Passat 2011 руководство

Service

Workshop Manual

Passat 2011 ➤

Passat Variant 2011 ➤

Wheels and Tyres Guide

Edition 03.2019

Service Department. Technical Information

Volkswagen Passat 2011 Workshop Manual (475 pages)

General body repairs, exterior

Table of Contents

Brand: Volkswagen
|
Category: Automobile
|
Size: 57.11 MB

• Table of Contents

  3

• Technical Data

  7

  • Vehicle Identification Data

    7

  • Vehicle Identification Number

    7

  • Passat 2011 ➤ , Passat Variant

    7

  • Safety Instructions

    9

  • Moulded Foam Elements

    10

  • Galvanized Body Parts, High/Higher-Strength and Hot-Formed Body Panels

    12

  • Body

    12

  • Laser Welding

    15

  • Body Panel Gaps/Shut Lines

    16

  • Body — Front

    16

  • Body — Centre

    17

  • Body — Rear

    18

  • Body — Rear (Variant)

    19

  • Body Dimensions

    20

  • Body — Front

    20

  • Body — Centre

    22

  • Body — Centre (Variant)

    27

  • Body — Rear

    28

  • Body — Rear (Variant)

    29

  • Floor Group — Front

    30

  • Floor Group — Centre

    31

  • Floor Group — Rear

    32

  • Tools

    33

  • Alignment Bracket Set

    34

  • Overview

    34

  • Portal Gauge

    35

  • Overview

    35

• Body — Front

  37

  • Renewing Left Console

    37

  • Tools

    37

  • Removing

    38

  • Installing

    40

  • Renewing Right Console

    42

  • Tools

    42

  • Removing

    43

  • Installing

    44

  • Renewing Retaining Bracket for Subframe

    46

  • Tools

    46

  • Removing

    47

  • Installing

    48

  • Renewing Bumper Bracket

    50

  • Tools

    51

  • Removing

    51

  • Installing

    52

  • Renewing Upper Wheel Housing Longitudinal Member

    54

  • Tools

    55

  • Removing

    56

  • Installing

    58

  • Renewing Front Wheel Housing

    62

• Tools

  63

• Removing

  63

• Installing

  65

• Repairing Threads for Securing Subframe (Suspension Subframe)

  72

• Tools

  73

• Contents of Thread Repair Kit

  73

• Repairing Threads

  74

• Renewing Front Longitudinal Member

  77

• Tools

  78

• Removing

  78

• Installing

  81

• Renewing Front Longitudinal Member — Part Section

  88

• Tools

  89

• Removing

  89

• Installing

  92

• Body — Centre

  97

• Renewing Roof

  97

• Tools

  98

• Removing

  100

• Installing

  102

• Renewing Roof — Vehicles with Sliding/Tilting Sunroof

  113

• Tools

  114

• Removing

  116

• Installing

  118

• Renewing Roof (Variant)

  130

• Tools

  131

• Removing

  133

• Installing

  135

• Renewing Roof — Variant with Panorama Sliding Sunroof

  146

• Tools

  147

• Removing

  149

• Installing

  151

• Renewing Roof Side Member

  163

• Tools

  164

• Removing

  164

• Installing

  166

• Foam Treating Roof Side Member

  172

• Renewing Front Roof Cross Member

  175

• Tools

  176

• Removing

  176

• Installing

  177

• Renewing Rear Roof Cross Member (Saloon)

  179

• Tools

  180

• Removing

  180

• Installing

  181

• Renewing Rear Roof Cross Member (Variant)

  183

• Tools

  184

• Removing

  184

• Installing

  185

• Renewing A-Pillar

  188

• Tools

  189

• Removing

  189

• Installing

  191

  • Renewing A-Pillar Reinforcement — Part Section

    198

  • Tools

    199

  • Removing

    199

  • Installing

    201

  • Renewing B-Pillar

    205

  • Tools

    206

  • Removing

    206

  • Installing

    208

  • Renewing B-Pillar Reinforcement — Part Section

    216

  • Tools

    217

  • Removing

    217

  • Installing

    219

  • Renewing Inner B-Pillar

    229

  • Tools

    230

  • Removing

    230

  • Installing

    232

  • Renewing Side Member

    235

  • Tools

    236

  • Removing

    236

  • Installing

    238

  • Renewing Front Side Member Reinforcement

    244

  • Tools

    245

  • Removing

    245

  • Installing

    246

  • Renewing Rear Side Member Reinforcement

    251

  • Tools

    252

  • Removing

    252

  • Installing

    253

  • Renewing Seat Middle Cross Member

    256

Volkswagen Passat 2011 Workshop Manual (281 pages)

