locations
Page 2085
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7143
WHAT ARE TRACKS?
15-28, and so on).
Page 3273
Bu-Ch
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 3176
Power Steering Line/Hose: Service and Repair Pressurized Line Mount Overview
Pressurized Line Mount Overview

1 Pressurized line
2 Speed nut
3 Clamp
4 Hex bolt
‹› M8 x 28
‹› Tightening specification => [ Pressurized Line to Manual Transmission 02J ] See:

5 Clamp
6 Pressure hose
7 Hex bolt
‹› M8 x 28
‹› Tightening specification => [ Pressurized Line to Manual Transmission 02J ] See:

Locations
Air Injection Control Valve: Locations

4 Secondary Air Injection (AIR) Solenoid Valve (N112)
Page 3390
Page 3374
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Sunroof / Moonroof Module: All Technical Service Bulletins Body - Sunroof Malfunctions or is
Inoperative
60 07 06
June 19, 2007

Page 7446
‹› Only replace together with clutch plate
4 Bolt M6, 13 Nm

Page 4693
Part 3
Procedures
Torque Converter: Procedures
Torque Converter, Draining
Torque Converter, Draining
‹› Oil extraction device (V.A.G 1358 A)
‹› Oil extraction probe (V.A.G 1358 A/1)
Drain torque converter when performing a major overhaul of the transmission or if the ATF has
become contaminated by abrasion as follows:
- Extract ATF from torque converter using (V.A.G 1358 A ) and probe (V.A.G 1358 A/1).
Torque Converter Installation Dimension, Checking
Torque Converter Installation Dimension, Checking
- When torque converter is installed correctly in transmission, distance - a - between lower contact
surfaces on threaded holes at torque converter and contact surface of converter housing is approx.
20 mm.
Page 57
Antenna Control Module: Diagnostic Aids
Page 6069
Part 1
Page 4249
Ground (GND)

Page 1978
Ground (GND)

Page 6349

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6762
^ No Stored DTCs, erase any stored DTCs.
Tool requirements:
^ Pass - Thru Vehicle Programming tool must be connected to the vehicle Data Link Connector
(DLC) and is connected to an Internet connection (Persistent connection is recommended).
^ Approved Battery charger.

Note:
Under no circumstances should the diagnostic connector or the Programming tool be unplugged
during the Pass - Thru Vehicle Programming procedure (damage to the ECM / TCM can occur).
Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF.
Procedure:
Page 3195
Page 7534
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5170
Electronic Throttle Actuator: Testing and Inspection
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Crank Seal Installer - AST Tool # 3266
Crankshaft: Tools and Equipment Crank Seal Installer - AST Tool # 3266
Crank Seal Installer
AST tool# 3266
Used to install Crankshaft oil seal (Vibration damper end).
- Made in Germany

Page 3065
Removing

Page 968
Steering Control Module: Diagnostic Aids
Page 99
Part 1
Page 3412
Relay Box: Application and ID Relay and Fuse Arrangements on Relay Panel, From July 2005
Page 1949
Part 1
Page 208
Ground (GND)

Locations

Page 4084
Part 3
Page 3701
‹› Internal dial gauge 50 to 100 mm
- Measure diagonally at 3 positions transversely - A - and longitudinally - B -.
Deviation from nominal size: Max. 0.08 mm.
‹› Cylinder bore must not be measured if the cylinder block is secured to the engine stand with the
engine lateral bracket (T03001), or else the results
may be incorrect.
Page 4078
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5787
Air Injection Control Valve: Testing and Inspection Emissions Controls
‹› Assisting hose, for example, coolant hose
Sequence
‹› Do not use compressed air during the following check!
- Disconnect the pressure hose - 2 - from Secondary Air Injection (AIR) solenoid valve (N112) - 3 -.
To do so, compress the securing ring.
- Disconnect the harness connector - 4 -.
- Slide the assisting hose - 1 -, for example, coolant hose, into the AIR solenoid valve.
Valve must be closed.
If air can be blown through the valve with the assisting hose properly sealed:
If valve is closed:
- Connect terminals on the connector connection - 5 - with adapter cables from (VAG 1594C) to the
battery positive (+) and negative (-).
Valve must be opened.
If no air can be blown through the valve with the assisting hose properly sealed:

Page 1267
Part 1
Page 3429
- Press the "Accept" button - arrow -on display.
- Press the - arrow - button on the screen display.
Recall 10V621000: Fuel Supply Line Replacement
Fuel Supply Line: All Technical Service Bulletins Recall 10V621000: Fuel Supply Line
Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Volkswagen/Jetta 2006-2010
Volkswagen/Jetta Sportwagen 2009
Volkswagen/New Beetle 2006-2010
Volkswagen/New Beetle Convertible 2006-2010
Volkswagen/Rabbit 2007-2009
MANUFACTURER: Volkswagen of America, Inc.
MFR'S REPORT DATE: December 14, 2010
NHTSA CAMPAIGN ID NUMBER: 10V621000
NHTSA ACTION NUMBER: N/A
COMPONENT: Fuel System, Gasoline: Delivery: Hoses, Lines/Piping, and Fittings
POTENTIAL NUMBER OF UNITS AFFECTED: 377,286
SUMMARY: Volkswagen is recalling certain model year 2006-2010 Jetta, New Beetle, New Beetle
Convertible, model year 2009 Jetta Sportwagen and model year 2007-2009 Rabbit vehicles
equipped with 2.5L engines. The Jetta, Jetta Sportwagen, and Rabbit vehicles may have a small
plastic tab located on the windshield washer fluid reservoir that may chafe against an underhood
fuel supply line. The New Beetle and the New Beetle Convertible vehicles may have a fastening
clamp on a hydraulic hose of the power steering system that may be located in an improper
position which could cause chafing against an underhood fuel supply line.
CONSEQUENCE: If chafing occurs, there is the potential for a fuel leak to develop. Fuel leakage,
in the presence of an ignition source, could result in a fire.
REMEDY: Dealers will inspect and if necessary replace the underhood fuel line. Additionally,
depending on the vehicle model, dealers will either remove the plastic tab from the windshield
washer fluid reservoir, or inspect the position of the fastening clamp and adjust the related
fastening clamp into the correct position. This service will be performed free of charge. The safety
recall is expected to begin on or before January 31, 2011. Owners may contact Volkswagen at
1-800-822-8987.
NOTES: Volkswagen safety recall No. 20I4/U1. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Page 927
Part 3
Page 3229
- Drain ATF.
- Finally, check ATF level and top off.

Overview

1 Fuel Filter

and Replacement.
2 Retaining Clip

‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 2830
- Multimeter
- Wiring diagram
Test procedure
Start diagnosis
1 -.
Checking wiring

Page 4700

Page 189
Part 3
Page 4025
1 - Cap
2 - Seal -
Replace if damaged
3 - Bolt
With rubber gasket
5-
10 Nm
6 - Vent line -
- Checking
8 - O-ring -
Replace if damaged
In long member
12 - Vent line -
13 - 10 Nm
15 - Fuel tank -
16 - Heat shield
Page 4773
Final procedures


Page 1068
Warranty
Information only.
removal.
A/C - Does Not Get Cold Enough
Control Module HVAC: All Technical Service Bulletins A/C - Does Not Get Cold Enough
87 07 17
Nov. 14, 2007
2016734
Vehicle Information
Condition
Air Conditioning Not Cold
Air conditioning is not cold after replacing or unplugging the A/C control unit or ambient
temperature sensor.
If the ambient temperature sensor or a/c control unit -E87- is unplugged or replaced for any reason,
the ambient temperature sensor -G17- must be reset in order to function properly.
Production Solution
Service
To reset/calibrate the A/C control unit perform one of the following methods:
^ Drive vehicle at 25 mph (41 kph).
^ With vehicle in PARK, let engine run for 20 minutes.
Warranty
Information only.
to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest
information.
Page 3460
legend.
wiring diagram.
harness.


question.)
19 - Legend



Control (EPC)) G188

Page 950
Part 3
Page 6516
Ground (GND)

Page 306
Part 3
Page 6628
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3013
‹› Engine/transmission jack (V.A.G 1383 A )
‹› Tensioning strap (T10038)
‹› Wheel hub support (T10149)
CAUTION! All bolts on suspension parts with bonded rubber bushings are always tightened in curb
weight position (unloaded condition).
Bonded rubber bushings can only be turned to a limited extent.
Parts with bonded rubber bushings must be brought into a position that corresponds to the position
in driving mode before being tightened (curb weight position)
Otherwise, the rubber bushing will be stressed resulting in a shortened service life.
This position can be simulated on the lifting platform by raising the axle on one side using
engine/transmission jack (V.A.G 1383 A ) and wheel hub support (T10149).
- For example, measure dimension - a - from center of wheel to lower edge of wheel housing using
a tape measure.
The measurement must be performed in curb weight position (unloaded condition).
- Note measured value. It will be required for tightening bolts/nuts.

Before lifting axle on one side, the vehicle must be secured to lift arms of the hoist using tension
straps ( T10038).
CAUTION! If a vehicle is not secured, there is danger that the vehicle could slip off the hoist!
- Turn wheel hub far enough until one of the holes for wheel bolts is on top.
- Install wheel hub support (T10149) with wheel bolt.
Threading in must only occur after dimension - a -, which was measured before installation
between the wheel hub center and the lower edge of wheel housing has been attained !
Page 5350
Page 1073

Page 657
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2939
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4469
Removing

Installing
Page 3323


Page 5829
Canister Purge Control Valve: Testing and Inspection
EVAP Purge Regulator Valve, Checking
‹› Multimeter.
Test requirements
‹› The Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) fuse OK.
Test procedure
Start diagnosis
- Disconnect the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) electrical
harness connector.
- Using a multimeter, check the Evaporative Emission (EVAP) Canister Purge Regulator Valve
(N80) terminals 1 and 2 for resistance.
Specified value: 14 to 25 ohms.
- Replace the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80).
If the specification is obtained:
- Star the engine.
- Using a multimeter, check the purge valve electrical harness connector terminal 1 to 2 for voltage.
Page 1966
Part 2
Tools and Equipment
Fuel Tank Unit: Tools and Equipment
Fuel Sender Spanner
AST tool# 3217
Used to remove and install the fuel gauge sending unit (139mm).
- Made in Germany

Page 1173
Page 7721
- Install rubber sound insulation.
- Install cover in upper part of center console.
Function
‹› Shift lever must rest in 3rd/4th shift gate when transmission is in neutral.
- Operate clutch.
- Shift through all gears several times. Pay particular attention to function of reverse gear lock.
Should a gear fail to engage smoothly after repeated selection, shift rod play (lift) should be
checked as follows:
- Select 1st gear.
- Push shift lever toward left until stop and release.
- Simultaneously (2nd technician), observe shift rod on transmission.
- When moving shift lever, shift rod must move approximately 1 mm in direction of - arrow -.
- If this is not the case, adjust shift mechanism => [ Shift Mechanism, Adjusting ] See: .
-G195-
Page 6656
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 133
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1669
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Wires
Wheel Speed Sensor Wires
‹› Wiring harness repair kit (VAS 1978)
- Disconnect harness connector from wheel speed sensor wire and wheel speed sensor.
- Rear side trim, removing
- Cut wheel speed sensor wire - arrow - using wire strip pliers from (VAS 1978) and remove faulty
piece of wire.
- Strip 15 mm of insulation at end of wire using wire strip pliers and fold un-insulated wire in half.
- Thread new wheel speed sensor wire.
- Clip in wheel speed sensor wire - arrows -.

Page 403
1 - Track Numbers

Installing

Page 2471
Page 5412
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4197
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2808
Page 3285
Engine Oil: Description and Operation
Engine Oil
Oil Capacities and Specifications
For engine oil capacities and specifications refer to the Owner's Manual.
Oil Dipstick Marks
1 Max. mark
2 Min. mark
a Area above hatched area up to the Max. mark: Do not add engine oil.
b Oil level at hatched area: Can be replenished with engine oil
c Range from the Min. mark to the hatched area: fill with a Max. 0.5 liters of engine oil.
Page 2198
Final procedures
1. Check the DTC memory => [ Diagnostic Mode 03 - Read DTC Memory ] See: Powertrain
Management/Computers and Control Systems/Testing
and Inspection/Scan Tool Testing and Procedures/Diagnostic Modes 01 - 09.

Code.
Page 4826
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 2791
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 477
WHAT ARE TRACKS?
15-28, and so on).
Page 498
Page 3998
- Cut the tube nozzle at the front mark (jet nozzle diameter approximately 1 mm).
‹› The control housing cover must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - A - onto the control housing cover as shown.
‹› The sealant bead must be 1.5 to 2.0 millimeter (mm) thick.
‹› Pay special attention to the course of the sealant bead in the area - arrow -.
- Install the control housing cover so that the alignment bushings engage in the bores in the
cylinder block.
- Install all bolts hand tight.
- First tighten all the bolts - 3 - to the cylinder block and upper oil pan to 10 Nm.
Page 5680
Final procedures

Page 4921
1 - Track Numbers

- Multimeter.
- Wiring diagram.
Test requirement
Test procedure
Procedure
step.
Checking wiring
resistance.
terminals terminals
6 (Can_Bus Low) 34

Page 603
Part 1
Page 2567
Page 1344
Part 2
Page 95
legend.
wiring diagram.
harness.


question.)
19 - Legend



Power Trunk / Liftgate Lock Actuator Position Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5563
Overview
1 Bracket
2 Connector
‹› Black, 6 pin
3 Nut, 10 Nm
5 Bracket

Page 5494
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.


Page 1635
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4439
Muffler: Service and Repair Front and Rear Mufflers, Separating and Connecting
Front and Rear Mufflers, Separating and Connecting
‹› A separating point has been provided in the connecting pipe for individual replacement of the
front or rear muffler.
‹› The separating point is marked by depressions around the circumference of the exhaust pipe.
‹› Body repair saw (VAG 1523A) or
‹› Chain pipe cutter (VAS 6254)
Separating
CAUTION! To prevent injuries from metal shavings, wear protective goggles and protective
clothing.
- Cut the exhaust pipe at the separation point - arrow 2 - using (VAG1523A) at a right angle.
Joining
‹› A second mechanic is required for installing the repair double clamp.

- Secure the front muffler in the retainers. The front double clamp remains loosely connected to the
pipes.
- Align the rear muffler horizontally and hold it in this position.
- Position the repair double clamp - 4 - at the side marks - arrow 1 - and - arrow 3 -.
Page 1332
Door Lock Cylinder Switch: Diagnostic Aids
Page 3665
‹› Measure radial clearance with Plastigage(R).
New: 0.023 to 0.043 mm wear limit: 0.07 mm
‹› Do not turn crankshaft when measuring radial play.
‹› Crankshaft dimensions, refer to => [ Crankshaft Dimensions ] See: Specifications/Crankshaft

Dimensions.
‹› Crankshaft locking, refer to => [ Crankshaft, Locking ] See: Procedures/Crankshaft, Locking.
5 Thrust Washers
‹› For bearing 3.
‹› Side lubricating grooves face outward.
6 Bearing Shell, for the Cylinder Block
‹› With a lubricating groove.
‹› Classification for replacement part ordering, refer to => [ Identification of Top Crankshaft Bearing
Shells ].
‹› Do not interchange used bearing shells (mark them).
7 Cylinder Block
Identification of Top Crankshaft Bearing Shells

thickness. Colored spots serve to identify the bearing thicknesses.
The letters marked on the lower sealing surface of the cylinder block identify which bearing
thickness must be installed in which location.
G Yellow B Blue W White
‹› If colored marks can no longer be seen, use the blue bearing shell.
‹› The lower crankshaft bearing shells are always shipped as replacement part with a "yellow"
colored mark.
Page 5843
Part 3
Page 3319
Brake Bleeding: Service and Repair Bleeding With Brake Filler/Bleeder Unit VAS 5234
Bleeding with Brake Filler/Bleeder Unit VAS 5234
‹› Brake filler bleeder unit (VAS 5234)
Venting brake system on vehicles with ABS is done the same as for vehicles with conventional
brake systems
- Connect brake filler bleeder unit (VAS 5234).
- Open bleeder screws in the prescribed sequence and bleed brake caliper and wheel brake
cylinder.
Bleeding Sequence
1. Left front brake caliper
2. Right front brake caliper
3. Left rear brake caliper
4. Right rear brake caliper
With bleeder bottle hose attached, leave bleeder screws open long enough that brake fluid exits
without bubbles.
A road test must be performed after bleeding. At least one ABS controlled braking must be
performed!
Change brake fluid=> 14.1
Pre-bleeding the brake system when one chamber of the brake fluid reservoir is completely empty
(e.g. due to a leak in brake system).
Bleeding Sequence
1. Bleeding left and right front brake caliper together at the same time
2. Bleeding left and right rear brake caliper together at the same time
- With bleeder bottle hoses attached, leave bleeder screws open long enough that brake fluid exits
without bubbles.
Page 882
^ With connector in both hands, slide locking clip rearward and separate connector halves. It may
be necessary to use a small hook tool to pull back the spring clip.
^ Move passenger seat to full reverse position and access connector panel.
^ Release lock on 10 pin connector under black connector panel. It may be necessary to use a
small hook tool to pull back the spring clip. Care must be taken not to damage surrounding
connectors and wiring.
^ Connect 10 pin connector of VAS 6103/02-1 to 10 pin seat harness connector as shown.
Page 4477
1 - Track Numbers

Locations

Page 441
1 - Track Numbers

Page 3188


Page 4487
Page 6837
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6447

Page 1393
Part 3
Page 153
Ground (GND)

Page 4827
- Remove nut - 1 -.
Page 5002
1 - Cap
2 - Seal -
Replace if damaged
3 - Bolt
With rubber gasket
5-
10 Nm
6 - Vent line -
- Checking
8 - O-ring -
Replace if damaged
In long member
12 - Vent line -
13 - 10 Nm
15 - Fuel tank -
16 - Heat shield
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4420
‹› The flex joint in the front exhaust pipe must not be bent more than 10 degrees, otherwise it may
be damaged.
- Disconnect the harness connector - 2 - for the oxygen sensor.
- Remove the heat shield at the top of the front exhaust pipe and free up the wiring harness for the
oxygen sensor in the exhaust manifold.
- Remove the exhaust manifold and remove it downward.
Installing
‹› Gaskets and self locking nuts must be replaced.
‹› Install the exhaust manifold, refer to => [ Exhaust Manifold Assembly Overview ] See: Exhaust
Manifold Assembly Overview.
‹› Install the front exhaust pipe with catalytic converter, refer to => [ Front Exhaust Pipe with
Catalytic Converter Assembly Overview ] See:
Catalytic Converter/Service and Repair/Front Exhaust Pipe With Catalytic Converter Assembly
Overview.
- Check the Diagnostic Trouble Code (DTC) memory of the Engine Control Module (ECM), repair
any stored malfunctions and then erase DTC memory. Refer to => [ Engine Control Module DTC
Memory, Checking and Erasing ] See: Powertrain Management/Computers and Control
Systems/Engine Control Module/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes.
Page 5753
stops.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1898
1 - Track Numbers

Page 3026
‹› Multimeter.
Test conditions
Test procedure
Start diagnosis
pressure.