General body repairs, interior

Table of Contents

Brand: Volkswagen
|
Category: Automobile
|
Size: 11.59 MB

• Table of Contents

  3

• Technical Data

  7

  • Identification

    7

  • Engine Number/Engine Data

    7

  • General Information

    9

  • Numbering of Cylinders

    9

  • Safety Information

    10

  • Safety Precautions During Work on Fuel System

    10

  • Safety Precautions When Using Testers and Measuring Instruments During a Road Test

    10

  • Safety Precautions When Working on the Cooling System

    11

  • Safety Precautions When Working on Ignition System

    11

  • Repair Notes

    12

  • Rules for Cleanliness

    12

  • Foreign Objects in Engine

    12

• Removing and Installing Engine

  13

  • Removing Engine

    13

  • Separating Engine and Gearbox

    21

  • Securing Engine on Engine and Gearbox Support

    23

  • Installing Engine

    25

  • Assembly Mountings

    27

  • Assembly Overview — Assembly Mountings

    27

  • Removing and Installing Engine Mounting

    28

  • Adjusting Assembly Mountings

    30

  • Checking Adjustment of Assembly Mountings (Engine and Gearbox Mountings)

    33

• Crankshaft Group

  34

  • Cylinder Block (Pulley End)

    34

  • Assembly Overview — Cylinder Block (Pulley End)

    34

  • Assembly Overview — Poly V-Belt Drive

    36

  • Removing and Installing Poly-V Belt

    37

  • Removing and Installing Tensioner for Poly V-Belt

    38

  • Removing and Installing Vibration Damper

    38

  • Removing and Installing Bracket for Ancillaries

    39

  • Removing and Installing Sealing Flange on Pulley End

    40

  • Cylinder Block, Gearbox End

    42

  • Assembly Overview — Cylinder Block, Gearbox End

    42

  • Removing and Installing Flywheel

    42

  • Renewing Crankshaft Oil Seal (Gearbox End)