Page 88
Condition
Page 7363
Removing
Installing
Page 1742
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1170
Part 2
Page 2974
Part 3
Page 5245
order)
Tip:
Page 6183
Page 5699
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5678
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Page 2546
Page 105
Communications Control Module: Service and Repair
Telephone System
Cellular Telephone Operating Electronics Control Module (J412)
CAUTION! Prior to working on the electrical system:
‹› Obtain the radio system anti-theft code.
‹› Switch off all electrical consumers.
‹› Switch off the ignition and remove the ignition key.
‹› Disconnect the battery.
The cellular telephone operating electronics control module is located under the center console in
the area of the parking brake lever.
Removing
- Switch off ignition, switch off all electrical consumers and remove ignition key.
- Remove the screws - arrows - from the cellular telephone operating electronics control module.
- Remove the cellular telephone operating electronics control module with the wire connection.
Installing
Tightening Specifications: 1.5 Nm.

Page 2807
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1164
1 - Track Numbers

Page 7978
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3280
SW-Wu
Page 5160
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2317


1 - Fuel filter -
Black
- From fuel tank
Blue
- To fuel tank
4 bar
6 - Gasket
Replace
7 - O-ring
Replace
Black
- To engine
9 - 3 Nm
10 - Bracket
Page 599
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4706
Brake Switch (Cruise Control): Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7483
- Press clutch pedal in direction of - arrow - to engage, ensure correct engaging while doing so.
- Install over-center spring => [ Over-Center Spring ] See: Over-Center Spring.
- Install clutch pedal switch (F36) => [ Clutch Pedal Switch ] See: Clutch Switch/Service and
Repair.
Tightening Specification
Page 6709
Part 2
Page 6752
want the Update Programming installed in their vehicle.
Updated ECM software that addresses:
^ Speed regulation of the camshaft adjuster.
^ Incorrect algorithm used in ECM software.
^ Exhaust popping noise is an exhaust resonance that becomes more audible under certain RPM
and load ranges during the catalyst heating phase of cold start.
^ Engine Control Modules Affected:
Production Solution
Update software addressed in production as of:
Service
PROCEDURE:
Tip:
diagnostic CAN bus.
Note:
The programming for this procedure is designed to work with the diagnostic CAN-BUS. The New
Beetle and New Beetle Convertible is an older platform which does not support the use of
CAN-BUS, instead, the New Beetle and New Beetle Convertible relies on the K-line for
communication. BEFORE attempting to flash these vehicles, remove Pin 6 from the Data Link
Connector (T-16) using special tool VAS 1978A. After the programming procedure has completed,
re-install Pin 6 into the Data Link Connector.
Engine Control Module Update - Programming (Flashing)
Tip:
diagnostic CAN bus.
When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs
linked to Guided Fault Finding function tests will be
Page 6763
- Click on "Continue" to proceed and follow the prompts to update ECM to the software level in the
table shown.
After Pass - Thru Vehicle Programming has been completed:
- Vehicle readiness code must be set.

Page 1230
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2982
- Insert rain sensor - 3 - in retaining ring - 2 - and bond to windshield without bubbles.
- Install clip - 1 -.
- Install rain sensor cover - 1 -.

Page 1637
Traction Control Switch: Diagnostic Aids
Page 2441
Part 1
Page 7769
plan)
TCM.
Warranty
Information only.
Page 4417
Exhaust Manifold: Locations
Exhaust Manifold With Attachments, Assembly Overview
1 - Gasket -
Replace
2 - 25 Nm -
Replace
3 - Exhaust manifold -
Coat stud bolts on cylinder head with hot bolt paste
- Remove downward
4 - Clip
5 - Warm air collector plate
6 - 10 Nm
7 - Heated Oxygen Sensor (HO2S) G39, 55 Nm -
Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body
- Color of harness connector: Black
8 - Brace
9 - 25 Nm -
Replace
10 - 25 Nm
Page 3867
1 - Track Numbers

Page 5301
Information Bus: Diagnostic Aids
Page 4947
1 - Track Numbers

Page 1811
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2740
Ground (GND)

Page 5575
Page 1282
Part 1
Page 3174
1 Automatic transmission
2 Pressurized line
3 Double bolt
‹› M10 x 20 - M8 x 12

4 Clamp
5 Hex nut
Page 5916
Part 3
Page 2453

Page 2134
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 5182
1 - Track Numbers

Page 3405
Connecting.
Cable Router in Engine Compartment
Connecting.
Removing
- Remove battery (A). Refer to => [ Battery A ] See: Starting and Charging/Battery/Service and
‹› Air Filter, Removing and Installing
- Disconnect the connectors and the hose connections on the air filter housing.
- Remove the screws - arrows - and then remove the battery tray.
- Unclip the cable router cover at the tabs - arrows - and fold the cover in the direction of travel.
- Unclip the remaining tabs - arrows - and remove the cover.

Page 2040
Installing, adjusting and locking new brake light switch (from 11.06, with the exception of 2 pin
brake light switches) => [ Installing, adjusting and locking ] See: Brake Light Switch, From 12.06.
Exception: 2 pin Brake Light Switch
To ensure secure installation, install brake light switch only once.
Before assembling the brake light switch, grease plunger head with polycarbamide grease (G 052
142 A2).
- Before installing, pull plunger out fully.
- Push brake pedal down as far as possible by hand.
- Guide brake light switch through fitting hole and reinstall by turning 90 degrees to right.
- Release brake pedal.
- Fit brake light switch connector.
- After adjusting the brake light switch check whether the brake pedal is on the end stop (rest
position).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Electronic Throttle Actuator: Description and Operation Electronic Power Control System Function
For Electronic Power Control (EPC), the throttle valve is not operated by a cable from the
accelerator pedal. There is no mechanical connection between the accelerator pedal and the
throttle valve.
The position of the accelerator pedal is transmitted to the Engine Control Module (ECM) via two
accelerator pedal position sensors (adjustable resistances, accommodated in one housing), that
are connected to the accelerator pedal.
The position of the accelerator pedal (driver controlled) is a main input for the ECM.
Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle
valve control module. This is true across the entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle drive according to the instructions of the ECM.
With the engine at a stand still and the ignition switched on, the ECM activates the throttle valve
actuator precisely according to the specifications of the Throttle Position (TP) sensor. This means,
if the accelerator pedal is pressed half way, the throttle drive opens the throttle valve to the same
With engine running (under load) the ECM can open and close the throttle valve independently of
the accelerator pedal position sensor.
throttle valve.
After evaluating the torque requirements of the various components such as the Air Conditioning
(A/C) system, automatic transmission, Anti-lock Brake System (ABS)/Electronic Stabilization
Program (ESP), etc., the ECM calculates the optimal throttle valve opening angle for the current
situation.
Aside from that, it results in clearly better pollutant output and consumption values under certain
load conditions.
"EPC" is a system containing all components that contribute to determining, controlling and
monitoring the throttle valve position, for example, TP sensor, throttle valve control module, EPC
warning light, ECM.
Page 7481
Installing
- Pull clutch pedal into passenger compartment.
- Insert over-center spring together with assembly clip (T10111) upward in direction of - arrow A -
into mounting bracket and turn in direction of - arrow B - while doing so.
- First, install over-center spring in bearing - arrow A - at rear.
- Press clutch pedal to bulkhead until over-center spring makes contact at mounting pin - arrow B -
of clutch pedal.
- Bring clutch pedal into rest position, while doing so remove assembly clip.

Page 2493

Page 4554
Ground (GND)

Page 2151
WHAT ARE TRACKS?
15-28, and so on).
Page 1412
Power Mirror Position Switch/Sensor: Diagnostic Aids
Page 1599
Lateral Accelerometer: Service and Repair ESP Sensor Unit, From 12.01
ESP Sensor Unit, from 12.01
Transverse acceleration sensor (G200) and rotation rate sensor (G202) are installed together in
one housing on a new bracket, at the same position in the vehicle.
ESP sensor unit (G419) - 1 - is secured to mounting bracket - a - for steering column - arrow -
together with bracket.
When ESP sensor unit (G419) is replaced, zero adjustment of transverse acceleration sensor
(G200 ) and of rotation rate sensor (G202) must be performed.
Removing
- Disconnect connector - arrow - from ESP sensor unit (G419).
- Remove bolt - 1 - and remove ESP sensor unit (G419).
- Remove nuts - a - from ESP sensor unit (G419) - 1 -.

Page 3421
After a service was performed, the previous service type must also be called up and reset.
There are two ways to reset the service interval display:
‹› using the reset button on the instrument cluster, refer to => [ Service Table ]
or using the
‹› (VAS 5051B)
Service Interval Display Resetting from 04.1999
Each service must be called up and reset individually.
Reset the service interval display using the knob - 1 - to set the trip odometer to zero when the
instrument cluster is in "reset mode."
Initiating the Reset Mode
- Press and hold the knob - 1 - for resetting the trip odometer to zero.
"OIL" or "OEL" appears in the display.
- Release the knob - 1 -.
The instrument cluster is now in reset mode.
‹› Pressing the button - 1 - quickly switch between " OIL" and "OEL" and "INSP" without resetting
the Service.
‹› Pressing and holding the button - 1 - will switch to the next Service and stay there for
approximately 10 seconds and then switches back.
Resetting the "OIL" or "OEL" Service
- Press the button - 1 - quickly until "INSP " appears.
- Press the button - 1 - for at least 10 seconds. When doing this, "INSP" will switch to "OIL" or "
OEL" and after 10 seconds the "OIL" or "OEL" Service will be reset. Three dashes will appear in
the display.
Page 2743
Part 1
Page 120
Entertainment System Control Module: Diagnostic Aids
Page 5093
Final procedures
1. Check the DTC memory => [ Diagnostic Mode 03 - Read DTC Memory ] See: Testing and
Inspection/Scan Tool Testing and
Testing and Inspection/Scan Tool Testing and
3. If the DTC memory was erased, generate readiness code => [ Readiness Code ] See: Testing
and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes/Readiness Code.

‹› Multimeter
Test requirements
Test procedure
Start diagnosis
Checking voltage

Page 4478
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6733
Tool requirements:
^ VAS 5051 or VAS 5052 (with Base CD V.11.00 and the Brand CD V.11.79.01 or higher).
^ "Update - Programming" (flashing) CD W420607A5SWU.
Tip:
Additional copies of the "Update - Programming" CD (Literature Number W420607A5SWU) may be

ordered from the Volkswagen Technical Literature Ordering Center at -->
http://www.vw.resolve.com/, or by calling from 8:00 a.m. to 8:00 p.m. EST Monday through Friday.
This number can be dialed in both the United States and Canada.
^ MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update process
can lead to ECM failure) (use an approved battery charger INC940 to maintain battery voltage).
^ VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure.
^ VAS 5052: connected to vehicle with battery voltage requirements met.
^ When performing the update programming procedure, ALL DTCs for all systems are erased.
^ DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored
DTCs for Customer concerns unrelated to the update programming procedure first.
Note:
Nonobservance of the following points may lead to ECM failure! VAS 5051 or VAS 5052 must
always be connected to the approved power supply at the approved voltages. Under no
circumstances should the power supply be interrupted or the diagnostic connector unplugged
during the update programming procedure. Any appliances with high electromagnetic radiation (i.e.
mobile phones) must be switched OFF.
Tip:
Before update programming, delete the fault memory in the ECM and TCM. Update programming
is not possible when an EEPROM fault is active. Reprogram ECM and TCM with CD - Part number
W420607A5SWU.
Note:
TCM reprogramming is only necessary if the feature for update programming is available.
Insert the programming CD into the VAS 5051 / 5052, and access the ECM.
Tip:
If the update programming button does not appear, the latest version has already been installed to
the level below.
^ Programming starts by pressing the "Update Programming" button and following the on screen
prompts.
Note:
Once update programming begins, on NO occasion should the Cancel button be selected.
^ Press the "Update Programming" button.

^ Once ECM update has been performed, access TCM and perform "Update Programming" if the
VAS 5051 / 5052 shows the "Update Programming" feature.
Tip:
Once update programming is complete, it is recommended to use 1001- Compiling Services

prompt to clear faults stored in various control modules.
Page 4549
Page 3991
Page 3780
No-Po
Page 3433
- Turn off ignition and disconnect diagnostic connection.
Page 6477

Page 6167
- End diagnosis.
Final procedures
End diagnosis.
Page 2860
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1982
Part 2
Page 1651
WHAT ARE TRACKS?
15-28, and so on).
Page 2786
WHAT ARE TRACKS?
15-28, and so on).
Page 177
Parking Assist Control Module: Service and Repair
Parking Aid
Parking Aid Control Module
The Parking Aid Control Module (J446) is located behind the right luggage compartment side trim.
Removing
- Remove the right luggage compartment trim.
- Disconnect the connectors - 2 - on the Parking Aid Control Module (J446) - 1 -.
- Remove the nuts - 3 - and remove the Parking Aid Control Module (J446) - 1 -.
Installing
- Tighten the nuts to 3 Nm.

Page 2585
Seat Belt Buckle Switch: Diagnostic Aids
Page 6774
2. Ensure that the following tester requirements are met:
^ VAS 5051A Minimum Base CD Version 15.00 installed
^ VAS 5051B/5052 Minimum Base CD Version 15.0 installed
^ Minimum Brand CD Version 15.96 installed regardless of tester used
^ VAS 5051X is plugged into a 110V AC Power supply at all times
^ Connect 5051B and 5052 to the Local Network
^ Connect 5051A to the Local Network before tester startup
Note:
Prior to launching VAS-PC application and starting control module update process, confirm tester
screen saver and power settings in accordance with Special Tools and Equipment - Service
Information Document # VSE-08-18. Failure to do so may result in the tester entering power save
mode during data transfer, and subsequent control module failure.
When using a VAS 5051B or VAS 5052A tester in conjunction with a VAS 5054A wireless
transmitter head for a flash procedure, please connect a USB cable between the transmitter head
and the tester. Failure to do so may lead to errors during the flash procedure.
3. Ensure the following vehicle requirements are met:
^ Connect vehicle to a powered Volkswagen approved Midtronics/InCharge 940 (INC-940)

tester/charger
^ Battery MUST have, and MUST maintain a minimum no-load charge of 12.5V
^ Turn off the radio and all other accessories, and when necessary, switch running lights off
^ Turn off any appliances with high electromagnetic radiation (i.e. mobile phones)
4. The Owner's Control Module Tuning Consent Form has been completed as necessary.
5. In the VAS Tester enter into GFF program. Allow GFF to interrogate all control modules before
proceeding.
6. Address or record all DTCs related to a customer concern before continuing. Sporadic
communication DTCs will be created during the flash
procedure and must be erased with all other sporadic DTCs by GFF after exiting the flash test plan.
Note:
If GFF does not interrogate all control modules, manually select and interrogate remaining modules
before proceeding
7. Enter the SVM test plan by selecting the following inside GFF: Go to >> Function/Component
Selection >> Software Version Management >>
Adapting Software.
8. Follow the on screen prompts for the SVM update procedure and enter the SVM Unit Code
(Action Code) found in the Conditional Technical
Bulletin when requested.
9. Enter your GeKo ID when requested and data will be transmitted to the SVM server, which will
respond with instructions to continue. The procedure
may include one, or any combination of the following for one or multiple control modules as
specified in the Technical Bulletin/RVU:
^ Check a Control Module
This will occur when SVM does not recognize the control module as valid for the vehicle. If there is
no customer concern and no DTC regarding this control module, report the issue to the Technical
Helpline.
^ Update a Control Module (flash)
^ Code a Control Module
10. During the flash procedure, an estimated time will be shown which is not used for actual SRT
calculation at this time.
ALWAYS continue until the following text is displayed: "Vehicle conversion/update has been
successfully performed. The changes have been stored in the system. Thank you".
Tip: The SVM Process must be completed in it's entirety so the database receives the update
confirmation response.
A warranty claim may not be reimbursed if there is no confirmation response to support the claim or
action is carried out that is not explicitly stated in the Technical Bulletin/RVU.
11. Verify that all steps or special procedures mentioned in the Technical Bulletin/RVU have been
carried out, and then finish the test plan and Exit
GFF via the Go to button. Answer the Warranty questions accordingly and print out or save the
Diagnostic Log when prompted.
Page 182
1 - Track Numbers

Page 2996
Alignment: Specifications Rear Wheel Alignment
Rear Wheel Alignment Specifications
Note:
Camber is not adjustable. Only slight corrections are possible by moving the subframe. Adjustment
range approx. 10' to 15'
Horn Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4688
Ground (GND)

Page 6497
WHAT ARE TRACKS?
15-28, and so on).
Locations

‹› Multimeter.
Test requirement
Test procedure
Start diagnosis

Page 7844
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7359
G195, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
-.
Checking wiring
Page 6984
WHAT ARE TRACKS?
15-28, and so on).
Instrument Panel Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6212
Part 2
Specifications
Fluid Pan: Specifications
Transmission Fluid Pan Bolts ..............................................................................................................
.......................................................................... 7 Nm
Tighten bolts in several stages in diagonal sequence

1 - Fuel filter -
Black
- From fuel tank
Blue
- To fuel tank
4 bar
6 - Gasket
Replace
7 - O-ring
Replace
Black
- To engine
9 - 3 Nm
10 - Bracket
Page 5888
Page 7540
Part 3
Page 4408
Part 1
‹› New Beetle
Page 456
1 - Track Numbers

Page 5421
Checking wiring

Page 6288

Page 5308
Information Bus: Scan Tool Testing and Procedures
VAG 1551, Connecting and Selecting Functions
VAG 1551, Connecting and Selecting Functions
‹› Scan tool (VAG 1551) or ( VAG 1552)
‹› Optional: vehicle diagnostic testing and information system (VAS 5051)/ (VAS 5052)
‹› Adapter cable (VAG 1551/3) or (VAG 1551/3B)
Prerequisites
‹› All fuses OK according to wiring diagram.
‹› Battery (B+) voltage at least 9 volts.
‹› Scan tool (VAG 1552) may be used instead of the scan tool (VAG 1551) , however a printout is
not possible.
‹› The following procedure and display references pertain only to scan tool (VAG 1551).
Connecting
With ignition switched off, connect scan tool ( VAG 1551) with adapter cable (1551/3) to the Data
Link Connector (DLC) as illustrated.
Select 1 "Rapid Data Transfer", switch on ignition.
Rapid data transfer HELP Input address word XX
- Press buttons 1 and 9 to select gateway address word 19.
Rapid data transfer Q 19 Gateway
- Press Q button to confirm input.
Page 994
Part 1
Page 805
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
30) to Ground.