    43

  • Crankshaft

    46

  • Assembly Overview — Crankshaft

    46

  • Renewing Needle Bearing in Crankshaft

    48

  • Crankshaft Dimensions

    50

  • Measuring Axial Clearance of Crankshaft

    50

  • Measuring Radial Clearance of Crankshaft

    50

  • Allocation of Main Bearing Shells

    51

  • Removing and Installing Sender Wheel

    55

  • Pistons and Conrods

    57

  • Assembly Overview — Pistons and Conrods

    57

  • Removing and Installing Pistons

    58

  • Checking Pistons and Cylinder Bores

    61

  • Separating New Conrod

    62

• Cylinder Head, Valve Gear

  64

  • Cylinder Head

    64

  • Assembly Overview — Cylinder Head

    64

  • Removing and Installing Cylinder Head

    66

  • Removing and Installing Cylinder Head Cover

    74

  • Assembly Overview — Vacuum Pump

    75

  • Removing and Installing Vacuum Pump

    76

  • Checking Compression

    77

  • Cover for Timing Chain

    81

  • Assembly Overview — Cover for Timing Chain

    81

  • Removing and Installing Timing Chain Cover

    82

  • Removing and Installing the Camshaft Control Valve Seal

    84

  • Assembly Overview — Valve Timing Housing

    85

  • Chain Drive

    87

  • Assembly Overview — Camshaft Timing Chains

    87

  • Removing and Installing Camshaft Timing Chain

    89

  • Removing and Installing Chain Drive Sprocket for High-Pressure Pump

    92

  • Removing and Installing Timing Chain and Chain Drive for Oil Pump

    93

  • Checking Valve Timing

    97

  • Adjusting Valve Timing

    99

  • Valve Gear

    104

  • Assembly Overview — Valve Gear

    104

  • Measuring Axial Play of Camshaft

    106

  • Removing and Installing Camshaft

    107

  • Removing and Installing Camshaft Adjuster

    111

  • Removing and Installing Camshaft Control Valve

    118

  • Removing and Installing Valve Stem Seals

    122

  • Inlet and Exhaust Valves

    125

  • Checking Valve Guides

    125

  • Reworking Valve Seats

    125

  • Valve Dimensions

    127

• Lubrication

  128

  • Sump, Oil Pump

    128

  • Assembly Overview — Sump/Oil Pump

    128

  • Removing and Installing Oil Spray Jet

    130

  • Removing and Installing Sump

    131

  • Removing and Installing Oil Pump

    133

  • Engine Oil

    137

  • Oil Filter, Oil Pressure Switch

    139

  • Assembly Overview — Oil Filter Housing, Oil Pressure Switch

    139

  • Checking Oil Pressure and Oil Pressure Switch

    141

Brand: Volkswagen
|
Category: Automobile
|
Size: 11.93 MB

• Table of Contents

  3

• 1 Engine List

  5

• 2 Service Work

  7

  • Information about Flexible or Fixed Service

    7

  • Service Tables

    11

• 3 General Information

  25

  • Raising Vehicle with Lifting Platform or Trolley Jack

    25

  • Stickers

    26

  • Connecting Vehicle Diagnostic Tester

    27

  • Vehicle Identification Number

    28

  • Vehicle Data Sticker

    29

  • Country Overview for Diesel Not Compliant with en 590

    30

  • Country Overview for Petrol Not Compliant with en 228

    31

  • Engine Code and Engine Number

    32

  • Severe Operating Conditions

    32

  • Countries with Hot Climate

    33

  • Countries with High Levels of Dust

    34

  • Identification Plate

    35

  • Shortened Intervals for Spark Plug Replacement

    35

• 4 Descriptions of Work

  40

  • Swivel Joints, Axle Mountings, Coupling Rod Bearings and Anti-Roll Bar Rubber Mounting

    42

    • Inspecting for Damage

      42

  • Activation of Environment Monitoring System (Front Assist): Checking

    43

  • Automatic Headlight Control and Static Cornering Light: Checking Function

    43

  • Front Passenger Front Airbag: Checking Key Switch and «ON/OFF Function

    44

  • Battery: Checking Battery Terminal Clamps for Secure Seating

    46

  • Battery: Checking with Battery Tester (Always Refer to Workshop Manual)

    49

  • Status of Battery: Reading, Sending Diagnosis Protocol Online

    49

  • Reducing Agent (Adblue®/Def): Replenishing

    50

  • Reducing Agent (Adblue®/Def): Changing

    55

  • Tyres: Checking Condition, Wear Pattern, Tyre Pressure and Tread Depth

    55

  • Brake and Clutch System: Changing Brake Fluid

    81

  • Brake System and Shock Absorbers: Inspecting for Leaks and Damage

    85

  • Brakes, Front and Rear: Checking Thickness of Brake Pads and Condition of Brake Discs

    86

  • Brake Fluid Level: Checking

    88

  • Diesel Particulate Filter: Checking

    89

  • Dual Clutch Gearbox 02E: Changing Gear Oil and Filter

    89

  • Electric Windows: Checking Positioning (Open and Close Functions)

    90

  • Natural Gas Tank: Renew

    91

  • Natural Gas Filler Connection and Sealing Cap: Check Condition, Clean if Necessary and Check Seal

    91

  • Fault Memory of All Systems: Reading with Vehicle Diagnostic Tester , Correcting Possible Faults

    91

    • According to Repair Guidelines

      91

  • Bonnet Catch Hook: Grease

    92

  • Gearbox, Final Drive and Drive Shaft Boots: Inspect for Leaks and Damage

    92

  • All-Wheel Drive Coupling: Changing Oil

    93

  • Interior and Exterior Body: Inspecting for Corrosion with Doors and Flaps Open

    97

  • Poly V-Belt: Renewing

    97

  • Poly V-Belt: Check Condition

    97

  • Cooling System: Checking Frost Protection and Coolant Level

    99

  • Diesel Fuel Filter: Renewing

    101

  • Air Filter: Cleaning Housing and Renewing Filter Element

    103

  • Multi-Purpose Additive for Diesel Fuel: Adding

    106

  • Multi-Purpose Additive for Petrol Fuel: Adding

    108

  • Memory Seat: Initialising

    109

  • Engine and Components in Engine Compartment: Inspecting for Leaks and Damage (from above and Below)

    109

  • Engine Cover Panel «Top»: Removing and Installing

    110

  • Engine Compartment Cover (Noise Insulation) «Bottom»: Removing and Installing

    113

  • Engine Oil Level: Checking

    113

  • Engine Oil: Draining or Extracting, Renewing Oil Filter and Replenishing Engine Oil

    114

  • Engine Oil: Capacities and Specifications

    120

  • Panorama Tilting/Sliding Roof with Rear Panorama Roof: Checking Function, Cleaning and Greasing Guide Rails, and Cleaning Wind Deflector

    120

  • Road Test: Performing (Driving Behaviour, Noises, Air Conditioner Etc.)

    123

  • Wheel Securing Bolts: Tightening to Specified Torque

    124

  • Radio Code: Reading Using Vehicle Diagnostic Tester

    127

  • Radio/Navigation System: Entering PIN of Anti-Theft Coding and Storing Local Radio Stations to Station Buttons

    128

  • Tyre Pressure Monitoring : Performing Basic Setting

    128

  • Tyre Repair Set: Checking

    131

  • Window Wash/Wipe System and Headlight Washer System: Checking Function

    131

  • Wiper Blade Protection: Removing

    135

  • Headlight Adjustment: Checking Halogen Headlights

    138

  • Headlight Adjustment: Checking Gas Discharge Headlights Without DLA

    141

  • Headlight Adjustment: Checking Gas Discharge Headlights with DLA

    145

  • Headlight Adjustment: Checking Fog Lights

    151

  • Sliding Sunroof Drains: Checking for Blockage, Cleaning if Necessary

    153

  • Service Interval Display: Resetting

    153

  • Service Interval Display: Recoding

    156

  • Sunroof: Checking Function, Cleaning and Greasing Guide Rails

    158

  • Track Rods: Checking Clearance, Attachment and Boots

    158

  • Auxiliary Heater: Setting Weekday in Menu of Dash Panel Insert

    158

  • Dust and Pollen Filter: Cleaning Housing and Renewing Filter Element

    159

  • Transportation Mode: Switching off

    160

  • Transportation Devices: Removing Blocking Pieces from Springs on Front Axle

    160

  • Transportation Devices: Removing Tie-Down Rings

    162

  • Door Arrester: Grease

    164

  • Clock and Date: Setting

    165

  • Underbody: Inspecting for Damage to Underbody Sealant, Underbody Panels, Routing of Lines, Plugs

    165

  • Camshaft Drive Toothed Belt (Diesel Engines): Renewing

    165

  • Spark Plugs: Renewing

    166

  • Natural Gas System: Inspect Natural Gas Tank for Corrosion and Leakage

    174

  • Natural Gas System: Checking Wax Layer between Natural Gas Fuel Tank and Fuel Tank Shut-Off Valve

    179

Brand: Volkswagen
|
Category: Automobile
|
Size: 1.72 MB

• Table of Contents

  5

• Technical Data

  7

• 1 General Notes on Air Conditioning Systems

  7

  • Introduction

    7

  • Additional Information

    7

  • Basics of Air Conditioning

    8

  • Vapour Pressure Table for Refrigerant R134A

    9

  • Refrigerant R134A

    10

  • Characteristics of Refrigerant R134A

    11

  • Refrigerant Machine Oil

    13

  • Comfort

    15

  • How Air Conditioning Works

    15

  • General Safety

    16

  • Safety Precautions for When Working on Vehicles with Air Conditioning and When Handling

    19

    • Refrigerant R134A

      19

  • Basics for Working on Refrigerant Circuit

    20

• 2 General Information on Refrigerant Circuit

  23

  • Refrigerant Circuit Components

    23

  • Design of Refrigerant Circuit

    31

  • Evacuation and Charging Valves for Quick-Release Couplings of Air Conditioner Service Station

    31

    • On Refrigerant Circuit

      31

  • Switch and Sender in Refrigerant Circuit and Related Connections

    33

  • Electrical Components Not Installed in Refrigerant Circuit

    36

  • Pressures and Temperatures in the Refrigerant Circuit

    38

  • Refrigerant Circuit with Expansion Valve

    38

  • Refrigerant Circuit with Restrictor and Reservoir

    40

  • Test and Measurement Work that Can be Performed Using a Pressure Gauge

    42

  • Air Conditioner Service and Recycling Equipment

    43

  • Notes to Repairs on Refrigerant Circuit

    44

• 3 Statutory Texts and Instructions

  45

  • Statutes and Regulations

    45

  • Recycling and Refuse Law

    50

  • Converting R12 Refrigerant Circuits to R134A Refrigerant Circuits and Repairing Them (Retrofitting)

    51

  • Maintaining Records on Refrigerant

    51

• 4 Refrigerant Circuit

  52

  • Important Repair Notes on Air Conditioning

    52

  • Retrofitting Refrigerant Circuit from R12 Refrigerant to R134A Refrigerant

    52

• 5 Working with the Air Conditioner Service Station

  53

  • Important Notes for Working with the Air Conditioner Service Station

    54

  • Connecting Air Conditioner Service Station for Measuring and Checking

    54

  • Draining Refrigerant Circuit Using Air Conditioner Service Station

    55

  • Evacuating Refrigerant Circuit Using Air Conditioner Service Station

    56

  • Charging Refrigerant Circuit Using Air Conditioner Service Station

    57

  • Bringing Air Conditioning System into Service after Charging

    58

  • Charging Container in Air Conditioner Service Station with Refrigerant

    59

  • Draining Air Conditioner Service Station

    59

• 6 Detecting Leaks in Refrigerant Circuit

  61

  • Leak Detection in Refrigerant Circuit Using Compressed Air or Nitrogen

    62

  • Searching for Leaks in Refrigerant Circuits Using Leak Detector V.A.G 1796

    64

  • Detecting Leaks in Refrigerant Circuit Using Leak Detecting System VAS 6196 or Leak Detecting