Page 4562
Page 6164
Page 27
- Antenna cables - double DIN (Premium VI) radio.
- Antenna cables - Phaeton 2004 > 2006
- Antenna cables - Satellite radio (Hard top vehicles)

Page 7106
Part 2
Page 4593
WHAT ARE TRACKS?
15-28, and so on).
Page 5188
Part 2
Page 2342
Part 3
Page 5374
wiring diagram.
Final procedures

Page 2591
‹› The sensor mat and seat cushion are one unit and may not be separated.
Page 5071
Page 929
Cooling System - Coolant Staining Around Water Pump
Area
Water Pump: Technical Service Bulletins Cooling System - Coolant Staining Around Water Pump
Area
19 09 03
July 16, 2009
2021142 Coolant Pump Replacement due to Mistaken Coolant Leak
Vehicle Information
Condition
Coolant staining around coolant pump area may cause incorrect diagnosis and unnecessary
replacement coolant pump.
Production Solution
Service
Upon inspection, a small coolant spot, or coolant staining is acceptable around coolant pump.
Page 5146
Data Link Connector: Diagnostic Aids
Page 117
Part 3
Page 5334
Page 1719
Page 3268
Li-Pe
Page 622
Part 3
Page 5910
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 832
Page 2483
Part 3
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2350

Page 3432
- Press the Accept button - arrow -on display.
Ending the Procedure
- Press the Go to button - arrow -on display.
- Press Exit button - arrow -on display.

Page 7201
1 Footwell vent
2 Instrument panel support
3 Heater unit
- Pull locking cable slightly out of cable sleeve and engage in locking lever - arrow C -.
- Engage locking lever mounting bracket into selector housing - arrow B -.
- Slide locking cable into steering lock => [ Locking Cable ] See: . Flattened side of locking cable
points downward.
- Connect clip - 2 - of locking cable - 3 -.

Page 6604
1 - Track Numbers

Timing and Oil Pump Drive Chain Overview
Timing Chain: Locations Timing and Oil Pump Drive Chain Overview

‹› At the top with a sliding insert.
3 Timing Chain
4 Tensioning Rail
5 Oil Pump Drive Chain Tensioner
‹› With tensioning rail.
6 Crankshaft Sprocket
‹› Part of the crankshaft.
‹› Secured to the upper oil pan.

Page 4311
Part 2
Page 2061
Combination Switch: Service and Repair
Steering Column Switch
Connecting.
‹› Torque Wrench (VAG 1331)
Removing
- Remove the steering wheel.
- Disconnect connectors - arrows -.
- Remove the steering column switch from the steering column.
Installing
Page 5103
Part 1
Page 6915
Removing
Note: ^
arrow 2 -.
Note: ^
Installing

Diagrams
Coolant Line/Hose: Diagrams
Coolant Hose Connection Diagram

1 Radiator
‹› Removal and installation, refer to => [ Radiator ] See: Radiator/Service and Repair.
2 Oil Cooler
3 Coolant Pump and Coolant Thermostat
‹› Coolant pump removal and installation, refer to => [ Coolant Pump ] See: Water Pump/Service
and Repair.
‹› Thermostat removal and installation, refer to => [ Coolant Thermostat ] See: Thermostat/Service
and Repair.
‹› Checking coolant thermostat - item 16 - => [ Coolant Thermostat ] See: Service and
Repair/Removal and Replacement/Cooling System
Components, Engine Side.
4 Cylinder Head/Cylinder Block
5 Expansion Tank
‹› With the sealing cap
‹› Checking pressure relief valve in cap. Refer to => [ Cooling System, Checking for Leaks ] See:
Testing and Inspection/Component Tests and
Page 5994
Fuel: Specifications
Fuel Type
Minimum of ..........................................................................................................................................
...................................................... 91 octane (RON)
Page 6211
Part 1
Coding
Control Modules
‹› Chassis
‹› Functions

Page 6972
7 24
8 25
- End diagnosis.
Final procedures
End diagnosis.
Page 3496
WHAT ARE TRACKS?
15-28, and so on).
Page 5492
Page 2283
Page 6039
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2946
Power Window Switch: Service and Repair Window Regulator Switches, From 05.2008
Window Regulator Switches, From 05.2008
Removing
- Disconnect the connector on the window regulator switch.
- Bend the frame outward at the top of the switch and remove the switch.
Installing
Fuel System - Fuel Related Driveability Issues
Fuel: Technical Service Bulletins Fuel System - Fuel Related Driveability Issues
0109-01
Affected Vehicles
Condition
01 09 01 Jan. 08, 2009 2014815 Supersedes T. B. Group 01 number 07-55 dated July 17, 2007
due to additional models and model year applicability.
Gasoline Quality
The use of contaminated gasoline, seasonal fuel changes (summer/winter fuel) or gasoline with a
low content of deposit control additives may result in one or more of the following conditions:
Excessive accumulation of deposits on intake valves, intake manifold, fuel injectors and
combustion chambers. Engine runs rough after cold start. Excessive engine cranking time.
Stumbles while driving. Rough engine idle. Loss of engine performance. Poor fuel economy.
Conditions may be severe enough to illuminate the MIL in conjunction with storage in the ECM data
memory of DTCs for misfire (example: P0300, P030x) and / or lean fuel system (example: P0171,
P0174, P1128, P1130, P1136, P1138).
1. Condition may be caused by use of contaminated gasoline. 2. Condition may be caused by use
of gasoline with a low content of deposit control additives.
Production Solution
Service
1. If use of contaminated gasoline is suspected:
Consider advising the customer to change gasoline source (brand/gas station). Contaminated
gasoline may exhibit one or more of the following characteristics:
- May have unique color and odor.
- May contain water.
- May contain sediments and suspended matter.
- May appear cloudy and (after settling) may show signs of separation.
If use of gasoline with a low content of deposit control additives is suspected:

Recommend to the customer the exclusive use of TOP TIER Detergent Gasoline. These products
provide improved deposit control performance. Current TOP TIER Gasoline retailers offering this
product in all their octane grades include the following brands:
QuikTrip Chevron Conoco Phillips 76 Shell Entec Stations MFA Oil Company Kwik Trip/Kwik Star
The Somerset Refinery, Inc. Chevron-Canada Aloha Petroleum Tri-Par Oil Company Shell-Canada
Page 2866
Page 5141
Part 1
Page 2934
WHAT ARE TRACKS?
15-28, and so on).
Page 5220
stop:
Checking resistance
Page 5590
Safety Precautions
connection.

components.
Module DTC Memory, Checking and Erasing ] See: Engine Control Module/Testing and
Page 856
- Press buttons -0- and -6- to end the output.
Rapid data transfer Q 06 End output
The airbag Airbag Malfunction Indicator Lamp (MIL) -K75- must go out after approx. 4 seconds.
Procedures
Shifter M/T: Procedures
Shift Mechanism, Adjusting
‹› Connecting pin (T10027)
‹› The following points are essential to ensure correct shift adjustment:
‹› Components of shift mechanism and linkage must be in proper working condition.
‹› Shift mechanism moves freely
‹› Transmission, clutch and clutch mechanism must be in proper working condition.
‹› Transmission in neutral
- Pull locking mechanism on shift cable and on selector cable toward front to stop in direction of -
arrow 1 - and then lock toward left in direction of - arrow 2 -.
Secure shift rod as follows:

Page 5342
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2275
Ground (GND)

Page 53
Part 2
Page 3337
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

‹› Multimeter.
Test requirements
Function
unit.
Test procedure
Start diagnosis

Page 1794
1 - Track Numbers

Page 553
Part 2
Page 4528
removal.
Parking Assist Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.


Page 3858
- Pry off the upper oil pan from the cylinder block at the designated points using a suitable
screwdriver - A -.
B Bearing cap 6 for the crankshaft C Bearing cap 1 for the crankshaft
Installing
- Remove the remainder of sealant from the upper oil pan and cylinder block using a rotating plastic
brush.
Page 2373
Part 3
DTC
For Misfire DTC
Group: 01
Number: 06-07
Date: Mar. 27, 2006
Self Diagnosis
2005 --> 2006
Condition
Service
Page 1886
WHAT ARE TRACKS?
15-28, and so on).
Page 4450
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 557
Instrument Panel Relay: Diagnostic Aids
Page 97
WHAT ARE TRACKS?
15-28, and so on).
Page 1189
Door Sensor/Switch (For Alarm): Diagnostic Aids
Service and Repair
Fluid Filter - A/T: Service and Repair
Oil Strainer
Removing
- Remove oil pan => [ Oil Pan ] See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and Repair.
- Remove oil strainer bolts - arrows -.
- Pull oil strainer - A - off valve body.
Installing
- Lightly coat seals on intake union of oil strainer with ATF.
‹› If the oil seals are loose or faulty replace the oil strainer
- Place oil strainer - A - on to valve body and tighten bolts - arrows - => [ (Item 9) Bolt, 11 Nm ]
- Install oil pan => [ Oil Pan ] See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Fluid Pan/Service and Repair.
- Fill with ATF, check ATF level and top off => [ ATF Level ] See: Fluids/Fluid - A/T/Testing and
Page 1022
Ground (GND)

Page 3012
The following work sequence must be followed!
1 Check front axle camber and adjust if necessary => [ Front Axle Camber, Adjusting ] See: Front
Axle Camber, Adjusting.
2 Check rear axle camber.
‹› Camber is not adjustable, notes => [ Rear Axle Camber, Adjusting ] See: Rear Axle Camber,
Adjusting.
3 Check rear axle toe and adjust if necessary.
The rear axle toe is not adjustable, notes => [ Rear Axle Toe, Adjusting ] See: Rear Axle Toe,
Adjusting.
4 Check front axle toe and adjust if necessary => [ Front Axle Toe, Adjusting ] See: Front Axle Toe,
Adjusting.
5 Check which suspension is installed in the vehicle. This information can be found on the vehicle
data sticker See: Description and Operation/Vehicle Data Label.
Rear Axle Toe, Adjusting
Rear Axle Toe, Adjusting

to Measure.
Overall toe setting of rear axle is not adjustable.
Only by moving the mounting brackets is it possible to even out individual toe settings uniformly.
If measured values are still not within specified range, check axle beam for damage and replace if
necessary.
- Loosen all bolts of mounting bracket - 1 -.
- Slide mounting bracket - 1 - laterally - arrows -.
2 Rear axle body
- Tighten bolts to 75 Nm.
- Always use new bolts!
Rear Suspension
Lifting into Curb Weight Position

Specifications

Page 2698
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2732
‹› M8 x 12
7 Hex bolt
‹› M8 x 12

8 Heat shield
Page 1204
Page 1103
Page 7480
Clutch Pedal Assembly: Service and Repair Over-Center Spring
Over-Center Spring
‹› Assembly clip (T10111)
Removing
- Slide driver's seat rearward as far as possible and bring steering wheel to highest position.
- Insert assembly clip (T10111) into over-center spring from right side.
- While doing this, make sure assembly clip is seated properly on over-center spring:
1 Assembly clip must make contact on rear part of over-center spring with claws directly above
brace - 1 -.
2 Press clutch pedal lightly in direction of bulkhead. Engage tab - 2 - of assembly clip into cut out of
over-center spring.
- Now press clutch pedal to bulkhead far enough until over-center spring can be removed
downward out of bearings on mounting bracket and clutch pedal.
- Bring clutch pedal to rest position.
- Turn over-center spring together with assembly clip (T10111) in direction of - arrow A - and
remove downward in direction of - arrow B -.
Page 2577
Ground (GND)

Page 5609
‹› Multimeter.
Test procedure
Start diagnosis
Specified values:
Page 7003
WHAT ARE TRACKS?
15-28, and so on).
Page 7737
Page 258
Part 1
Page 7603
‹› Arbor 50 mm dia. (VW432)
‹› Thrust pad (VW442)
‹› Thrust pad (VW 447 i)
‹› Press appliance (VW 459/2)
‹› Box wrench (46 mm) (3252 A)
‹› Wheel bearing assembly set (3253)
Removing
Pressing wheel hub out of wheel bearing housing
Pulling bearing inner race off of wheel hub

Page 494
Part 1
Page 4092
Note:
Cooling system flushing due to coolant mixing or incorrect coolant is not covered by warranty.
Warranty Information Only.
Page 4676
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3313
Refrigerant Oil: Fluid Type Specifications
Refrigerant oil
Capacity ...............................................................................................................................................
....................................................... 135 cc (4.6 fl. oz)
Type .....................................................................................................................................................
...................................................................... PAG oil
Part Number ........................................................................................................................................

............................................................. G 052 154 A2
Page 7763
Warranty
Information only.
removal.
Page 2557
and/or user manual.

Page 7617
Wheel Bearing: Aftermarket Tools
Rear Wheel Bearing Press
AST tool# 3420
VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle.
- VW/Audi Rear Wheel Bearing Press
- Applicable to Newer Golf, Jetta and New Beetle

Page 5073
‹› Multimeter.
Test procedure
Start diagnosis
Specified values:
Page 5473
6 (Can_Bus Low) 58
- End diagnosis.
Final procedures
erased, generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes
End diagnosis.
‹› Multimeter.
Test requirements

Test procedure
Page 396
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 101
Part 3
Page 2343
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4381
Active Exhaust System Actuator: Diagnostic Aids
Page 1582
Ground (GND)

Page 1182
WHAT ARE TRACKS?
15-28, and so on).
Locations
Page 11
Alarm Module: Service and Repair
Anti-Theft Immobilizer Control Module, Removing And Installing
Anti-theft immobilizer control module functions are integrated with the instrument cluster.
In the event of faulty Anti-Theft immobilizer control module functions, the entire instrument cluster
requires replacement and adaptation afterwards.
Page 6264
‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
‹› New Beetle
Page 5707
- Remove nut - 1 -.
Page 3292
Page 966
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Suspension Control Pressure Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6007
Page 496
Part 3
Page 7466
- Then remove nuts - arrows 2 - for bracket - B -.
- Remove bracket.
- Turn stop - A - for clutch pedal in direction of - arrow - and remove it.
- Then press master cylinder first to stop in direction of - arrow 1 -.

Page 5911
Ground (GND)

Page 6182
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3868
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6899
Page 4728
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3050
Page 6558
Page 7450
Clutch Disc: Service and Repair Clutch, LuK
Clutch, LuK
Removing

Installing


Page 2250
Page 921
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 317
- Insert brake pedal actuator (V.A.G 1869/2 ).
- Attach bleeder bottle bleeder hose to left front and right rear brake caliper bleeder screw and
open bleeder screws.
- Operate brake pedal using brake pedal actuator at least 60 mm.
- Close left front and right rear bleeder screws.
- Do not remove brake pedal actuator (V.A.G 1869/2 ).
- Place a sufficient number of lint-free cloths under control module and hydraulic unit.
CAUTION! Make sure that the brake fluid does not come in contact with the terminals.
- Remove brake lines from ABS hydraulic unit (N55 ) - 1 - to master brake cylinder and tie up.
- Remove remaining brake lines from ABS hydraulic unit (N55).
- Seal brake lines and threaded bores using plugs from repair set (1H0 698 311 A).
- Remove bolts - arrows - from bracket for control module/hydraulic unit.
- Remove ABS hydraulic unit (N55) together with ABS control module (J104).
Control Module, Removing from Hydraulic Unit
- Place hydraulic unit with control module on a clean and flat surface on the floor.
Page 1508

Page 2197
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 1678
Yaw Rate Sensor: Service and Repair ESP Sensor Unit G419, Removing and Installing, Vehicles
From 12.0
ESP sensor unit G419, removing and installing, Vehicles from 12.0
The sensor for transverse acceleration G200 and the sender for rotation rate G202 are assembled
together in one housing on a new bracket, at the same place in the vehicle.
The ESP sensor unit G419 - 1 - is fixed with a bracket on the steering column bearing bracket - a -.
When the ESP sensor unit G419, is replaced, a zero compensation of the sensor for transverse
acceleration G200 and the sender for rotation rate G202 must be performed.
Removing
- Disconnect connector - arrow - from the ESP sensor unit G419.
- Remove bolt - 1 - and ESP sensor unit G419.
- Remove nuts - a - from the ESP sensor unit G419 - 1-.
- Remove ESP sensor unit G419.
CAUTION: Strong vibrations can destroy the lateral acceleration sensor G200 and the yaw rate
sender G202.
Installing
- Installation is carried out in the reverse sequence of removal.
- Enter radio code.
- Perform basic settings on the sensor for transverse acceleration G200 and sender for rotation
rate G202.
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5925
legend.
wiring diagram.
harness.


question.)
19 - Legend



Data Link Connector: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3988
Part 3
Page 4699
Final procedures

Vehicle Level Sensor With Automatic Headlight Vertical
Aim Control
Ride Height Sensor: Service and Repair Vehicle Level Sensor With Automatic Headlight Vertical
Aim Control
Vehicle Level Sensor with Automatic Headlight Vertical Aim Control
Vehicles with gas discharge headlights have an automatic vertical aim control system as standard
equipment.
To function properly, the automatic vertical aim control system needs information about
compression travel or rebound travel at the front and rear axles.
For this, the position of left control arm relative to body is transferred to left front level control
system sensor (G78) via a coupling rod. This sensor passes on electrical signals to the control
module for the vertical aim control system.
On the rear axle these signals are passed on from left rear level control system sensor (G76) to the
control module.
These signals are needed to determine vehicle level.
The automatic headlight vertical aim control reacts automatically to changes in vehicle level.
The vehicle level can change in the following situations:
‹› Operating with something in tow
‹› Various load conditions: vehicle empty, vehicle partially or completely loaded
‹› Driving slowly or quickly.
CAUTION! Adjustment of headlights!
It is always necessary to check the basic setting of the headlights when:
‹› The retaining clip for the coupling rod on the control link has been loosened
‹› The lower control arm has been removed and reinstalled or replaced
‹› Installation work has been performed on left rear level control system sensor (G76)
‹› The vehicle level sensor has been replaced

Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 6408
Ignition Coil: Testing and Inspection
Ignition Coil with Power Output Stage, Checking
The following procedure is used to diagnose all Ignition Coils with Power Output Stage.
‹› Multimeter.
‹› Diode test lamp.
Test requirements
‹› The Ignition Coils with Power Output Stage ( N70, N127, N291, N292, N323) fuses OK.
‹› The Motronic Engine Control Module (ECM) Power Supply Relay (J271) OK.
‹› The Engine Speed (RPM) Sensor (G28) OK.
‹› The Camshaft Position (CMP) Sensor (G40)OK.
Test procedure
Start diagnosis
- Remove the Ignition Coils with Power Output Stage (N70, N127, N291, N292, N323) electrical
harness screws.
- Disconnect the ignition coil electrical harness connectors from the Ignition Coils with Power
Output Stage (N70, N127, N291, N292, N323).
Checking ground supply
- Using a test lamp connected to Battery Positive, check terminals 2 and 4 of the Ignition Coils with
Power Output Stage ( N70, N127, N291, N292, N323). The test lamp should be ON for each
terminal check.
If the test lamp was Not ON during a terminal check:
- Check the circuit for an open or high resistance.