    65

    • System VAS 6201 or a Later Model

      65

Brand: Volkswagen
|
Category: Automobile
|
Size: 7.27 MB

• Table of Contents

  3

• Technical Data

  5

  • Safety Information

    5

  • Safety Precautions When Working on Air Conditioning Systems

    5

  • Safety Measures When Working on Vehicles with a Start/Stop System

    5

  • Safety Precautions When Working on the Cooling System

    5

  • General Information

    7

  • Notes Concerning Odours in Air Conditioned Vehicles

    7

  • Notes for Vehicles with Start-Stop System

    7

  • Repair Notes

    8

  • Checking Cooling Output

    8

  • Working on Refrigerant Circuit

    9

  • Refrigerant Circuit Seals

    9

  • Notes on Control Motors

    10

  • Technical Data

    16

  • Refrigerant Capacity

    16

  • Refrigerant Oil Capacities

    16

  • Oil Distribution

    17

• Heating

  18

• Air Conditioning System

  19

  • Overview of Fitting Locations — Air Conditioning System

    19

  • Overview of Fitting Locations — Components Located in Front Section of Passenger Compartment

    19

  • Refrigerant Circuit

    24

  • System Overview — Refrigerant Circuit

    24

  • Assembly Overview — Condenser

    26

  • Removing and Installing High-Pressure Sender G65

    26

  • Removing and Installing Expansion Valve

    28

  • Removing and Installing Condenser

    30

  • Removing and Installing Desiccant Bag or Cartridge

    32

  • Removing and Installing Evacuating and Charging Valves on Low and High-Pressure Side

    38

  • Air Conditioner Compressor

    41

  • Assembly Overview — Pulley

    41

  • Removing Air Conditioning Compressor from and Installing on Bracket

    42

  • Removing and Installing Air Conditioner Compressor

    44

  • Checking High-Pressure Safety Valve on Air Conditioner Compressor

    47

  • Removing and Installing Pulley

    48

  • Control Motors

    51

  • Overview of Fitting Locations — Front Control Motors

    51

  • Removing and Installing Temperature Flap Control Motor V68

    53

  • Removing and Installing Defroster Flap Control Motor V107

    55

  • Removing and Installing Air Recirculation Flap Control Motor V113

    57

  • Removing and Installing Left Temperature Flap Control Motor V158

    62

  • Removing and Installing Right Temperature Flap Control Motor V159

    64

  • Removing and Installing Right Temperature Flap Control Mo- Tor V159

    64

  • Removing and Installing Indirect Ventilation Flap Control Motor V213

    66

  • Removing and Installing Fresh Air/Recirculated Air, Air Flow Flap Control Motor V425

    67

  • Removing and Installing Front Air Distribution Flap Control Motor V426

    69

  • Removing and Installing Air Distribution Flap Control Motor V428

    70

  • Removing and Installing Fresh Air/Air Recirculation, Air Flow Flap Actuator

    71

  • Front Heater and Air Conditioning Unit

    72

  • Assembly Overview — Heater and Air Conditioning Unit

    72

  • Removing and Installing Evaporator

    77

  • Dismantling and Assembling Evaporator Housing

    77

  • Removing and Installing Heater and Air Conditioning Unit

    78

  • Dismantling and Assembling Heater and Air Conditioning Unit

    82

  • Removing and Installing Air Distribution Housing

    84

  • Dismantling and Assembling Air Distribution Housing

    85

  • Checking Auxiliary Air Heater Element Z35

    87

  • Removing and Installing Auxiliary Air Heater Element Z35

    88

  • Removing and Installing Evaporator Temperature Sensor G308

    89

  • Removing and Installing Dust and Pollen Filter

    89

  • Removing and Installing Fresh Air Blower Series Resistor with Overheating Fuse N24

    90

  • Removing and Installing Fresh Air Blower V2

    91

  • Removing and Installing Fresh Air Blower Control Unit J126

    93

  • Removing and Installing Heat Exchanger

    93

  • Removing and Installing Condensation Drain

    97

  • Checking Condensation Drain

    98

  • Air Duct

    99

  • Assembly Overview — Air Duct and Air Distribution in Passenger Compartment

    99

  • Removing and Installing Centre Vent

    100

  • Removing and Installing Driver or Front Passenger Side Air Vents

    101

  • Removing and Installing Rear Vents

    102

  • Removing and Installing Driver Side Footwell Vents

    103

  • Removing and Installing Front Passenger Side Footwell Vents

    104

  • Removing and Installing Left or Right Side Window Vents

    105

  • Removing and Installing Rear Footwell Vent

    106

  • Removing and Installing Rear Centre Console Vent Duct

    107

  • Removing and Installing Rear Footwell Vent

    108

  • Removing and Installing Fresh Air Intake

    108

  • Removing and Installing Glove Box Cooling

    109

  • Checking Forced Ventilation for Passenger Compartment

    109

  • Removing and Installing Forced Ventilation for Passenger Compartment

    110

  • Operating and Display Unit

    112

  • Overview of Operating and Display Unit

    112

    • Overview of Control and Display Unit, Air Conditioning System with Electric and Manual Controls, as of WEEK 22/2012