Page 5082
Control Modules
Procedure
‹› Body

Page 7153
End diagnosis.
Page 7572
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7900
3 51
4 39
- End diagnosis.
Final procedures
End diagnosis.
Page 4820
Page 653
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3338
Warranty
Information only.
removal.
Page 1981
Part 1
Page 4854
- Press the <- key.

Page 299
1 - Track Numbers

Page 6005
‹› Black
4 Fuel Return Line
‹› Blue
‹› 4 bar
6 Gasket
‹› Replace
7 O-ring
‹› Replace
8 Fuel Supply Line
‹› Black
9 Bolt, 3 Nm
10 Bracket

Compressor/Pump Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5368
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis

U0101/28773/01315
37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Page 7246
- Engage selector lever cable - 1 - into clip - arrow - on transmission. Maintain a distance of at least
5 mm to ATF cooler when routing selector lever cable.
- Install air filter housing.
- Engage locking cable at selector mechanism into locking lever => [ Locking Cable ] See: Shift
Interlock/Shift Interlock Cable/Service and Repair.
- Adjust locking cable => [ Locking Cable, Adjusting ] See: Shift Interlock/Shift Interlock
Cable/Adjustments.
- Ignition key removal lock, checking function => [ Ignition Key Removal Lock, Checking Function ]
See: Shift Interlock/Testing and Inspection.
Board ] See: Selector Mechanism Cover and Circuit Board.
- Install selector lever handle => [ Selector Lever Handle ] See: Selector Lever Handle.
- Adjust selector lever cable => [ Selector Lever Cable, Checking and Adjusting ] See: Shift
Linkage/Shift Cable/Testing and Inspection.
- Check shift mechanism => [ Selector Mechanism, Checking ] See: Testing and Inspection.
- Code radio.
Selector Mechanism Assembly Overview
Selector Mechanism Assembly Overview
Removing => [ Selector Mechanism ] See: Selector Mechanism.

Page 7254
Shifter A/T: Overhaul
Selector Mechanism
Selector Mechanism
‹› Lubricate bearing areas and slide surfaces with polycarbamide grease (G 052 142 A2).
1 Selector lever handle
‹› Removing and installing => [ Selector Lever Handle ] See: Removal and Replacement/Selector
Lever Handle
2 Sleeve
‹› Engages in selector lever handle
‹› Locks removal of selector lever handle
3 Cover
‹› With circuit board and frame
‹› Assembly overview => [ Selector Mechanism Cover Assembly Overview ] See: Removal and
Replacement/Selector Mechanism Cover
Assembly Overview
‹› Removing and installing => [ Selector Mechanism Cover and Circuit Board ] See: Removal and
Replacement/Selector Mechanism Cover and
Circuit Board
4 Printed circuit board

Page 2308
‹› Multimeter.
Test conditions
Function test
(G71) at idle:
- Erase the DTC. Generate readiness code. Refer to => [ Readiness Code ] See: Powertrain
Test sequence

Checking wiring

Page 1134
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7761
Tip:
Page 6661
- Remove nut - 1 -.
Installing


Page 4454
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 409
Part 2
Page 3016
The setting is OK however if setting value deviates from specified value no greater than 2'.
Be sure that boot is not twisted after turning tie rods.
Page 3532
1. Thrust piece E-5 2. Thrust sleeve E-65-1 3. Hollow piston cylinder HKZ-15 4. Special nut
E-8-214 and tie bolt
Pull bearing inner race off hub
Pressing in wheel bearing
Molykote grease G 052 723 A2

- Press the <- key.

Page 5114
1 - Track Numbers

Page 3389
Page 4825
Requirements:

Work procedure:
Wiring Harness With 14-Pin Connector
Wiring Harness: Service and Repair Wiring Harness With 14-Pin Connector
Wiring Harness with 14-Pin Connector

Removing
- Draw up a diagram of all sensors and solenoid valves with corresponding connectors similar to
the illustration.
- Before disconnecting harness connectors at solenoid valves, mark solenoid valve and
corresponding connector.
‹› It is absolutely required to draw the diagram and make identifying marks so that connectors at
solenoid valves cannot be interchanged
unintentionally when reinstalling the wiring harness.
‹› An interchanged connection may possibly destroy the transmission.
- Carefully pry out retainer tabs of connectors at solenoid valves - 2 - to - 9 - using a small
screwdriver and disconnect connectors.
Page 2853
strip - 2 -.
Page 1631
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2152
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7566
Ground (GND)

Page 3035
11 Air Duct
13 Intake Tube

Page 360
WHAT ARE TRACKS?
15-28, and so on).
Page 6684
3 51
4 39
- End diagnosis.
Final procedures
End diagnosis.
Page 2924
Headlamp Igniter Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6612
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1522
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 741
Specifications
Clutch Fluid: Specifications
Brake Fluid Type
Note: Does not apply to vehicles equipped with DSG transmissions. Refer to Automatic
Transmission/Transaxle for correct fluid specifications See: Automatic
Transmission/Transaxle/Specifications
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 38
Section 2 - Radio antenna system diagnosis through radio unit

Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the
radio unit.
All models except Touareg and Phaeton:
- Select AM or FM.
- Press and hold the mix button (black arrow).
- Screen will appear that shows "Service Test mode" (white arrow).
- Press mix button briefly.
^ Test one indicates current antenna status, i.e. ON or OFF (arrow).

Page 6154
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 1008
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1423
Part 2
Page 6500
Part 2
Page 3362
Page 7136


Page 7173
Warranty

Page 2355
Final procedures

Page 676
Part 2
Page 4387
1 - Track Numbers

Page 6040
Page 2422
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 23
Section 2 - Radio antenna system diagnosis through radio unit

Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the
radio unit.
All models except Touareg and Phaeton:
- Select AM or FM.
- Press and hold the mix button (black arrow).
- Screen will appear that shows "Service Test mode" (white arrow).
- Press mix button briefly.
^ Test one indicates current antenna status, i.e. ON or OFF (arrow).

Page 1796
Ground (GND)

Page 3832
Page 3792

Page 3352
Fuse Arrangements In Fuse Bracket/Battery - Description
Page 782
Page 1878
High Pressure Sensor / Switch: Service and Repair
A/C Pressure Switch and High Pressure Sensor
Removing
‹› Components can be removed without discharging refrigerant system.
- Disconnect electrical connection to switch/sensor
- Remove by turning switch/sensor - B - counterclockwise (switch/sensor threaded onto refrigerant

pipe equipped with Schrader valve).
Installing
- Install in reverse order of removal, noting the following.
‹› Always replace O-ring seal - A - (10.8; 1.8mm)
‹› Tightening torque 5 Nm.

Page 226
Part 1
Engine - Oil Filler Cap Separation
Engine Oil Filler / Breather Cap: Customer Interest Engine - Oil Filler Cap Separation
Condition
17 07 04
Mar. 2, 2007
2010384 supersedes Technical Bulletin Group 17 number 05-06 dated Oct. 18, 2005 due to
inclusion in ElsaWeb and additional models.
Cap, Oil Filler, Comes Apart When Removing Engine Cover
Oil filler cap separates when engine cover is improperly removed.
See Repair Group 24 - Multiport Fuel Injection (MFI), Engine cover with air filter, removing and
installing.
Note:
Oil filler cap can be repaired. Do not replace oil filler cap!
Production Solution
N/A
Service
If oil filler cap has separated:
Tip:
Make sure that the symbol on oil filler cap is facing in the correct direction.
Page 6017
Part 1
Page 6223

- Remove valve body => [ Valve Body ] See: Automatic Transmission/Transaxle/Valve

Body/Service and Repair/Valve Body.
Installing

See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Valve Body Assembly
Overview.
- Install valve body => [ Valve Body ] See: Automatic Transmission/Transaxle/Valve Body/Service
and Repair/Valve Body.
Page 2106
Part 3
Page 6948
- Top off ATF => [ ATF, Filling ] See: Service and Repair/09G Transmission/ATF, Filling.
Page 344
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2496
Final procedures

Condition

37 06 07 Dec. 22, 2006 2012681
-G509-, caused by:
Production Solution
Service
DTCs.

Page 5106
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3640
^ Only replace as set
7 - Circlip
8 - Piston pin
^ If difficult to move, heat piston to 60° C
^ Removing and installing using a Pilot Drift VW 222 A
9 - Piston
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor
10 - Piston rings
^ Offset gaps by 120°
^ Use piston ring pliers for removal and installation
^ Markings face toward piston crown
Bearing shells - installed positions
Bearing shell - 2 - without oil bore for connecting rod cover. -
Place bearing shells centrally into connecting rod and connecting rod cap.
Dimension - a - must be same at left and right.
Locations


Page 991
Ground (GND)

Page 5748
End diagnosis.
Service and Repair
Clutch Master Cylinder: Service and Repair
Master Cylinder
‹› Pliers (T10005)
Removing
- Remove control module and ABS hydraulic unit.
‹› For the following work, make sure brake fluid does not come into contact with longitudinal
member or transmission. However, in case of contact
clean this area thoroughly.

- Lay lint-free cloth under master cylinder.
- Disconnect return hose - A - to brake fluid reservoir and seal.

Page 2634
Ground (GND)

Page 1339
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1381
Hood Sensor/Switch (For Alarm): Diagnostic Aids
Page 7027
Tip:
Page 4582
- Multimeter.
- wiring diagrams.
Test requirements
- Fuse SB42 OK.
- The generator OK.
Test procedure
Start diagnosis
Ground (GND).
- Crank the engine.
16/MOT 65

Page 4606
stop:
Checking resistance
Locations


Page 6654
Page 926
Part 2
Page 1168
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2477
legend.
wiring diagram.
harness.


question.)
19 - Legend



1 - Fuel filter -
Black
- From fuel tank
Blue
- To fuel tank
4 bar
6 - Gasket
Replace
7 - O-ring
Replace
Black
- To engine
9 - 3 Nm
10 - Bracket
Page 4922
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 259
Part 2
Page 1571
Part 2
Page 5968
Final procedures

Left Drive Flange Shaft Oil Seal
Seals and Gaskets: Service and Repair Left Drive Flange Shaft Oil Seal
Left Drive Flange Shaft Oil Seal
Removing
- Remove left wheel.

- Remove center and left sections of sound insulation below engine/transmission.
- Turn steering as far as possible toward left.
- Remove drive axle.
- Place appropriate receptacle underneath transmission.
- Remove bolt for flange shaft. To do this, screw two bolts into flange and counter-hold flange shaft
centrally using a pry bar.
- Pull out flanged shaft with compression spring.
- Pull out seal for flange shaft using slide hammer complete set (VW 771) and pulling hook (VW
771/37 ).
Page 3147
Engine Oil, Filling
General Information
Page 5352
‹› Multimeter.
Test conditions
Function test
(G71) at idle:
- Erase the DTC. Generate readiness code. Refer to => [ Readiness Code ] See: Testing and
Test sequence

Checking wiring

Page 2430
Final procedures

Page 7129
Page 1611
Part 1
Locations
Firing order
1-2-4-5-3

Page 895
Part 2

Page 952
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7860
1 - Track Numbers

Page 905
1 - Track Numbers

Page 6517
WHAT ARE TRACKS?
15-28, and so on).
Page 2864
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Locations
Firing order
1-2-4-5-3
Page 624
Page 2951
1 - Track Numbers

Instrument Panel Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4306
legend.
wiring diagram.
harness.


question.)
19 - Legend



Locations
Ride Height Sensor: Locations

2 Left rear level control system sensor (G76) on rear axle
3 Left front level control system sensor (G78) on front axle

Page 3589
Part 1
Page 3442
Ground (GND)

Page 7864
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2932
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4620
Page 392
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4976
Ground.
Final procedures


Page 4970
1. Lock Cylinder
3. Securing lever
Installing
Page 4931
Page 6824
Part 2
Page 651
Ground (GND)

Page 635
Ground (GND)

Page 6132
‹› Checking, refer to => [ Switch Over Valve Checking ].
8 O-ring
9 to Evaporative Emission (EVAP) Canister
10 from EVAP Canister
11 Wiring Router
‹› In the longitudinal member.
12 Vent Line
‹› Secure with spring type clips.
13 Bolt, 10 Nm
14 Protective Plate
15 Fuel Tank
‹› Support using the engine and transmission jack (VAG 1383A) when removing.
‹› Removal and installation, refer to => [ Fuel Tank ] See: Service and Repair/Removal and
Replacement.
16 Heat Shield
‹› For the fuel tank.
17 Lock Washer
18 Cover for Fuel Tank
‹› Replace
20 Securing Strap
‹› Observe the varying lengths.
‹› Installed position: Locating point (hole) points in the driving direction.
21 Fuel Filter
‹› Installed position: Arrow points in direction of flow.
‹› Assembly overview, refer to => [ Fuel Filter Assembly Overview ].
‹› Removal and installation, refer to => [ Fuel Filter ] See: Service and Repair/Removal and
Replacement.
22 Supply Line
‹› Black

‹› To disconnect from the fuel filter, press in the securing ring on the connecting piece.
‹› To the fuel rail.

Fluid - M/T: All Technical Service Bulletins M/T - Humming Noise When Turning at Low Speeds
34 06 02
June 12, 2006
2011899
Affected Vehicles
under load.
Production Solution
Service
model years.
Page 4678
Page 1702
for resistance.

Page 602
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1083
Removing
Note: ^
arrow 2 -.
Note: ^
Installing

Page 4194
Part 1
Page 4891
Page 3529
Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed
Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed
^ Thrust piece 40 - 105
^ Hub puller 3283
^ Collar F/Wheel Brg. Inner Race 3423
^ Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2
^ - 2 - Puller Kukko 18/0
^ Foot pump with high pressure hose V.A.G 1389 A/1
If there is a hand pump V.A.G 1389/1 available it can also be modified for use as a foot pump. To
do so, use conversion kit V.A.G 1389/4.
Page 7731
Assembly is performed in reverse order of removal. Note the following:
- Insert shift knob into cover.
- Press clamping sleeve on shift knob and engage.
- Install shift knob and cover together.
Shift Mechanism
Shift Mechanism
‹› Hose clamp pliers (V.A.G 1275)
‹› Torque wrench 5-50NM (V.A.G 1331)
‹› Grease (G 000 450 02)
Removing
Page 262
Page 6019
Part 3
Page 4069
- Guide the coolant pump - A - through between the longitudinal member and cylinder block and
remove it.
Installing
components.
Note the installed position of coolant pump before installing.
- Rotate the pulley so that the arrow - A - (relative to engine axis) points upward vertically. Holes in
the pulley must align opposite the bolts - arrows -.
- First, firmly bolt the engine mount to the engine, then align the engine/transmission assembly free
of tension via a shaking motion and tighten the bolts to the subframe.
‹› Tightening specifications for the engine and transmission mounts. Refer to => [ Fastener
Tightening Specifications ] See: Specifications/Engine
Assembly - Fastener Tightening Specifications.
- Install the lock carrier.
- Install the bracket for the reservoir and power steering line.
Page 6420
Ground.
Final procedures


Page 4581
Page 4975
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 5171
Page 924
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3956
Timing Chain: Locations Timing Chain Assembly Overview
Timing Chain Assembly Overview

‹› Do not disassemble.
‹› Not pressed onto the camshaft.
‹› When removing, press off lightly, if necessary.
3 Cylinder Head
4 Tensioning Rail
‹› Securing, refer to => [ Oil Pump Drive Chain Assembly Overview ] See: Engine Lubrication/Oil
Pump/Service and Repair/Oil Pump Drive
Page 5839
WHAT ARE TRACKS?
15-28, and so on).
Page 476
Ground (GND)

Page 1248
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 894
Part 1
Page 7948
Page 333
Temperature Gauge: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5216
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3540
Wheel Bearing: Service and Repair Rear Suspension
Wheel Bearing and Hub Unit
‹› Grease cap puller (VW 637/2)
‹› Seal installer (3241)
‹› Installation sleeve wheel brg. (3420)

Removing
- Raise vehicle.
- Remove wheel.
Loosen dust cap from seat by tapping lightly on claw of grease cap puller (VW 637/2).
- Pull off dust cap.

Page 7962
Checking wiring

Page 885
^ Navigate to Vehicle Self Diagnosis 15- Airbag, interrogate fault memory and erase fault codes.
Page 5865
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7920
legend.
wiring diagram.
harness.


question.)
19 - Legend



NOTE:
J217.
Procedure
0301
Removal
J217.
Installation
Page 5610


Page 675
Part 1
Procedures
Engine Oil: Procedures
Engine Oil, Checking Level
Please note the following:
- After stopping the engine, wait for at least 3 minutes for the oil to flow back into the oil pan.
- Pull out dipstick, wipe off with a clean cloth and re-insert dipstick again up to stop.
Page 6234
WHAT ARE TRACKS?
15-28, and so on).
Page 4723
Part 1
Page 3384
Fuse: Application and ID Fuse Arrangements in Fuse Panel, Instrument Panel, Left, From July
2005
Fuse Arrangements in Fuse Panel, Instrument Panel, Left
Page 3680
‹› Height of sealant bead above the sealing surface: approximately 1.0 mm
- Install the sealing flange using (T03004) onto the crankshaft and press uniformly onto the cylinder
block.
- Tighten the bolts - A - uniformly in a diagonal sequence.

following:
‹› Remove the (T40069) from cylinder block and install the locking bolt.
Page 5311
* Display field blank
Display Group 126, Evaluating

Page 2072
Part 2
Page 1494
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4396
Page 2050
WHAT ARE TRACKS?
15-28, and so on).
Specifications
Technical Data
‹› 2 Replace the ECM. Refer to => [ Engine Control Module ] See: Computers and Control
Systems/Engine Control Module/Service and Repair.
Page 620
Part 1
Page 3296
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5522
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 3625
Page 2583
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 48
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 316
Electronic Brake Control Module: Service and Repair
ABS Control Module and Hydraulic Unit
Removing
Component location:
The ABS control module (J104) is bolted to the hydraulic unit and is located at left in engine
compartment.
CAUTION! Do not bend brake lines near the hydraulic unit!
- Remove bolts - 3 -, - 4 - and - 5 -.

- If present, remove protective housing for relay from cable channel.
- Draw as much brake fluid as possible from brake fluid reservoir using a bleeder bottle.
- Disengage connector - arrow 1 - and disconnect - arrow 2 - from control module.