      115

  • Overview of Operating and Display Unit, Climatronic up to Week 44/2011

    116

  • Overview of Operating and Display Unit, Climatronic up to Week 21/2012

    119

  • Overview of Operating and Display Unit, Climatronic from Week 22/2012

    121

  • Removing and Installing Operating and Display Unit

    122

  • Other Controlling and Regulating Components

    126

  • Removing and Installing Sunlight Penetration Photosensor G107

    126

  • Principle of Operation of Air Quality Sensor G238

    126

  • Removing and Installing Air Quality Sensor G238

    128

  • Removing and Installing Ambient Temperature Sensor G17

    128

  • Removing and Installing Left Vent Temperature Sender G150

    129

  • Removing and Installing Right Vent Temperature Sender G151

    129

  • Removing and Installing Left Footwell Vent Temperature Sender G261

    130

  • Removing and Installing Right Footwell Vent Temperature Sender G262

    130

Brand: Volkswagen
|
Category: Automobile
|
Size: 9.45 MB

• Table of Contents

  3

• Technical Data

  5

  • Identification

    5

  • Allocation of PR Number — Brakes

    5

  • Technical Data

    6

  • Technical Data for Brakes

    6

  • Brake Test

    8

  • General Information

    8

  • Checking Vehicles with Front-Wheel Drive

    8

  • Checking Vehicles with Four-Wheel Drive

    8

  • Checking Parking Brake

    9

• Anti-Lock Brake System

  11

  • General Information

    11

  • Repair Instructions for Repair Work on ABS

    11

  • Vehicle Diagnosis, Testing and Information System

    12

  • Overview of Fitting Locations

    14

  • Abs/Esp

    14

  • Control Unit and Hydraulic Unit

    18

  • Assembly Overview

    18

  • Removing and Installing Control Unit and Hydraulic Unit

    21

  • Connecting Brake Lines to Hydraulic Unit

    29

  • Sensors

    32

  • Assembly Overview — Speed Sensor on Front Axle

    32

  • Removing and Installing Speed Sensor on Front Axle

    33

  • Assembly Overview — Speed Sensor on Rear Axle

    33

  • Removing and Installing Speed Sensor on Rear Axle

    35

  • Removing and Installing ESP Sensor Unit

    36

  • Removing and Installing Steering Angle Sender

    37

  • Removing and Installing Brake Servo Vacuum Sender

    37

• Brakes — Mechanism

  39

  • Front Brakes

    39

  • Assembly Overview — Front Brakes

    39

  • Removing and Installing Brake Pads/Linings

    42

  • Removing and Installing Brake Caliper

    47

  • Rear Brakes

    51

  • Assembly Overview — Rear Brakes

    51

  • Removing and Installing Brake Pads/Linings

    54

  • Removing and Installing Brake Caliper

    57

  • Handbrake

    60

  • Overview of Fitting Locations — Parking Brake

    60

  • Removing and Installing Control Unit

    61

  • Removing and Installing Parking Brake Motor

    61

  • Brake Pedal

    64

  • Assembly Overview — Brake Pedal

    64

  • Separating Brake Pedal from Brake Servo

    66

  • Connecting Brake Pedal to Brake Servo

    67

  • Removing and Installing Brake Pedal

    67

  • Removing and Installing Mounting Bracket

    70

• Brakes — Hydraulics

  75

  • Front Brake Calipers

    75

  • Assembly Overview — Front Brake Caliper

    75

  • Removing and Installing Brake Caliper Piston

    76

  • Rear Brake Calipers

    82

  • Assembly Overview — Rear Brake Caliper

    82

  • Removing and Installing Rear Brake Caliper Piston

    83

  • Brake Servo and Brake Master Cylinder

    86

  • Assembly Overview — Brake Servo/Brake Master Cylinder

    86

  • Removing and Installing Brake Light Switch

    90

  • Removing and Installing Brake Master Cylinder

    92

  • Removing and Installing Brake Servo

    106

  • Vacuum System

    124

  • Assembly Overview — Vacuum Pump

    124

  • Assembly Overview — Electric Vacuum Pump

    125

  • Checking Non-Return Valve

    126

  • Removing and Installing Brake Servo Pressure Sensor

    126

  • Checking Vacuum System

    126

  • Brake Lines

    131

  • Repairing Brake Lines

    131

  • Hydraulic System

    136

  • General Notes on Brake Fluid

    136

  • Pre-Bleeding Hydraulic System

    136

  • Bleeding Hydraulic System Following Standard Procedure

    138