Page 7651
Part 2
Page 6464
Ground (GND)

Page 5555
Part 3
Leak Detection Pump: Testing and Inspection
Leak Detection Pump, Checking
‹› Multimeter.
Test requirements
‹› The Leak Detection Pump (LDP) (V144) fuse is OK.
‹› The engine must be completely cooled down. IAT must match ECT within 5 Degrees C in order
for the LDP to operate. Let sit overnight if
possible when testing for voltage to the pump motor.
Test procedure
Start diagnosis
- Remove the right rear wheel housing liner. Refer to the Repair Information.
- Disconnect the Leak Detection Pump (LDP) (V144 ) electrical harness connector - 2 -.
- Using a multimeter, check the Leak Detection Pump (LDP) (V144) for resistance as follows:
Page 3859
Note the shelf life date.
‹› The upper oil pan must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - 1, 2 and 3 - as shown onto a clean sealing surface of the upper oil pan.
- Place the upper oil pan onto the cylinder block and align it on the transmission side.
- Install 2 bolts each at the front and rear hand tight.
- Wipe off excess sealant in area of the - arrows -.

Page 1704
Checking wiring
Final procedures

09.

Code.
Page 4911
Part 1
Page 5881
Ground (GND)

Page 5820
Part 2
Page 6213
Part 3
Page 5194
Page 7321
WHAT ARE TRACKS?
15-28, and so on).
Page 6365
Vehicle Information
Condition
Campaign
Note:
Symptoms:
^ MIL ON.
^ Rough idle.
Production Solution

Service
Page 21
^ Location: Behind rear section of molded headlining.
Antennas
All models use four antennas items -2-, 4- (qty. 2) & -7-.
^ Antennas (R130, R131) are integrated into rear hatch glass.
^ Antenna R11 in left rear side glass.
^ Antenna R93 in right rear side glass.
Antenna amplifiers
All models use four antenna amplifiers items -1-, -3-, -5- & -6-.
^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window.
^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window.
Phaeton
Page 547
1 - Track Numbers

Page 4749
Part 3
Page 1758
legend.
wiring diagram.
harness.


question.)
19 - Legend



Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3731
4 - Ribbed Belt - Tensioner roller, generator, a/c compressor, power steering pump and
crankshaft/vibration damper
1 Bolt
2 Power Steering Pump Pulley
3 Bolt
4 Power Steering Pump

Page 2261
Code.
Rain Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Communications Control Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3791
Engine Oil: Removal and Replacement
prevents leaks.
Or

Page 6165
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6983
Ground (GND)

Page 7432
- Replace O-ring on connector.
- Press connector with new O-ring into transmission up to limit stop.
- Tighten bolt of 14-pin transmission connector => [ (Item 35) Bolt, 6 Nm ] See: Valve Body/Service
and Repair/Valve Body Assembly Overview.
- Tighten bolts of bracket for harness connectors of speed sensors, => [ (Item 14) Bolt, 7 Nm ] See:
Valve Body/Service and Repair/Valve Body Assembly Overview and => [ Oil Strainer ] See: Fluid
Filter - A/T/Service and Repair.
- Tighten bolt for bracket of Transmission Fluid Temperature Sensor (G93) to 11 Nm.
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3600
Conditions
Page 600
Ground (GND)

Hazard Warning Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5212
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6789
WHAT ARE TRACKS?
15-28, and so on).
Page 3118
- For fuel tank
17 - Lock washer
Replace
21 - Fuel filter -
22 - Supply line -
Black
- To fuel rail
23 - Vent line -
White
24 - Seal -
Replace
- Check fuel pump.

27 - Supply line -
Black
- To fuel filter
28 - Return line -
Blue
- To fuel filter

Page 6793
Part 3
Page 538
Part 2
Page 291
Part 3
Steering Angle Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3972
Timing Cover: Service and Repair
Chain Compartment Cover
‹› Trim removal wedge (3409)
components.
Removing
- Remove the battery holder bolts - arrows - and remove the battery holder from the vehicle.
- Remove the coolant pipe at the coolant thermostat housing and vacuum pump bracket.
- Remove the retaining clip - arrow - and remove the coolant pipe - A -.
Page 4687
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4745
WHAT ARE TRACKS?
15-28, and so on).
Page 2102
WHAT ARE TRACKS?
15-28, and so on).
Page 1264
Ground (GND)

Page 6465
WHAT ARE TRACKS?
15-28, and so on).
Page 1785
Page 4983
supply line - 2 -.
Delivery and Air Induction/Fuel Pump/Testing and Inspection/Fuel Pump Checking, Engine Code
BPS (Plastic Fuel Tank).
Regulator ] See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and
Replacement.
Page 1960
1 - Track Numbers

Page 6302
WHAT ARE TRACKS?
15-28, and so on).
Brake Fluid Pressure Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2602
WHAT ARE TRACKS?
15-28, and so on).
Page 5650
Checking wiring
Final procedures


Page 3894
- Remove nut - 1 - for the line - 2 - for the power steering at the engine and disconnect the line from
the threaded pin.
- Remove the oil dipstick out of the intake manifold and press retaining ring - 4 - downward.
- Remove the oil dipstick guide tube from the bottom of the cylinder block.
- Cover the opening in the cylinder block.
- Loosen the intake manifold bolts - arrows - using (T10107A).
Bolts remain in the intake manifold.

Page 2159
Interior Light Switch: Service and Repair
Door Contact Switch
Door contact switch is integrated in door lock and cannot be replaced separately.
If the door contact switch is faulty, then the entire door lock must be replaced.
Page 6084
Final procedures

Page 5372
Final procedures


Page 7845
Part 1
Page 1405
WHAT ARE TRACKS?
15-28, and so on).
Page 2056
Page 3835
Removing
Page 7613
2 Brake disc
3 Dust cap
An appropriate seal can only be achieved with a new dust cap.
Only then can an optimal function and long service life be guaranteed
‹› Pressing off and driving in => [ Wheel Bearing and Hub Unit ] See: Wheel Bearing and Hub Unit.
‹› M20 x 1.5
‹› Tightening specification => [ Rear Axle ] See: Specifications/Mechanical Specifications/Steering

and Suspension/Suspension/System
Wheel bearing, wheel hub and rotor are installed together in one housing.
This wheel bearing/wheel hub unit is maintenance-free and adjustment free. It is not possible to
adjust or service the unit.
6 Axle beam

Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 1051
Tip:
Page 2726
Ride Height Sensor: Description and Operation
equipment.
control module.

Page 7848
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3011
* Camber is not adjustable. Only slight corrections are possible by moving the subframe.
Adjustment range approximately 10' to 15'.
* Camber is not adjustable. Only slight corrections are possible by moving the subframe.
Adjustment range approximately 10' to 15'.
Rear Axle
Vehicle Alignment
Page 616
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1342
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3266
Engine Oil: Technical Service Bulletins Engine - Oils Meeting Manufacturer's Standard
17 09 07
June 30, 2009
2012855 Supersedes T.B. Group 17 Number 09-05 dated March 30, 2009 due to reorganization of
attached world wide oil specifications list to eliminate confusion.
Vehicle Information
Condition
Engine Oils Which Meet Volkswagen Oil Quality Standards VW 502 00, VW 505 01 and VW 504
00/507 00 (U.S. ONLY)
Information only.
Production Solution
Service
Attached is a Worldwide list of engine oils which currently meet Volkswagen Oil Quality Standard
VW 502 00, VW 505 01 and VW 504 00/507 00.
TIP:
SOME ENGINE OILS LISTED ON THE ATTACHMENT MAY NOT BE AVAILABLE IN NORTH
AMERICA. Please refer to the specific Vehicle Owner's Manual, published Technical Bulletins and
Fluid Capacity Charts to select the appropriate oil required for each Volkswagen vehicle.
The sample list below are products generally available in the North American market that meet
Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00 specification at
the time of this publication.
Page 499
ABS Light Relay: Diagnostic Aids
Coding
Control Modules
‹› Chassis
‹› Functions

Page 6846
Locations
2 - Air shroud

6 - 5 Nm
7 - Bolt
8 - Fan wheel
9 - Fan ring
10 - Cover
12 - 5 Nm
13 - Washer
14 - Bolt
15 - Connector
16 - 5 Nm
Page 716
Part 2
Page 7634
Flywheel: Service and Repair

‹› Quantity: 5
‹› Replace
3 Bolt, 10 Nm
‹› Removal and installation, refer to => [ Sealing Flange, Belt Pulley Side ] See: Engine, Cooling
and Exhaust/Engine/Cylinder Block
Assembly/Sealing Flange, Engine Front/Service and Repair/Sealing Flange, Belt Pulley Side.
5 Cylinder Block
‹› Replace
Page 6851

Page 4677
Page 4452
Part 2
Page 6248
Ground (GND)

Service and Repair
Rain / Fog Sensor: Service and Repair
Flush-Bonded Windows
Rain Sensor
Removing
- Unclip rain sensor cover - 1 - using plastic wedge.
- Unhook clip - 1 - from retaining ring - 2 - and remove rain sensor - 3 - from windshield (light
bonding).
Installing
When installing rain sensor after replacing windshield or rain sensor, the following must be
observed:
‹› As a replacement part, windshields are supplied with retaining ring. After installing windshield,
clean glass thoroughly in area of retaining ring
using cleaning solution (D 009 401 04).
‹› It is not possible to reuse rain sensor. Replacement is supplied with adhesive already applied for
installation of rain sensor to windshield. Bonding
can be used for only one installation.
‹› To guarantee function of rain sensor, rain sensor must be bonded to windshield completely free
of bubbles.
- Remove protective cover for adhesive from new sensor.
- Connect harness connector - 4 -.

Page 7028
09G Transmission
Seals and Gaskets: Service and Repair 09G Transmission
Torque Converter Oil Seal
Torque Converter Oil Seal
‹› Extractor Lever (VW 681)
Removing
- Pry out seal using Extractor Lever (VW 681).
Installing
- Drive in seal flush using thrust piece (T10175 ).
Selector Shaft Seal
Selector Shaft Seal

Page 3000
Alignment: Description and Operation Vehicle Data Label
Vehicle Data Label
Page 568
Ground (GND)

Page 1481
WHAT ARE TRACKS?
15-28, and so on).
Page 7925
Part 2
Page 4483
Part 2
Locations

Page 7869
Page 7775
Page 4295
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5064
Ground (GND)

Canister Purge Solenoid: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6262

Page 2431
09.

Code.
Page 6589
Ground (GND)

Engine Code BPS
Injection.
replaced.
Injection.
connection.
Page 998
Page 1419
Ground (GND)

Page 2184

Page 3769
Engine Oil: Technical Service Bulletins Engine - Oils Meeting Manufacturer's Standard
17 09 07
June 30, 2009
2012855 Supersedes T.B. Group 17 Number 09-05 dated March 30, 2009 due to reorganization of
attached world wide oil specifications list to eliminate confusion.
Vehicle Information
Condition
Engine Oils Which Meet Volkswagen Oil Quality Standards VW 502 00, VW 505 01 and VW 504
00/507 00 (U.S. ONLY)
Information only.
Production Solution
Service
Attached is a Worldwide list of engine oils which currently meet Volkswagen Oil Quality Standard
VW 502 00, VW 505 01 and VW 504 00/507 00.
TIP:
SOME ENGINE OILS LISTED ON THE ATTACHMENT MAY NOT BE AVAILABLE IN NORTH
AMERICA. Please refer to the specific Vehicle Owner's Manual, published Technical Bulletins and
Fluid Capacity Charts to select the appropriate oil required for each Volkswagen vehicle.
The sample list below are products generally available in the North American market that meet
Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00 specification at
the time of this publication.
Page 1848
Part 1
A/C Pressure Switch, Checking
High Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch, Checking
A/C Pressure Switch, Checking
Visual check: Ensure that O-ring (color: red) 10.8mm x 1.8mm is seated in groove.
Switch function between contacts -T4a/1- and -T4a/2- (at connector housing) switches A/C Clutch
(N25) off whenever:
‹› excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or if
system is overcharged)
‹› insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out).
Switch function between contacts -T4a/3- and -T4a/4- (at connector housing) switches Coolant Fan
(V7) to 2nd speed when refrigerant pressure rises.
Switching conditions
‹› Contacts - 1 - and - 2 - open below 1.2 bar (17.4 psi) and closed above 2.4 bar (34.8 psi)
switching threshold
‹› Contacts- 1 - and - 2 - open above 32 bar (464 psi) and closed below 24 bar (348 psi) switching
threshold
‹› Contacts - 3 - and - 4 - closed above 16 bar (232 psi) and open below 12.5 bar (181.2 psi)
switching threshold
Switch function, checking

ABS Wheel Speed Sensor
Brake Booster Vacuum Sensor: Service and Repair ABS Wheel Speed Sensor
Front Axle
Removing
- Raise vehicle.
- Disconnect harness connector - 1 - from wheel speed sensor wire and wheel speed sensor.
- Remove bolt - 2 - from wheel bearing housing.

- Disconnect ABS wheel speed sensor from wheel bearing housing.
Installing
- Before inserting wheel speed sensor, clean inner surface of hole and coat sensor completely with
securing grease (G 000 650 ).
- Insert wheel speed sensor in hole of wheel bearing housing and tighten bolt to 8 Nm.
- Turn wheels completely to left and right stop positions and check clearance to ABS wheel speed
sensor wiring.
Rear Axle
Removing
- Raise vehicle.
- Disconnect harness connector - 1 - from wheel speed sensor wire and wheel speed sensor.
Page 1751
Brake Switch (Cruise Control): Diagnostic Aids
Page 1095
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 4698
Page 7759
Service and Repair
Shift Cable: Service and Repair
Shift Mechanism Cable Assembly Overview

‹› Lubricate bearing areas and slide surfaces with grease ( G 000 450 02).
1 Shift cable
‹› Connect with cable retainer => [ (Item 11) Cable retainer ]
‹› Installed position => [ Shift Mechanism Installation Position ] See: Shifter M/T/Service and
Repair/Removal and Replacement/Shift
Mechanism Installation Position.
2 Selector lever cable
‹› Connect with cable retainer => [ (Item 10) Cable retainer ]
‹› Installed position => [ Shift Mechanism Installation Position ] See: Shifter M/T/Service and
Repair/Removal and Replacement/Shift
Mechanism Installation Position.
3 Lock washer
4 Shift housing
5 Lock washer
‹› When removing, do not damage cables

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5695
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2702
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 166
1 - Track Numbers

Page 6066
Ground (GND)

Page 3787
Engine Oil: Fluid Type Specifications
Engine Oil Gasoline engines: Only oils meeting VW oil quality standard:
............................................................................................................................. VW502 00 Use oil
viscosity ...............................................................................................................................................
............................................................ 5W-40 if not available, 5W30 or 0W40.
Do not overfill! Overfilling engine oil can cause misfire DTCs to be stored in ECM (J220). To
prevent overfill, add approx. 0.5L less than capacity, start engine and let run until engine operating
temp is appox. 60°C (140°F), turn OFF ignition, wait approx. 3 minutes, check dipstick, then fill to
MAX. See Repair Manual for details. Turbo engines only: After changing oil and filter, start and run
engine at idle until oil pressure light goes out. DO NOT rev engine, this could cause damage/failure
of the turbocharger.
Page 7912

- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking resistance
resistance.

Page 5915
Part 2
Page 1364
Fuel Door Switch: Service and Repair
Remote Fuel Filler Door Release Switch and Remote Rear Lid Release Switch
The Remote Fuel Filler Door Release Switch (E204 ) and the Remote Rear Lid Release Switch
(E188 ) inside the driver door are a single unit and cannot be replaced separately. The entire
switch unit must be replaced.
Removing
- Remove the door trim panel on the driver side.
- Disconnect the connector on the switch.

- Press the tabs - arrows - and remove the switch housing - 1 - from the door trim panel.
Installing

Page 397
Page 1485
Part 3
Page 1421
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4267
WHAT ARE TRACKS?
15-28, and so on).
Page 1074
Function
Page 5749
Requirements:

Work procedure:
Page 7043
Page 1955
Dimmer Switch: Service and Repair
Removing

Installing

Page 7835
7 24
8 25
- End diagnosis.
Final procedures
End diagnosis.
Page 1784
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2383
- Remove nut - 1 -.
Installing


Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7823
WHAT ARE TRACKS?
15-28, and so on).
Page 56
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6276
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2022
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5184
Ground (GND)

Seat Memory Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4412
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7866
Part 2
Specifications

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1716
Part 2
Page 4828
- Remove nut - 1 -.
Installing


Page 3448
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Specifications
Technical Data
‹› 2 Replace the ECM. Refer to => [ Engine Control Module ] See: Powertrain
Management/Computers and Control Systems/Engine Control
Module/Service and Repair.

Page 1862
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5750
Removing
- Remove bolts - 4 -, - 5 - and - 6 -.
wrench - 3 -.
Page 3045
NOTE:
Specifications
Valve: Specifications
Valve Dimensions
‹› Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.
Page 4397
Active Exhaust System Actuator: Diagnostic Aids
Brake Fluid Level, Checking
Brake Fluid: Service and Repair Brake Fluid Level, Checking
Brake Fluid Level, Checking
Brake fluid level at the delivery inspection:
For the delivery inspection the fluid level must lie at the MAX. marking - 1 -.
‹› To prevent the brake fluid from overflowing from the reservoir, the level must not be over the
MAX mark.
Brake fluid level at inspection service:
Brake fluid level must always be evaluated depending on brake pad wear.
During operation of the vehicle, the brakes are automatically readjusted depending on wear of the
brake pads. Because of the adjustment, brake fluid level will be slightly lower as a result.
‹› Recommended brake fluid level when brake pad wear limit is nearly reached:
"At MIN-marking and slightly above it", "NO TOPPING OFF REQUIRED".
‹› Recommended brake fluid level when brake pads are new, or pad wear limit is not nearly
reached:
"Between MIN- and MAX-Marking".

Page 5490
Part 3
Page 3748
Part 3
Locations


Page 2755
Ground (GND)

Page 3869
Ground (GND)

Page 742
Page 2117
5 Control arm
6 Hex bolt

7 Coupling link
8 Hex nut

9 Bracket
10 Stabilizer bar
11 Connector
13 Pop rivet bolt
Page 4183
Checking wiring
Final procedures

09.

Code.
Locations
Parking Brake Warning Light Switch F9

Page 4601
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 7787
Checking
- Multimeter.
- Wiring diagram.
Requirements
- Fuse SA6 OK.
- Fuse SB28 OK.
- Fuse SC14 OK.
Test procedure
Start diagnosis
Checking voltage


Page 989
1 - Track Numbers

Page 3718
Valve Spring: Tools and Equipment Valve Spring Compressor - AST Tool # VW 541-1 A
Valve Spring Compressor
AST tool# VW 541-1 A
Valve Spring Compressor.
- Made in Germany

Page 3135
- Lay sealing ring in oil filter housing seal groove so service flag -A- is aligned toward top.
feeling above sealing ring with finger -arrows-.
- Press new oil filter insert -2- onto oil filter housing center tube -4- as far as stop.
- Install oil filter housing -4- with new sealing ring -3- and new oil filter insert -2- by hand until almost
on oil filter housing stop -1-.
- Tighten oil filter housing -2- to 25 Nm.

Installing

Page 7388
‹› Note different length of bolts:
Bolt on brackets for wiring harness - 1 - and - 2 - with new bolts hand-tight.
Tighten remaining valve body bolts - arrows -, - arrows A - and - arrows B - hand-tight.
‹› If wires - 3 -, - 5 - and - 9 - are too short to connect to sensors or to screw on at points

designated on the valve body, they have been routed
incorrectly or are jammed by the valve body. Valve body must be removed again and wires routed
correctly.
Page 5768
Page 4095
Coolant: Fluid Type Specifications
Coolant System
Type .....................................................................................................................................................
................... Phosphate-free coolant G 012 A8F A4
Color ....................................................................................................................................................
.............................................. lilac or violet (purple)
Specification ........................................................................................................................................
............................................................. TL VW 774F
Use phosphate-free coolant G 012 A8F A4 G12+ (purple), Valvoline G12 (purple) is really G12+.
Note the following mixing combinations:
G11 (green) & G12 (pink) NO G11 & Valvoline G12 OK G11 & G12+ OK G12 & Valvoline G12 OK
G11 & G12 & G12+ NO G11 & G12 & Valvoline G12 NO
Frost protection is required down to approx. -25°C (-13°F). In countries with arctic climates, frost
protection is required down to approx. -35°C (-31° F). The anti-freeze ratio must be a minimum of
40%, otherwise frost protection is reduced. The recommended mixture ratio is 50:50. If greater frost
protection is required (very cold climates), the amount of G 012 A8F A4 can be increased, but only
up to 60%. This provides frost protection to approx. -40°C (-40°F). Do not reduce the coolant
concentration by adding water, even in warmer seasons/countries, as cooling effectiveness will be
reduced.
‹› New Beetle
Page 7827
Part 3
Page 1583
WHAT ARE TRACKS?
15-28, and so on).
Page 406
WHAT ARE TRACKS?
15-28, and so on).
Page 2277
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 542
Instrument Panel Control Module: Diagnostic Aids
Page 5818
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1456
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5703
Checking wiring
terminals 1
47
3 1 and 2
4 1 and 2
5 22
7 10
8 21
9 36
- End diagnosis.
Final procedures
Page 3974
‹› Sealing surfaces must not be damaged under any circumstances. If necessary, use the (3409).
‹› After removing the chain compartment cover, clean the (3409 ) which is intended for the removal
of interior parts.
Installing
- Remove the remainder of sealant from the chain compartment cover and from the cylinder head
using a rotating plastic brush.
- Clean the coolant connection on the cylinder head, see - item 1 - in => [ Coolant Connection ]
See: Cooling System/Service and Repair/Removal and Replacement/Cooling System
Components, Engine Side. If necessary, remove coolant deposits with a copper wire brush or fine
sandpaper (minimum 100 grit). If the connection is worn, replace it using locking fluid (D 000600
A2).
- Replace the seal in the chain compartment cover. Refer to => [ Chain Compartment Cover Seal ]
See: Seals and Gaskets/Timing Cover Gasket/Service and Repair.
- Replace the seal in the coolant thermostat housing.
‹› The chain compartment cover must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - A - as shown to a clean sealing surface of chain compartment cover.
Page 1915
Ground (GND)

Page 5140
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3844
Oil Filter Adapter: Locations Oil Filter Bracket Assembly Overview

1 Bolt, 25 Nm
‹› Removing:
3 Gasket
‹› Replace

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Locations


Page 1115
Part 1
Page 5687


Page 7292
- Remove mounting bolts - 1 - and - 2 -.
- Remove transmission mount - C -.
Installing
- Install transmission mount - C -.
- Both bolts - 1 - must be replaced.
- Carefully pull up transmission to transmission mount using engine support bridge spindles.
CAUTION! Before installing the transmission bracket/transmission mounting bolts, ensure that the
bracket and mounting are absolutely parallel to one another or the threads will be damaged. Press
the transmission upward in the area of the final drive using Engine/transmission jack (V.A.G 1383 A
), if necessary.
- Bolt transmission mount to transmission plate - A - with bolts - 2 -, see tightening torques => See:
Service and Repair/Removal and Replacement/09G Transmission/Transmission.
CAUTION! Only remove engine support bridge (10 - 222 A) when bolts for left and right subframe
mounts are tightened to tightening torque.
Page 5381
Ground (GND)

Seat Belt Buckle Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3145

Page 2671
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4906
1 - Track Numbers

Page 3688
^ Only replace as set
7 - Circlip
8 - Piston pin
^ If difficult to move, heat piston to 60° C
^ Removing and installing using a Pilot Drift VW 222 A
9 - Piston
^ Mark installed position and cylinder allocation
^ Arrow on piston face points toward belt pulley side
^ Install with piston ring compressor
10 - Piston rings
^ Offset gaps by 120°
^ Use piston ring pliers for removal and installation
^ Markings face toward piston crown
Bearing shells - installed positions
Bearing shell - 2 - without oil bore for connecting rod cover. -
Place bearing shells centrally into connecting rod and connecting rod cap.
Dimension - a - must be same at left and right.
Page 5092
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 3861
following:
‹› After installing the oil pan, allow the sealant to dry for approximately 30 minutes. Only after then
may the engine oil be added.
Page 4287
Ground (GND)

Lower Oil Pan
Oil Pan: Service and Repair Lower Oil Pan
Lower Oil Pan
Removing
- Drain the engine oil.
‹› Observe disposal regulations!
- Remove the lower oil pan bolts.
- Pry off the lower oil pan at the lift out pockets provided - arrows - on the upper oil pan. Be careful
not to damage the sealing surfaces in the process.
- Replace the damaged lower oil pan.

Installing
- Remove the remainder of sealant from the upper and lower oil pans using a rotating plastic brush.
Page 2464
WHAT ARE TRACKS?
15-28, and so on).
Page 7778
Warranty
Information only.
removal.
Page 5732
strip - 2 -.
Page 5510
(MAF) Sensor (G70).
‹› Multimeter
Test requirements
Test procedure
Start diagnosis

Sensor (G70):
Page 7124
Track 1-14
named Track 1-14.
Track 169-182
reference box.

A/C - Insufficient Heater Output at Idle
Coolant Reservoir: All Technical Service Bulletins A/C - Insufficient Heater Output at Idle
Condition
80 07 05
Sept. 14, 2007
2011762 Supersedes T.B. Group 80 number 07-01 due to addition of coolant reservoir and
warranty table information change.
Customer States Heater Output is Sufficient while Driving But is Reduced When Idling
While driving heat output from HVAC will warm cabin area sufficiently when setting is at high, med,
or low, but when idling, heat output greatly diminishes.
For example, output temperature from center vent while driving is approximately 160°F (71°C), but
while sitting at idle, output temperature decreases to approximately 90°F (32°C).
May be caused by a small amount of air in cooling system.
Production Solution
Improved coolant reservoir as of VIN:
1C_7M 518233
1Y_7M416166
Service
Install improved coolant reservoir Part No. 1C0121407 E, see Repair Manual Group 19 Engine -
Cooling system, in ElsaWeb.
After installation:
^ Purge the air from coolant system using the VAS 6096 "Cooling System Charge Unit" as follows.
WARNING
Prior to working on any cooling system, always review and follow all Notes, Tips, and Warnings in
Group 19 - Engine - Cooling system.
Tip:
Illustrations used in this Bulletin are from documentation included with the VAS 6096 "Cooling
System Charge Unit".
Procedure:
^ Install the VAS 6096 onto the Cooling System using the appropriate adapters (fig. 1).
Page 5770
Checking wiring
open circuit.
Ground.
Final procedures


Page 6903
STACK:

Service and Repair
Timing Cover Gasket: Service and Repair
Chain Compartment Cover Seal
‹› Arbor (VW 195)
‹› Tube 60 mm dia. (VW 415A)
‹› Fitting sleeve (3241/4)
Conditions
‹› Chain compartment cover removed
Driving out the Seal
Driving in the Seal
- Support the chain compartment cover with supports - arrows - on a firm surface and press in the
new seal until seated.
Page 686
Relay Box: Application and ID Relay and Fuse Arrangements on Relay Panel, From July 2005
Shifter A/T: Testing and Inspection
Selector Mechanism, Checking
Starter must not be able to be operated in selector lever positions " R", "D", "S" and in Tiptronic
position.
For speeds exceeding 5 km/h and shifting into selector lever position " N", the shift lock solenoid
must not engage to lock the selector lever. Selector lever can be shifted into a driving gear.
For speeds below 5 km/h (almost standstill) and shifting into selector lever position "N", the shift
lock solenoid must only engage after approx. 1 second. Selector lever can only be shifted out of
position " N" with the brake pedal depressed.
Selector lever in position "P" and ignition switched on:
‹› Brake pedal not depressed:
Selector lever is locked and cannot be switched out of position " P". Shift lock solenoid locks
selector lever.
‹› Brake pedal depressed:
Shift lock solenoid enables selector lever. Selecting a driving gear is possible. Switch selector lever
slowly through from "P" to " S"; while doing this check whether selector lever position in instrument
cluster matches selector lever position.
Selector lever in position "N" and ignition switched on:
‹› Brake pedal not depressed:
Selector lever is locked and cannot be switched out of position " N". Shift lock solenoid locks
selector lever.
‹› Brake pedal depressed:
Shift lock solenoid enables selector lever. Selecting a driving gear is possible.
Selector lever in position "D" and ignition switched on:
‹› Move selector lever to Tiptronic gate:
The lighting under "D" symbol in the selector lever position display must go out and the "+" and "-"
symbols must light up.
The display of the selector lever position in the instrument cluster must change from "PRNDL" to
"654321" when shifting selector lever to the Tiptronic gate.
- Check and adjust selector lever cable => [ Selector Lever Cable, Checking and Adjusting ] See:
Shift Linkage/Shift Cable/Testing and Inspection.
- Check ignition key removal lock => [ Ignition Key Removal Lock, Checking Function ] See: Shift
Interlock/Testing and Inspection.
Page 6309
Memory Positioning Module: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7336
stops.

Headlamp Alignment Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3726
Drive Belt: Testing and Inspection
Ribbed Belt, Checking
- Lift vehicle.
- Remove engine compartment cover, engine side

- Remove bolt/screw - 1 -.
- Release clips - 2 -.
- Take cover out of retainers - 3 -.
NOTE: Do not reuse the clips, renew clips each time cover is removed.
- Crank engine by hand at vibration dampener/pulley - arrow -. Check ribbed belt for: -
Sub-surface cracks (cracks, core ruptures, cross sectional breaks)
- Layer separation (top layer, cord strands)
- Base break-up
- Fraying of cord strands
- Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks)
- Traces of oil and grease

Page 6755
^ Reset readiness code.
Page 3520
lamp (K32) lights up in instrument panel
Replacement.
18 Bracket
19 Bolt
Front Brakes, FN 3
operating position.
Page 3570
legend.
wiring diagram.
harness.


question.)
19 - Legend



Window Regulator Switches, Through 05.2008
Power Window Switch: Service and Repair Window Regulator Switches, Through 05.2008
Window Regulator Switches, Through 05.2008
Removing
- Disconnect the connector on the window regulator switch.
- Bend the frame outward on the long side of the switch and remove the switch.
Installing
Page 4208
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6097
Fuel Rail: Service and Repair

1 Bolt, 3.5 Nm
2 Fuel Rail
3 Fuel Supply Line
4 O-ring
‹› Replace
5 Retaining Clip
‹› Removal and installation, refer to => [ Fuel Injectors ] See: Fuel Injector/Service and Repair/Fuel
Injectors.
‹› Checking, refer to => [ Fuel Injectors, Checking Injection Quantity and for Leaks ] See: Fuel
Injector/Testing and Inspection/Fuel Injectors,
Checking Injection Quantity and For Leaks.
7 Intake Manifold
8 Protective Cap
Page 2363
strip - 2 -.
Page 4191
Ground (GND)

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3024
supply line - 2 -.
Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Testing and Inspection/Fuel
Page 3829
and Inspection.
5 from Intake Hose
Replacement.
6 Vent Hose
7 Dust Cap
9 Seal
‹› Replace
11 Gasket
‹› Replace
12 Oil Cooler
Information.
System/Diagrams.
13 Bolt, 25 Nm
15 Gasket
‹› Replace

Locations

Page 4379
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3535
Removing securing ring
Pressing out wheel bearing from wheel bearing housing
Coat entire surface with Molykote grease

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4746
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1679
Connect VAS5051 and select function.
Torque settings:
Torque settings
Page 6127
Page 2280
Part 3
Page 6291
Page 4558
Part 2
Page 1440
Part 3
Page 2776
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Engine Controls - MIL ON/DTC's P001, P000A Set
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC's P001, P000A Set
Number: PT01-07-48
Date: May 15, 2007
Subject: Updated Programming, MIL ON P0011, P000A Stored in ECM Fault Memory
Model(s): See Model Table Below
2006-2007
Condition
MIL ON, DTC P0011, P000A stored in ECM fault memory.

Model Table
Service
Tip:
The "Pass - Thru Vehicle Programming" process may overwrite any "TUNED" ECM/TCM
programming.
A "TUNED" ECM or TCM is described as any ECM or TCM altered so as to perform outside the
normal parameters and specifications approved by Volkswagen of America, Inc..
If you encounter a vehicle with a "Tuned" ECM or TCM, prior to performing the "Pass - Thru
Vehicle Programming" procedure:
Overview

1 Fuel Filter
‹› Removal and installation, refer to => [ Fuel Filter ] See: Fuel Delivery and Air Induction/Fuel
Tank/Service and Repair/Removal and
Replacement.
[ Fuel Filter Installed Position ] See: Fuel
Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement.
2 Retaining Clip

Page 2414
1 - Track Numbers

‹› Multimeter.
Test requirement
Test procedure
Start diagnosis
Precautions
00 08 04
Aug. 18, 2008
applicability.
Vehicle Information
Condition

Production Solution
N/A
Service
Oxygen sensors.
Warranty
Information only.
Page 7896


Page 5364

- Start the engine.

Page 3007
Alignment: Service and Repair
Checking Wheel Alignment
‹› The vehicle shows handling problems.
‹› Involved in an accident and components have been replaced.
‹› Axle components have been removed.
‹› Tires are worn on one side.
‹› Check suspension, wheel bearing, steering and steering linkage for excessive play and damage
‹› Tread depth difference of no more than 2 mm on an axle
‹› Tires inflated to prescribed pressure
‹› Curb weight of vehicle
Fuel tank must be full
Spare tire and vehicle tools are installed in appropriate position in vehicle
The water container for the windshield/headlight cleaning system must be full.
‹› Be sure that the sliding plates and turn tables are not touching the end stop when checking
wheel alignment
‹› Test equipment must be properly adjusted and attached to the vehicle (see equipment
manufacturer's instructions)!
If necessary, contact the manufacturer for familiarization with the proper use of the equipment.
After a certain period, wheel alignment platforms and computer equipment can lose their original
leveling setting and adjustments.
Wheel alignment platforms and wheel alignment analyzer/computer should be serviced and
calibrated at least once a year.
- Precision equipment of this type should be treated with due care and knowledge.
Vehicle Data Label
Vehicle Data Label
Page 6235
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6588
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1549
1 - Track Numbers

Page 2485
Page 2563
2 - Bolt
‹› 9 Nm
3 - Connector
Driver and Front Passenger Side Airbag Sensor In Lower B-Pillar From 05/03
Airbag
be scrapped.
Driver and Front Passenger Side Airbag Sensor in Lower B-pillar from 05/03
Removal
- Remove the side trim.
- Remove harness connector - 3 - and bolts - 2 -.

Page 6936
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5456
Page 3875
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2292
Ground.
Final procedures
09.

Code.
Page 5838
Ground (GND)

Page 2816
1 - Track Numbers

Page 388
1 - Track Numbers

Page 5817
WHAT ARE TRACKS?
15-28, and so on).
Page 3698
Deviation from nominal size ................................................................................................................

....................................................... max. 0.08 mm
Engine Controls - Exhaust Noise/DTC's P0011/P000A
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls -
Exhaust Noise/DTC's P0011/P000A
01 07 57
August 24, 2007
2015972 Supersedes;
^ Technical Bulletin 2013355 - CD part number W42SWUP0011

^ Technical Bulletin 2013222 - CD part number W420506JETTAEXH
^ Technical Bulletin 2011742 - CD part number W42COLDSTARTEX
^ Technical Bulletin 2012640 - CD part number W42MILP2097
Vehicle Information
Condition
Note:
Purge CD's associated with the above listed technical bulletins.
Update Programming for ECM part number beginning with "07K"
Updated ECM software resolving various powertrain concerns.
Note:
Prior to performing Update Programming, please inform the customer that this software update
addresses all of the concerns listed above. Once the Control Module programming is complete, the
module cannot be returned to its original state. Please inform the customer that their concern
addressed by this technical bulletin will not be resolved without this software update. Do not
perform Update Programming if the customer does not
Page 5500
Page 7699
Warranty

Page 1448
1 - Track Numbers

Page 6943
Fluid - A/T: Fluid Type Specifications
Planetary gearbox Lubricant ................................................................................................................

.................................................................................................. VW ATF Part number .......................
..............................................................................................................................................................
....................... G 052 162
Final drive Lubricant ............................................................................................................................

................................................... SAE 75w-90 Synthetic Gear oil Part number ..................................
..............................................................................................................................................................
............ G 052 145
Planetary gearbox and final drive Lubricant ........................................................................................

............................................................................................................................ DSG oil
Lubricant ..............................................................................................................................................
.......................................................... ATF G 055 025
Crankshaft Seal, Transmission Side
Crankshaft Main Bearing Seal: Service and Repair Crankshaft Seal, Transmission Side
Crankshaft Seal, Transmission Side
‹› Assembly tool (T10122)
‹› Pulling hook (T20143)
Removing
- Remove the transmission.
- Lock the crankshaft. Refer to => [ Crankshaft, Locking ] See: Cylinder Block
Assembly/Crankshaft/Service and Repair/Procedures/Crankshaft, Locking.
- Pull out the seal using (T20143/2).
Do not damage the crankshaft sealing surface when doing this.
Installing
‹› Do not additionally oil or grease the sealing lip of the oil seal!
- Clean the sealing surfaces. They must be free of oil and grease.
- Before installing, remove any remaining oil from the end of the crankshaft with a clean cloth.
- Insert the (T10122/1) onto the (T10122/2 ) and slide the seal - A - onto the (T10122/2 ).
Page 1765
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3543
- Install brake disc.
- Drive in dust cap.
‹› Always replace dust caps.
‹› Damaged dust caps allow moisture to enter. Therefore, always use the tool shown.