  • Subsequent Bleeding of Hydraulic System

    139

  • Testing for Leaks

    139

Brand: Volkswagen
|
Category: Automobile
|
Size: 7.16 MB

• Table of Contents

  3

  • Technical Data

    5

    • Repair Instructions

      5

    • General Information

      5

    • Suppression Measures

      5

    • Overview of Battery, Transmitter and Receiver Unit, Fuse and Wiring Harness

      6

    • Installation and Operation of Two-Way Radios with a Transmitting Power above 10 Watts

      7

    • Mobile Telephones or Portable Two-Way Radios Without Separate External Aerial

      7

    • Transmitting Power and Aerial Fitting Locations

      7

    • General Repair Instructions

      9

  • Communication

    12

    • Radio / Radio Navigation Systems R / J503

      13

    • Components of Radio / Radio Navigation Systems R / J503

      13

    • Overview of Fitting Locations — Radio / Radio Navigation System R / J505

      28

    • Removing and Installing Radio / Radio Navigation Systems R / J503

      45

    • Interface for External Multimedia Unit R215

      48

    • Pin Assignments

      50

• 2 Sound System

  69

  • General Notes on Amplifiers

    69

  • System Overview — Amplifier R12

    69

  • Removing and Installing Amplifier R12

    72

  • General Notes on Loudspeaker Systems

    74

  • Removing and Installing Front Bass and MID-Range Loud- Speakers

    74

  • Removing and Installing Front Bass and MID-Range Loudspeakers

    74

  • Removing and Installing Rear Bass Loudspeakers R17 / R15

    75

  • Removing and Installing Front Treble Loudspeakers R22 / R20

    76

  • R14

    77

  • Removing and Installing Rear Treble Loudspeakers R16

    77

  • Removing and Installing Rear Treble Loudspeakers R16 / R14

    77

  • Aerial Systems

    79

  • System Overview — Aerial Systems, Saloon

    79

  • System Overview — Aerial Systems, Estate

    85

  • Removing and Installing Aerial Modules and Aerial Amplifiers

    90

  • Removing and Installing Roof Aerial RX5

    93

  • CD Changer

    95

  • General Information

    95

  • Removing and Installing CD Changer R41

    95

• 5 Telephone System

  98

  • General Notes on Universal Preparation for Mobile Phone UTP

    98

  • System Overview of Universal Mobile Phone Preparation

    99

  • Utp

    99

  • Removing and Installing Telephone Bracket

    102

  • Removing and Installing Mobile Telephone Operating Elec- Tronics Control Unit J412

    104

  • Removing and Installing Mobile Telephone Operating Electronics Control Unit J412

    104

  • Changing Mobile Phone Cradle from Old to New Dash Pan- el

    105

  • Changing Mobile Phone Cradle from Old to New Dash Panel

    105

  • Removing and Installing Emergency Button E276

    107

  • Removing and Installing Telephone Microphone R38

    108

  • Components of Reversing Camera System

    110

  • Reversing Camera

    110

  • Assembly Overview — Reversing Camera

    111

  • Removing and Installing Reversing Camera R189

    112

  • Calibrating Reversing Camera

    114

  • Removing and Installing Reversing Camera System Control Unit J772

    117

  • Renewing Video Cable

    118

  • General Information

    121

  • Multifunction Steering Wheel

    121

  • Removing and Installing Steering Wheel Multifunction Buttons E441 / E440

    121

  • Components of Connection for External Multimedia Units

    123

  • Connection for External Multimedia Devices

    123

  • Connectors, Connection for External Multimedia Devices

    128

  • Removing and Installing Connection for External Audio Sources R199

    131

  • Removing and Installing Interface for External Multimedia Devices R215

    132

Brand: Volkswagen
|
Category: Automobile
|
Size: 4.84 MB

• Table of Contents

  3

• Technical Data

  5

  • Safety Information

    5

  • Safety Regulations for Working on Fuel Supply

    5

  • Safety Precautions When Using Testers and Measuring Instruments During a Road Test

    5

  • Safety Precautions When Working on Vehicles with a Start/Stop System

    6

  • Identification

    7

  • Engine Number/Engine Data

    7

  • General Information

    8

  • Rules for Cleanliness When Working on Auxiliary/Supplementary Heater and Fuel System