Page 7305
Part 3
Page 3071
Conditions
Locations


Page 1750
Page 65
WHAT ARE TRACKS?
15-28, and so on).
Page 1222
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
38 08 01
Oct. 16, 2008
2018720
Vehicle Information
Condition
DTC Description

switch.
Production Solution
Service
(GFF) test plan.

Page 3879
pressure.
‹› => [ Oil Pump, through MY 2007 ] See: Oil Pump/Service and Repair/Oil Pump, Through MY
2007.
‹› => [ Oil Pump, from MY 2008 ] See: Oil Pump/Service and Repair/Oil Pump, From MY 2008.

Page 1426
Page 2506
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 2107
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 3624
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet

Page 6431
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking wiring
open circuit.
Page 1117
Part 3
Page 7150
Page 5856

Page 5066
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3036

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 7130
Page 3962
Chain Assembly Overview.
6 Timing Chain
‹› Removing:
- Work procedure same as for "Adjust valve timing". Refer to => [ Valve Timing, Adjusting ] See:
Cylinder Head Assembly/Adjustments.
- Remove the vacuum pump. Refer to => [ Brake Booster Vacuum Pump ] See: Brakes and
Traction Control/Power Brake Assist/Vacuum Pump/Service and Repair/Brake Booster Vacuum
Pump.
- Mark direction of travel.
‹› Note when installing:
- Install in original direction of rotation.
- Chain must lie correctly in the tensioning and guide rails.
7 Strainer
‹› Replace
8 Bolt, 10 Nm
‹› Secure with locking pin (T03006).
10 Gasket
‹› Replace
‹› Replace
‹› Replace
Page 3779
Lo-NI
Page 4563
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 3105
- Remove screws - arrows -.
- Lift right plenum panel cover - 1 - and remove from clips at front and rear edge.
- Pull cover - 1 - toward center of vehicle and out of retainer in A-pillar to remove.
- Remove screws - arrows - and remove right closeout panel - 1 -.
- Remove rubber grommet - 1 -.

Page 4018

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 222
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6840
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 820
Page 1795
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1433
1 - Track Numbers

Page 6467
Part 1
Page 4085
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
ATF Level
Fluid - A/T: Testing and Inspection ATF Level
ATF Level
Observe these notes as well.
‹› About this workshop manual => [ General Repair Information ] See: Description and
Operation/09G Transmission/General Repair Information
‹› About ATF => [ Automatic Transmission Fluid ] See: Description and Operation/09G
Transmission/Automatic Transmission Fluid
‹› About "filler tube" => [ Transmissions with and without
filler tube ] See: Description and Operation/09G Transmission/Transmission
If ATF must be added, use only ATF listed in.
Outer CV Joint
Constant Velocity Joint: Service and Repair Outer CV Joint
Outer CV Joint
In order to replace the grease in case of strong contamination, joint must be disassembled or if the
journal surface of the balls must be checked for wear and damage.
Removing
- Mark position of ball hub to ball cage and to housing before disassembling, using a scribe or
grindstone.
- Swing ball hub and ball cage.
- Remove balls in sequence.
- Turn cage, until the two rectangular windows - arrow - contact joint body.
- Lift out cage with hub.
- Swing segment of hub into the rectangular window of cage.
- Fold hub out from cage.
The 6 balls for each joint belong to a tolerance group. Check stab axle, hub, cage and balls for
small depressions (pitting buildup) and chafing. Excessive circumferential backlash in joint makes
itself noticed via tip-in shock, in such cases the joint should be replaced. Flattening and running
marks of the balls are no reason to replace the joint.
Installing
- Press in half of the total grease amount into the joint body.
Page 7020
plan)
TCM.
Warranty
Information only.
Page 1650
Ground (GND)

Page 7146
Part 2
Page 1968
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5004
NOTE:
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5280
‹› Multimeter.
Test requirements
Function
Test procedure
Start diagnosis
- Start the engine.

misdiagnosis.
Clutch Release Mechanism Assembly Overview
Clutch Release Bearing: Service and Repair Clutch Release Mechanism Assembly Overview
Clutch Release Mechanism Assembly Overview

1 Transmission
2 Ball stud, 25 Nm
3 Seal for input shaft
‹› Replace => [ (Item 12) Guide sleeve ] See: Manual Transmission/Transaxle/Service and
Repair/Removal and Replacement/Transmission and
Clutch Housing Assembly Overview
4 Guide sleeve
‹› With vulcanized O-ring
‹› If O-ring is damaged, replace O-ring and guide sleeve together
‹› Lubricate guide sleeve with MoS2 grease in area of release bearing
5 Retaining spring
‹› Secure to clutch release lever
6 Securing bolt, 20 Nm
7 Clutch release lever

Page 4916
Page 5897
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
30) to Ground.

Engine Code BPS
‹› Observe safety precautions. Refer to => [ Safety Precautions ] See: Fuel Delivery and Air
Induction/Service Precautions/Safety

replaced.
‹› Observe the safety precautions. Refer to => [ Safety Precautions ] See: Fuel Delivery and Air
Induction/Service Precautions/Safety
connection.
Page 2809
Page 2538
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 638
Part 1
Page 5410
Ground (GND)

Page 6082
1318).
disconnected.
Check Valve, Checking ] See: Testing and Inspection/Fuel Pump Checking, Engine Code BPS
(Plastic Fuel Tank).
and Operation.
Page 540
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 330
Part 2
Page 1767
Clutch Switch: Diagnostic Aids
Passive Occupant Detection System (PODS) Underside
Assembly Overview, USA
Seat Occupant Sensor: Service and Repair Passive Occupant Detection System (PODS)
Underside Assembly Overview, USA
Airbag
Passive Occupant Detection System (PODS) Underside Assembly Overview, USA
1 - Pressure Transfer Hose
2 - Passenger Occupant Detection System Pressure Sensor (G452)
3 - Passenger Occupant Detection System Pressure Sensor (G452) harness connector
‹› Do not disconnect.
4 - Passenger Occupant Detection System Seat Belt Force Sensor (G453) harness connector
‹› Do not disconnect.
5 - Passenger Occupant Detection System Control Module (J706)
6 - Seat Frame
7 - Connector
8 - Passenger Occupant Detection System Seat Belt Force Sensor (G453) Harness Connector
Page 6381
Note
Production Solution
Service
Procedure
Note
bulletin.
Page 127
Ground (GND)

Page 5844
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5397
Control Modules
‹› Body

Page 4859
1 - Track Numbers

Seat Occupant Classification Module - Air Bag: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1584
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4784
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1967
Part 3
Page 6519
Part 1
Page 2278
Part 1
Page 3465
Part 2
Locations

Page 5099
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7199
Shift Interlock Cable: Service and Repair
Locking Cable
Removing
- Place selector lever in position "P".
- Remove driver's side airbag unit and steering wheel.
- Remove left trim below instrument panel.
- Remove steering column trim.
- Remove bolts - 1 - from handle for steering column height and longitudinal adjustment - 2 -.
- Switch ignition key to driving position (ignition on).
- Pull out clip - 2 - of locking cable - 3 -.

Page 6129
Fuel Gauge Sender: Service Precautions
Safety Precautions
connection.

components.
Module DTC Memory, Checking and Erasing ] See: Computers and Control Systems/Engine
Control Module/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes.
Page 3222
- Start engine.
- Raise vehicle.
- Press ->.
If a test temperature between 35 °C and 45 °C is displayed:
- Install new seal to plug and tighten to 15 Nm. This completes the ATF check.
If no ATF drips out of inspection hole:

Page 348
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7557
Page 5189
Part 3
Page 3931
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 64
Ground (GND)

Fuel Injector: Service and Repair Fuel Rail and Injectors Assembly Overview

1 Bolt, 3.5 Nm
2 Fuel Rail
3 Fuel Supply Line
4 O-ring
‹› Replace
5 Retaining Clip
‹› Removal and installation, refer to => [ Fuel Injectors ] See: Fuel Injectors.
‹› Checking, refer to => [ Fuel Injectors, Checking Injection Quantity and for Leaks ] See: Testing
and Inspection/Fuel Injectors, Checking
Injection Quantity and For Leaks.
7 Intake Manifold
Page 1119
Page 4080
WHAT ARE TRACKS?
15-28, and so on).
Page 1923
Superheat Switch: Diagnostic Aids
Page 4137
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 168
Ground (GND)

Page 7404
Page 6953
- With engine running, install adapter for filling oil VAS 6262/2 hand-tight.
- Add 1 l of ATF.
- Pull off adapter for oil filling VAS 6262 at quick-release connection and check:

Drain ATF until it drips.
If no ATF drips out: -
Add another liter.
CAUTION: An ATF level which is too low or too high will impair the function of the transmission. But
if the transmission was 2 liters low, it must be carefully inspected. There is probably a major leak.
Draining and Filling ATF
Draining and Filling ATF, 09G, 6 Speed A/T

Power Mirror Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6016
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1990
‹› Checking, refer to => [ Switch Over Valve Checking ].
8 O-ring
9 to Evaporative Emission (EVAP) Canister
10 from EVAP Canister
11 Wiring Router
‹› In the longitudinal member.
12 Vent Line
‹› Secure with spring type clips.
13 Bolt, 10 Nm
14 Protective Plate
15 Fuel Tank
‹› Support using the engine and transmission jack (VAG 1383A) when removing.
‹› Removal and installation, refer to => [ Fuel Tank ] See: Powertrain Management/Fuel Delivery
16 Heat Shield
‹› For the fuel tank.
17 Lock Washer
18 Cover for Fuel Tank
‹› Replace
20 Securing Strap
‹› Observe the varying lengths.
‹› Installed position: Locating point (hole) points in the driving direction.
21 Fuel Filter
‹› Installed position: Arrow points in direction of flow.
‹› Assembly overview, refer to => [ Fuel Filter Assembly Overview ].
22 Supply Line
‹› Black
‹› To disconnect from the fuel filter, press in the securing ring on the connecting piece.
Page 4587
Page 6662
stops.

Page 3380
Fuse Arrangements In Fuse Bracket/Battery - Description
Page 112
Ground (GND)

Stored
Condition

May be caused by:
Malfunctioning ECM.
Production Solution
Not Applicable.
Service
Warranty
Information only.
Page 4150
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6884

Page 6790
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1026
Part 2
Page 973
1 - Track Numbers

Page 7609
Wheel Bearing: Service and Repair Rear Suspension
‹› Grease cap puller (VW 637/2)
‹› Seal installer (3241)
‹› Installation sleeve wheel brg. (3420)

Removing
- Raise vehicle.
- Remove wheel.
Loosen dust cap from seat by tapping lightly on claw of grease cap puller (VW 637/2).
- Pull off dust cap.

Page 7922
WHAT ARE TRACKS?
15-28, and so on).
Page 2372
Part 2
ABS Light Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 6372
Page 5628
Part 2
Page 4362
- Carefully lower the engine with transmission only as far downward - arrow 2 - until pin - 4 - of
transmission mount bracket can be slid toward the left - arrow 3 - out from under the transmission
mount.
- Slide the engine/transmission assembly until it stops at left longitudinal member.
- Rotate the pulley so that arrow - A - (relative to engine axis) points upward vertically.
- Remove the coolant pump bolts - arrows -.
- Pull the coolant pump - A - out of the cylinder block.

Page 2547
Air Bag Deactivation Switch: Diagnostic Aids
Page 5329
Part 1
Page 1675
- Remove screw - arrow - (hidden under a cover cap) from glove box - 1 -.
- Remove 4 screws - 1 -.
- Unclip trim - 2 - at top and take off instrument panel.
- Remove the six screws - 3-.
- Remove impact plate - 4 -.
Location: The sender for rotation rate G202 - 1 - and the sensor for transverse acceleration G200 -
2 - are secured to a bearing bracket on the steering column - 3-. a - Steering column
- Pull connector - arrows - off sender for rotation rate G202 and pull connector off sensor for
transverse acceleration G200.
- Remove bolt - 1 - and remove sender for rotation rate G202 and sensor for transverse
acceleration G200.
Removing sender for rotation rate G202

Page 2081
1 - Track Numbers

Page 5675

Page 6605
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3808
^ Locate the upper cap portion index mark.
^ Position the lower cap so that the molded parallel lines (black arrows) align with the handle of the
top portion, and the top piece index mark rests between the parallel lines.
^ Align the upper portion of the cap over the lower portion and press firmly together.
Tip:
The oil filler cap will not be damaged during this action and will operate as designed.
Warranty
N/A information only
No special tools required
No special parts required

Page 2746
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 6194
Installing
Service and Repair
Tire Inflator Bottle: Service and Repair
Tire Repair Kit, Checking
The tire repair kit is located in the spare wheel well - arrow -
In addition to the compressor, the tire repair kit contains a tire inflation cylinder with sealant.
‹› The tire sealant in the bottle has a limited shelf-life.
‹› Therefore, on the bottle, the expiration date - arrow - is displayed.
In this example, the expiration date 05/2003 has passed, and the bottle must then be replaced.
- Verify the expiration date.
- Replace tire sealant, if expiration date has been reached.
CAUTION! ‹› Tire sealant must not be older than 4 years.
‹› If the bottle was opened, e.g. for a flat tire, it must also be replaced.
‹› Residual tire sealant or full bottles, which have expired, must be disposed of.
‹› Old tire sealant or remainder of it must not be mixed with other fluids and must be disposed of.
Page 1242
A RR - Outer Right B RRC - Right Center C LRC - Left Center D LR - Outer Left
‹› When installing the sensor, make sure the coupling ring (black silicone ring) is mounted on the
sensor head correctly and that it does not fall off or
become jammed when inserting into the sensor bracket.
‹› Both retaining tabs on the sensor must engage audibly in the sensor bracket when installing.
- Make sure the sensor is seated correctly in the bracket after installing. Dimension - a - for the
circular gap between the sensor head and sensor bracket must be even all around on the outer
side of the bumper cover.
Page 3878
540/1A) and a M8 x 100 bolt - A -.
switch.
Page 4433
Service
Any evidence of heat shield damage described in the Technical Background section of this bulletin
will require replacement of the heat shield. See Repair Manual Group 26 Exhaust system,
Emission controls in ElsaWeb.
Warranty
Information only.
No Special Parts Required.
No Special Tools Required.
Page 7945
Part 3
Page 4806

Page 6596
Page 7276
Torque Converter: Removal and Replacement
Table of Contents
=> [ Torque Converter Oil Seal ] See: Seals and Gaskets/Service and Repair/09G
Transmission/Torque Converter Oil Seal
=> [ Torque Converter, Installing ] See: Torque Converter, Installing
Torque Converter Assembly Overview
Torque Converter Assembly Overview
1 Torque converter
‹› Secure torque converter on removed transmission to keep it from falling out => [ Transmission,
Transporting ] See: Service and
Repair/Procedures/09G Transmission/Transmission, Transporting
‹› Installing => [ Torque Converter, Installing ] See: Torque Converter, Installing
‹› Installation dimension => [ Torque Converter Installation Dimension, Checking ] See:

Procedures/Torque Converter Installation Dimension,
Checking
2 Oil seal
‹› Replace => [ Torque Converter Oil Seal ] See: Seals and Gaskets/Service and Repair/09G
Transmission/Torque Converter Oil Seal
Torque Converter, Installing

Page 1402
1 - Track Numbers

Page 1346
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2931
1 - Track Numbers

Page 6606
Ground (GND)

Page 4874
Page 6047
- Connect terminals - 4 - of the connector and fuel pump using an adapter cable from (VAG
1594C).
‹› This step allows the fuel pump to run when the engine is not running.
- Check the injectors for leaks (visual inspection).
‹› Only 1 to 2 drops per minute may emit from each injector when the fuel pump is running.
If the fuel loss is greater:
- Disconnect the connection to the battery positive (+) and replace the leaking fuel injector. Refer to
=> [ Fuel Injectors ] See: Service and Repair/Fuel Injectors.
‹› If the fuel injectors are replaced, erase the adaptation values and adapt the Engine Control
Module (ECM) again. Refer to vehicle diagnosis,
testing and information system "Guided Functions".
‹› Always use new seals.
Injection Quantity, Checking
‹› Fuel pressure must be OK, checking. Refer to => [ Fuel Pressure Regulator and Residual
Pressure Checking, Engine Code BPS ] See: Fuel
Pressure/Testing and Inspection/Fuel Pressure Regulator and Residual Pressure Checking,

Engine Code BPS.
‹› Fuel rail is removed.
‹› Fuel injectors installed in the fuel rail and fuel line connected.
‹› Fuel pump runs (connected to battery with adapter cables)
- Place a fuel injector to be tested into a graduated measuring glass from (VAG 1602).
- Using the adapter cables from (VAG 1594C), connect one terminal of the injector to be checked
to engine ground (GND).
Page 2959
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5185
WHAT ARE TRACKS?
15-28, and so on).
Page 4105
General Diagnostics.
6 Intake Manifold
‹› Connection only for coolant heated throttle valve control module.
8 Quick Release Coupling
9 Heater Core
‹› Replace coolant after replacing.
10 Transmission Oil Cooler
‹› Only for vehicles with a automatic transmission.
11 Coolant Line
12 Coolant Distribution Housing

Page 4305
1 - Track Numbers

Page 7946
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 7407
Warranty
Information only.
removal.
Page 1151
Part 3
Page 4651
Ground (GND)

Specifications
Piston: Specifications
Piston and Cylinder Dimensions
‹› 1 Measurement does not include graphite coating (thickness = 0.02 mm). The graphite coating
wears off.
Page 6081
supply line - 2 -.
and Operation.
Testing and Inspection/Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank).
Page 7322
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 6265
Page 5558
Page 5898
- Start the engine.
If the LED was ON:
Checking wiring

Page 6318
Installing
Page 4337
Ground (GND)

Page 6041
Fuel Injector: Diagnostic Aids
Page 1642
Right Rear ABS Whel Speed Sensor G44

Page 1614
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Service Precautions
Relay Box: Service Precautions
Locations

Page 5354

Page 5816
Ground (GND)

Page 5557
Page 2233
Page 7154
Requirements:

Work procedure:
Page 2416
Ground (GND)

Page 5576
Page 1501
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 167
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 1199
Part 1
Page 1021
legend.
wiring diagram.
harness.


question.)
19 - Legend



Brake Fluid Pump Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 5143
Part 3
Page 1312
Removing
- Loosen the switch housing - arrow - from the frame with a screwdriver and then remove it.
Installing

Page 1575
Brake Fluid Pressure Sensor/Switch: Diagnostic Aids
Page 7203
- Install steering wheel and airbag.
- Code radio.