    8

  • Repair Notes

    9

  • Routing and Attaching Lines

    9

  • General Repair Instructions

    9

• Assembly Overview — Fuel Tank, Vehicles with Front-Wheel Drive

  10

• Fuel Supply System

  10

  • Assembly Overview — Fuel Tank, Vehicles with Four-Wheel Drive

    14

  • Emptying Fuel Tank

    18

    • Emptying Fuel Tank When Fuel Pump Is Intact

      18

    • Continued for All Vehicles

      20

    • Vehicles with Auxiliary Heater

      20

    • Special Tools and Workshop Required

      26

    • Emptying Fuel Tank at Fuel Delivery Unit Flange

      27

  • Removing and Installing Fuel Tank

    30

    • Continuation for All Other Engine Codes

      33

    • Vehicles with Engine Code BWS or CCZB

      39

    • Vehicles with Engine Code CNNA

      39

  • Assembly Overview — Fuel Delivery Unit/Fuel Gauge Sender

    45

  • Fuel Delivery Unit, Fuel Gauge Sender

    45

  • Installation Position of Fuel Delivery Unit

    46

  • Removing and Installing Fuel Delivery Unit, Fuel Gauge Sender

    47

    • If a New Fuel Delivery Unit Is Installed

      54

    • Installing Fuel Line

      54

    • Assignment of Plug-In Connectors

      55

    • Colour Assignment

      55

  • Plug-In Connectors

    55

  • Separating Plug-In Connectors

    55

  • Fuel Filter

    59

  • Activated Charcoal Filter with Fuel Tank Leak Detection

    60

  • Assembly Overview — Activated Charcoal Filter System

    60

  • Removing and Installing Activated Charcoal Filter

    61

  • Checking Fuel System for Leaks

    62

  • Schematic Overview of Activated Charcoal Filter System

    67

  • Activated Charcoal Filter Without Fuel Tank Leak Detection

    70

  • Assembly Overview — Activated Charcoal Filter System

    70

  • Removing and Installing Activated Charcoal Filter

    70

  • Checking Fuel Tank Breather

    71

  • Accelerator Pedal

    74

  • Assembly Overview — Accelerator Module

    74

  • Removing and Installing Accelerator Pedal Module — GX2-

    74

  • Checking Fuel System Pressurisation Pump G6

    77

  • Checking Function and Voltage Supply

    77

  • Fuel Pump

    77

    • Test Sequence

      78

    • Vehicle Diagnostic Tester

      78

    • Checking Fuel Pressure

      80

    • If no Fault Is Found

      85

    • If Reading Matches Specification

      85

    • If Specification Is Not Obtained

      85

    • Checking Holding Pressure

      88

    • Checking Residual Pressure at Flange for Delivery Unit

      90

    • If no Fault Can be Determined

      90

    • If Pressure Drops Again (Leak on Fuel Tank Side)

      90

  • Removing and Installing Suction-Jet Pump

    110

    • Function of Suction-Jet Pump

      112

    • If Engine Starts OK Now

      112

    • Removing Suction-Jet Pump

      112

    • Installing Suction-Jet Pump

      113

  • Removing and Installing Fuel Gauge Sender G

    115

  • Senders and Sensors

    115

  • Removing and Installing Fuel Gauge Sender 2 G169

    116

Brand: Volkswagen
|
Category: Automobile
|
Size: 1.76 MB

• Table of Contents

  3

  • Wheels, Tyres, Vehicle Geometry

    5

  • Wheel and Tyre Combinations

    5

  • General Information

    5

  • Explanations Regarding World Regions

    6

• Wheel Allocation

  12

  • 61/2 J X

    12

  • 61/2 J X 17 Offset

    14

  • X 18 Offset

    18

    • Dimensions:

      18

  • Wheel Offset in MM: Wheel Load in Kg

    19

  • Dimensions: / 2 J X

    20

  • Wheel Load in Kg: 650

    20

  • Recommended Summer Tyres

    21

  • Recommended Summer Tyres, Worldwide Except North America, China, Japan, South America, Taiwan, India

    21

  • Recommended Summer Tyres, India

    22

  • Recommended Summer Tyres, Japan

    22

  • Recommended Summer Tyres, South America

    22

  • Recommended Summer Tyres, Taiwan

    22

  • Recommended All-Season Tyres

    23

  • Recommended All-Season Tyres, Worldwide Except North America and China

    23

  • Recommended All-Season Tyres, Worldwide Except North America, China, Brazil and

    23

  • Recommended Winter Tyres

    24

  • Recommended Winter Tyres, Passat Alltrack, Worldwide Except North America and China

    24

  • Recommended Winter Tyres, Passat Saloon, Passat Variant, Worldwide Except North America

    24

  • Recommended Temporary Spare Tyres and Wheels

    25