Page 5075
2.
Checking wiring

Page 6314
stop:
Checking resistance
Page 3620
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Locations

1 Intake Tube
2 Spring Type Clip
4 O-ring
‹› Replace
5 Bolt, 2 Nm
7 Bolt, 2 Nm
8 Filter Element
9 Air Duct
10 Bolt, 8 Nm
Page 1892
Page 5959
Part 2
Page 1065
Page 6281
Page 701
Installing

Owner's Manual
General Information
Page 4309
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3847
and Inspection.
5 from Intake Hose
Replacement.
6 Vent Hose
7 Dust Cap
9 Seal
‹› Replace
11 Gasket
‹› Replace
12 Oil Cooler
Information.
System/Diagrams.
13 Bolt, 25 Nm
15 Gasket
‹› Replace
Page 4985
‹› Multimeter.
Test conditions
Test procedure
Start diagnosis
pressure.

Auxiliary Heater Element Relay: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1066
Tip:
Page 7198
- Remove adjusting gauge.
- The function of ignition key removal lock must be checked => [ Ignition Key Removal Lock,
Checking Function ] See: Testing and Inspection.
Page 3884
Engine Oil Pressure: Testing and Inspection
540/1A) and a M8 x 100 bolt - A -.
switch.
Page 995
Part 2
Page 4065
- Remove the pendulum support bolts - arrows -.
540/1 A) and a M8 x 100 bolt - A -.
- Empty the power steering reservoir using (VAG 1782) and remove it.
- Remove the bracket nuts - 2 - for the power steering reservoir.

Page 190
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5190
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 4956
Page 6982
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 7507
of burnt clutches.

Page 3745
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Locations
Ambient Temperature Switch F38

Page 5993
No special tools required.
Page 4574
Final procedures

Central Control Module: Customer Interest Body - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

Page 834
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 6804
Installing

37 07 17
Aug. 9, 2007
2015855
Vehicle Information
Condition

Production Solution
Service

Locations

Page 5183
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 6150
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 1013
Page 4426
- Replace if damaged
Installation position of double clamp
- Align double clamp - 1 - to marking on catalytic converter - 2 -.
- - a - = 5 mm
Mounting bolts must not project beyond lower edge of double clamp.
Page 1052
Page 1114
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 4622

Page 6756
Warranty
removal.
Page 1478
1 - Track Numbers

Page 6788
Ground (GND)

Specifications
Fuel Pressure
At idle speed ........................................................................................................................................

....................................................................................................................................... at least 3.0
bar
Page 7591
8 Concealment cap
‹› Remove
10 Ribbed bolt w/washer assembly, 125 Nm
14 Cover plate
15 Hex bolt, 10 Nm
16 Wheel bearing
17 Circlip
19 Brake pads
lamp ( K32) lights up in instrument panel
Replacement.
21 Bracket
Installing

Page 7704
Fluid - M/T: Service and Repair
Gear Oil, Checking and Filling
Checking gear oil level using the familiar method is no longer possible.
Engine/transmission inclination was changed
Lower edge of filler hole - arrow 1 - is therefore located beneath new oil level - arrow 2 -.
Gear oil level can only be checked if gear oil is drained completely and then filled up again:
‹› Hose (approximately 600 mm long, outside diameter 10 mm) with commercially available funnel
Preparation
- Remove battery and battery tray.
- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.
Page 2552
Crash Sensor For Side Airbag, Passenger Side G180

Page 4766
Final procedures

Page 3353
Fuse: Locations Relay and Fuse Arrangements on Relay Panel, From July 2005
Page 1633
Part 2
Page 3533
- Put wheel bearing - 1 - , pressure piece - 2 - (put collar into bearing), and hollow piston cylinder -
3 - with tie bolt on wheel bearing housing.
nut - 5 -.
1. Wheel bearing 2. Thrust piece E-13-1 3. Hollow piston cylinder HKZ-15 4. Thrust piece E-10 5.
Special nut E-8-214 and tie bolt
Pressing in wheel hub
1. Wheel hub 2. Hollow piston cylinder HKZ-15 3. Thrust piece E-5 4. Special nut E-8-214 and tie
bolt
Installation is in reverse order of removal. Note the following: -
Tighten bolts for control arm and ball joint on to old marks.
- Install wheel and tighten.

Page 7957
- Install selector lever handle => [ Selector Lever Handle ] See: Automatic
Transmission/Transaxle/Shifter A/T/Service and Repair/Removal and Replacement/Selector Lever
Handle.
- Check selector mechanism => [ Selector Mechanism, Checking ] See: Automatic

Transmission/Transaxle/Shifter A/T/Testing and Inspection.

Page 3279
Sh-SW
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 3973
- Disconnect connectors - 1 and 3 -.
- Disconnect the pressure pipe - 2 - from the Secondary Air Injection (AIR) valve.
- Remove the rear coolant pipe - 4 -.
- Disconnect the vacuum hose - 6 - from the vacuum pump and disconnect the connector - 7 -.
- Remove the brackets - 8 and 9 - and set the wiring harness with pressure pipe aside.
- Press the bracket for the knock sensor wiring harness at the AIR valve slightly toward the rear.
- Remove the coolant distribution housing - 5 - and set it aside with the coolant hoses connected.
- Remove all the bolts for the chain compartment cover.
- Pry off the chain compartment cover - 1 - uniformly from the cylinder head - 2 - at the top and
bottom recesses.
Page 3469
Page 7811
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 1235
Part 2
Page 6686
5 38
6 50
- End diagnosis.
Final procedures
End diagnosis.
Page 1803
Page 5758
1 - Track Numbers

Page 2906

Page 1883
1 - Track Numbers

Page 6478
Shift Lock Solenoid
Removing
Board ] See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service
and Repair/Removal and Replacement/Selector Mechanism Cover and Circuit Board.
- Raise vehicle.

Page 4446
1 - Track Numbers

Page 7850
Parking Assist Distance Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 2695
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 3061

Locations


Page 4395
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 41
If no apparent connection problems:
- Replace amplifier.
If concern is poor FM reception:
- Disconnect all amplifiers, tune radio to high-powered station for your area.
- Connect amplifiers one at a time.
If reception is indicated:
- Disconnect that amplifier and move on to next amplifier.
If at any point in reconnecting amplifiers there is a loss in reception and there are no connection
issues:
- Replace that amplifier and check again.
If there is no reception change when disconnecting and reconnecting all amplifiers:
- Replace diversity/antenna selection box.
Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast)
- Check connections at antenna base.
- Check for corrosion at mounting.
If corrosion is found:
- Clean mount and apply anti-seize gel to mounting.
If concern is no AM and/or little or poor AM/FM reception,
- Replace antenna base.
Section 4- Antenna cables

If antenna cables are required:
- Antenna cables - single DIN (Premium V) radio.

Page 866
O1-A302 "PASSENGER AIRBAG OFF" indicator will continue to operate properly during this fault.
During the ignition cycles following the occurrence, the status light indicated the occupant status of
the passenger seat properly.
After switching ignition ON, Airbag Monitoring indicator light stays illuminated and DTC 02511 014
"Seat Occupied Recognition Control Module Fault" is stored in DTC memory.
Production Solution
Update Programming.
Service
Prior to performing the following procedure:

Locations
Clutch Pedal Position (CPP) Switch F194

Page 5335
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Checking voltage
terminals.


Page 7433
Wiring Harness: Service and Repair Wiring Harness With 8-Pin Connector
Wiring Harness with 8-Pin Connector

Removing
- Disconnect connectors from hydraulic pressure sensors - 1 - and - 4 -.
- Disconnect harness connectors - 2 - and - 5 -.
‹› If harness connector is damaged, wiring harness or Transmission Input Speed (RPM) Sensor
(G182) or Transmission Output Speed (RPM) Sensor
( G195) must be replaced.
Sunroof / Moonroof Module: Customer Interest Body - Sunroof Malfunctions or is Inoperative

60 07 06
June 19, 2007

Page 2148
1 - Track Numbers

Page 451
Control Module HVAC: Diagnostic Aids
Page 4154
Part 1
Page 3862
Oil Pan: Tools and Equipment
Hex Ball Socket
AST tool# T 10058
Hex ball socket with 5mm tip.
- Applicable to: VW/Audi Oil Pan Bolts
- Made in Germany

Braking Sensor/Switch: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 4912
Part 2
Page 2922
Part 3
G182, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking wiring
Page 6237
Part 2
Page 2274
legend.
wiring diagram.
harness.


question.)
19 - Legend



Power Seat Motor Position Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Timing Chain: Service and Repair Timing and Oil Pump Drive Chain Overview

‹› At the top with a sliding insert.
3 Timing Chain
4 Tensioning Rail
5 Oil Pump Drive Chain Tensioner
‹› With tensioning rail.
6 Crankshaft Sprocket
‹› Part of the crankshaft.
‹› Secured to the upper oil pan.

Page 570
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 7697
Tip:
Tip:
Page 191
Page 227
Part 2
Replacement
ECM Replacement
01 07 54
July 10, 2007
2011168
Condition
Vehicle Information
Diagnostic aid.
Production Solution
Service

Page 7592
22 Bolt
G182, Checking
- Multimeter
- Wiring diagram
Requirements
Test procedure
Start diagnosis
Checking wiring
Page 130
Part 1
Page 6681

Page 7291
‹› The right adapter (10 - 222 A /3) with tension belt (T10038) must not be used.
Continued for all vehicles
- Remove bolts - 2 - in order to loosen transmission bracket - A - from transmission mount.
- Remove cover from cable channel - A -.
- Set aside wiring harness - B - in order to reach mounting bolts - 1 - and - 2 -.

Page 7813
Page 81
Condition
Page 3993
Checking wiring
open circuit.
Ground.
Final procedures

09.

Code.
Page 3415
HID Headlamp
Headlamp Alignment Sensor: Service and Repair HID Headlamp
Left Front Level Control System Sensor
HID Headlamp
Left Front Level Control System Sensor
Removing
- Turn the steering so far to the left until the limit stop.
- Loosen the nuts - arrows -.
- Remove the Left Front Level Control System Sensor (G78) and bracket.
- Disconnect the connector.
Installing
- After the installation, the Left Front Level Control System Sensor (G78) must be adjusted.
Left Rear Level Control System Sensor
HID Headlamp
Left Rear Level Control System Sensor

Removing
- Loosen the nuts - arrows -.

Page 5072
Page 5633
‹› Multimeter.
Test conditions
Function test
(G71) at idle:
- Erase the DTC. Generate readiness code. Refer to => [ Readiness Code ] See: Testing and
Test sequence

Checking wiring

Page 879
O1-A302 "PASSENGER AIRBAG OFF" indicator will continue to operate properly during this fault.
During the ignition cycles following the occurrence, the status light indicated the occupant status of
the passenger seat properly.
After switching ignition ON, Airbag Monitoring indicator light stays illuminated and DTC 02511 014
"Seat Occupied Recognition Control Module Fault" is stored in DTC memory.
Production Solution
Update Programming.
Service
Prior to performing the following procedure:

Page 4380
Page 7730
5 Bushing
6 Seal
‹› Pry out with screwdriver
‹› Installing => [ Drive in sealing ring to stop. ] See: Service and Repair/Overhaul/Shift Mechanism
7 Hex nut, 23 Nm
‹› Self-locking
8 Transmission shift lever
‹› Insert so that master spline aligns with shift rod
‹› Can be replaced with shift mechanism installed
Lever/Actuator Lever ] See: Shift Linkage/Shift Cable/Service and Repair
9 Cap
‹› For transmission breather
10 Lock washer
11 Sealing cap
12 Spring
‹› Not installed in all transmissions
‹› Reinstall if present
Boot, Disconnecting From Shift Lever and Installing on Shift Knob
Boot, Disconnecting from Shift Lever and Installing on Shift Knob
‹› Hose clamp pliers (V.A.G 1275)
- Turn inner side of cover toward outside.
- Carefully press off clamping sleeve - arrows - using a screwdriver, while doing so pull off shift
knob.
Page 1371
1 - Track Numbers

ATF Level
Fluid - A/T: Testing and Inspection ATF Level
ATF Level
Observe these notes as well.
‹› About this workshop manual => [ General Repair Information ] See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Description
and Operation/09G Transmission/General Repair Information
‹› About ATF => [ Automatic Transmission Fluid ] See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Description and
Operation/09G Transmission/Automatic Transmission Fluid
‹› About "filler tube" => [ Transmissions with and without
filler tube ] See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and

Operation/09G Transmission/Transmission
If ATF must be added, use only ATF listed in.
Page 51
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 3876
Page 4048
Installing
audibly.

Page 7265
- Raise vehicle.

Page 7126
Part 2
Page 713
WHAT ARE TRACKS?
15-28, and so on).
Ride Height Sensor: Diagram Information and Instructions
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Page 7102
Ground (GND)

-G195-
Page 5388
Page 1277
1 - Track Numbers

Page 4819
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 2021
WHAT ARE TRACKS?
15-28, and so on).
Heater
Heater
‹› Multimeter.
Test requirements
Test procedure
Start diagnosis
Page 4082
Part 1
Page 7670
‹› Installed location => [ Installation position of thrust washer for
tapered ring ] See: Overhaul/Differential
16 Tapered ring
‹› With grooves to engage thrust washer
‹› Installation location: Taper toward differential housing
17 Circlip
‹› Holds tapered ring, thrust washer and compression spring in position with flanged shaft removed
18 Thrust washer union
‹› Install coated with gear oil
‹› On some transmissions, the thrust washer union was made with a ridge => [ On some
transmissions the thrust washer union
was made with a ridge in area of holes. ] See: Overhaul/Differential
19 Large differential bevel gear
‹› Installing => [ Installing differential planetary gears ] See: Overhaul/Differential
20 Threaded piece
21 Differential bevel gear axle
‹› Driving out using drift
22 Roll pin
‹› For securing axle for differential bevel gears
‹› Removing and installing => [ Removing and installing roll pin for differential
bevel gear axle ] See: Overhaul/Differential
23 Small differential bevel gear
24 Large differential bevel gear

Page 4736
‹› Multimeter.
Test requirements
Nm.
Test procedure
Start diagnosis

Checking wiring
Page 1251
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Page 5298
Part 3
Fuse Block: Service and Repair Left Instrument Panel Fuse Holder
Connecting.
Connecting.
CAUTION! ‹› When removing and installing components in visible area (switches, covers, trim,
etc.), cover by taping the areas at which a prying
Removing
- Carefully pry out the side covers from the instrument panel.
- Remove the screws - 1 - and remove the fuse panel - 2 -.
Installing
- Tighten the screw to 3 Nm.
Current fuse assignments.

Page 2092
Hazard Warning Switch: Service and Repair
Emergency Flasher Switch and Front Passenger Airbag Disabled Indicator Lamp, From 06.2003
CAUTION! Follow the safety precautions when working on the airbags.
Removing
- Remove the center trim in the instrument panel.
- Loosen the connectors - arrows -.
- Remove the switch in - direction of arrow -.
Installing
Alignment: Service and Repair Checking Wheel Alignment
‹› The vehicle shows handling problems.
‹› Involved in an accident and components have been replaced.
‹› Axle components have been removed.
‹› Tires are worn on one side.

Page 229
Ground (GND)
ws = white
sw = black
ro = red
br = brown
gn = green
bl = blue
gr = grey
li = violet
ge = yellow
or = orange
Fuse Colors:
30 A - Green
25 A - White
20 A - Yellow
15 A - Blue
10 A - Red
7,5 A - Brown
5 A - Beige
3 A - Violet
Page 5831
- Check the wiring for a short to voltage, high resistance or an open circuit.
Final procedures


Page 4409
Part 2
Page 3890
Testing and Information System VAS 5051 "Guided Functions".
18 - Seal -
Replace if damaged
Page 791
Part 2
Page 1198
Track 1-14
named Track 1-14.
Track 169-182
reference box.

Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

-G195-
Page 1380
Page 2115
Headlamp Alignment Sensor: Service and Repair Vehicle Level Sensor With Automatic Headlight
Vertical Aim Control
equipment.
control module.

Page 3776
Bu-Ch
Page 1884
legend.
wiring diagram.
harness.


question.)
19 - Legend



Page 2445
Page 5933
Right Front ABS Wheel Speed Sensor G45
Right Front ABS Wheel Speed Sensor G45

Page 1713
WHAT ARE TRACKS?
15-28, and so on).
Systems)
Standard Equipment
installed.
Engine Specific
engine.
components.

Volkswagen - New Beetle - Wiring Diagram - 2007 - 2008

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Page 3788

Engine Oil: Description and Operation

Oil Capacities and Specifications

Oil Dipstick Marks

b Oil level at hatched area: Can be replenished with engine oil

3 - Relay Panel - Indicated by grey area.

10 - Component designation Use legend at bottom of page to identify the component.

12 - Wire cross-section size (in mm sq.) and wire colors

15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter

17 - Reference of internal connection continuation Letters indicate where connection continues on

20 - Power/Ground Distribution Circuit Identification Following are the most common

Switch Battery Positive Voltage (B+) from ignition/starter switch

Battery Positive voltage (B+), hot at all times

Oxygen Sensor: Locations Component Location Overview

Component Location Overview

‹› Component location: In the exhaust manifold.

‹› Only for engine code BPR.

‹› Component location: In center catalytic converter.

‹› Component location: In rear catalytic converter.

Fuse Block: Service and Repair

Left Instrument Panel Fuse Holder

Fuse Panel and Relay Carrier

Left Instrument Panel Fuse Holder

- Remove the instrument panel trim panel on the driver side.

- Remove the screws - 1 - and remove the fuse panel - 2 -.

Install in reverse order of removal, noting the following:

- Tighten the screw to 3 Nm.

Current fuse assignments.

Relay Panel and 13-Pin Relay Carrier

Fuse Panel and Relay Carrier

Drive Belt: Diagrams

Ribbed belt routing

Ribbed belt routing

10. Belt pulley - coolant pump

Fuel Tank With Attachments And Fuel Filter, Assembly Overview

4 - Tank flap unit -

With rubber gasket

Ensure seated tightly

To remove valve unclip sideways out of support

10 - From EVAP canister

Ensure seated tightly

- Secure with spring-type clips

Support using Engine/transmission jack V.A.G 1383 A when removing

‹› If lower ribs are used, these can be damaged

- Remove engine cover.

‹› Note installation position of ignition coils with power output stages!

CAUTION! Make sure wires are not kinked or damaged.

Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection

Engine Coolant Temperature Sensor 1, Checking

CAUTION! ‹› Cooling system is under pressure.

‹› Danger of scalding when opening!

Special tools, testers and auxiliary items required

‹› The Motronic Engine Control Module (ECM) ( J220 ) fuses OK.

‹› Battery voltage at least 12.5 volts.

‹› A/C switched off.

‹› Ground connections between engine/transmission/chassis OK.

‹› Ignition switched OFF.

- Switch the ignition ON.

- Using the scan tool, check the coolant temperature:

If the specified value was Not obtained:

- Continue test according to the following table:

Fuel Pressure Sensor/Switch: Diagnostic Aids

Explanation Of Troubleshooting Procedures

HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS?