Фольксваген джетта 5 инструкция по эксплуатации

Volkswagen Jetta 2005 Service Manual (4954 pages)

1.8 L turbo, 1.9 L TDI and PDI diesel. 2.0L Gasoline, 2.8L VR6

Table of Contents

Brand: Volkswagen
|
Category: Automobile
|
Size: 13.1 MB

• Table of Contents

  3

• Starter, Current Supply, CCS

  9

• Battery a

  9

• Types of Battery

  9

• Warning Notices and Safety Regulations

  9

• Battery Terminal Connection

  9

• Checking Battery a

  10

• Charging Battery a

  11

• Disconnecting and Connecting Battery a

  12

• Disconnecting and Connecting Battery a ( Battery a in Engine Compartment)

  12

• Removing and Installing Battery a

  15

• Removing and Installing Battery a ( Battery a in Engine Compartment)

  15

• Starter B

  21

• Checking Starter B

  21

• Removing and Installing Starter B (Automatic Gearbox)

  22

• Removing and Installing Starter B (DSG)

  43

• Removing and Installing Starter B (Manual Gearbox)

  68

• Alternator C

  96

• Securing Battery Positive Wire on Alternator C

  96

• Checking Poly V-Belt

  96

• Checking Alternator C

  97

• Alternator C 1.4L Petrol Engine

  98

• Alternator C 1.4L FSI Engine

  103

• Alternator C 1.4L, TSI Engine

  108

• Alternator C 1.6L Petrol Engine

  114

• Alternator C 1.6L FSI Engine

  118

• Alternator C 2.0L FSI Engine

  122

• Alternator C 2.0L TFSI Engine

  129

• Alternator C 2.5L Petrol Engine

  136

• Alternator C 1.9L Diesel Engine

  139

• Alternator C 1.9L Diesel Engine with Diesel Particle Filter

  146

• Alternator C 2.0L SDI Engine

  152

• Alternator C 2.0L Diesel Engine

  156

• Alternator C 2.0L CR Diesel Engine

  161

• Alternator C 2.0L TSI Engine

  166

• Removing and Installing Poly-V Belt Pulley on Alternator C

  171

• Voltage Regulator C1 for Alternator C

  176

• Cruise Control System (CCS)

  180

• Gauges, Instruments

  181

• Dash Panel Insert

  181

• Renewing Dash Panel Insert

  181

• Removing and Installing Dash Panel Insert (up to MY2009)

  182

• Removing and Installing Dash Panel Insert (from MY2010)

  183

• Back of Dash Panel Insert (up to MY2009)

  184

• Back of Dash Panel Insert (from MY2010)

  184

• Pin Assignment of Connectors at Dash Panel Insert

  184

• Warning Lamp Symbols on Dash Panel Insert (up to MY2009)

  184

• Warning Lamp Symbols on Dash Panel Insert (from MY2010)

  186

• Service Interval Display

  188

• Resetting Service Interval Display

  188

• Windscreen Wash/Wipe System

  189

• Windscreen Wiper System

  189

• Deactivating Wiper Motor Control Unit J400 APP Function

  189

• Assembly Overview — Windscreen Wiper System

  191

• Removing and Installing Windscreen Wiper System

  191

• Removing and Installing Wiper Arms

  196

• Adjusting Wiper Blade Park Position

  196

• Removing and Installing Joint-Free Wiper Blades

  198

• Removing and Installing Rain and Light Sensor G397

  198

• Coding Rain and Light Sensor G397

  200

• Windscreen Washer System

  202

• Assembly Overview — Windscreen Washer System

  202

• Removing and Installing Washer Fluid Reservoir

  203

• Removing and Installing Windscreen and Rear Window Washer Pump V59

  205

• Removing and Installing Windscreen Washer Fluid Level Sender G33

  206

• Removing and Installing Windscreen Washer System Spray Jets

  207

• Adjusting Windscreen Washer System Spray Jets

  207

• Rear Window Wiper System

  208

• Assembly Overview — Rear Window Wiper System

  208

• Removing Rear Window Wiper

  208

• Adjusting Rear Window Wiper Park Position

  210

• Removing and Installing Joint-Free Wiper Blades

  211

• Rear Window Washer System

  213

• Assembly Overview — Rear Window Washer System

  213

• Removing and Installing Washer Jet

  214

• Adjusting Spray Jet

  214

• Headlight Washer System

  215

• Assembly Overview — Headlight Washer System

  215

• Removing and Installing Headlight Washer System Pump V11

  216

• Removing and Installing Spray Jet Pop-Up Cylinders

  217

• Removing and Installing Spray Jet Assembly

  217

• Adjusting Headlight Washer System Spray Jets

  218

• Bleeding Headlight Washer System

  218

• Washer Fluid Line Hose Couplings

  220

• Hose Repair

  221

• Lights, Bulbs, Switches — Exterior

  222

• Headlights with Halogen Bulbs (up to MY2009)

  222

• Assembly Overview

  222

• Removing and Installing Headlight

  223

• Adjusting Headlight Installation Position

  225

• Renewing Bulbs

  226

• Removing and Installing Headlight Range Control Motor

  232

• Repairing Headlight Retaining Tabs

  239

• Converting Headlights for Use When Driving on the Left or Right

  241

• Adjusting Headlights

  243

• Headlights with Halogen Bulbs (from MY2009)

  244

• General Description

  244

• Assembly Overview

  244

• Removing and Installing Headlight

  246

• Adjusting Headlight Installation Position

  248

• Renewing Bulbs

  249

• Removing and Installing Headlight Range Control Motor

  255

• Repairing Headlight Securing Tabs

  259

• Converting Headlights for Use When Driving on the Left or Right

  262

• Adjusting Headlights

  265

• Headlights with Gas Discharge Bulbs (up to MY2009)

  266

• Operation and Safety Notes for Gas Discharge Bulbs

  266

• Assembly Overview

  269

• Removing and Installing Headlight

  270

• Adjusting Headlight Installation Position

  270

• Renewing Bulbs

  270

• Removing and Installing Headlight Range Control Motor

  276

• Removing and Installing Gas Discharge Light Control Unit

  279

• Control Unit for Headlight Range Control J431

  280

• Vehicle Level Sender

  283

• Repairing Headlight Securing Tabs

  284

• Converting Headlights for Use When Driving on the Left or Right

  285

• Adjusting Headlights

  285

• Headlights with Gas Discharge Bulbs and Cornering Lights (from MY2010)

  286

• General Description

  286

• Assembly Overview

  287

• Removing and Installing Headlight

  288

• Adjusting Headlight Installation Position

  290

• Renewing Bulbs

  290

• Headlight Starter for Gas Discharge Bulb

  295

• Power Output Module for Headlight

  296

• Headlight Range Control Unit J431

  298

• Headlight Range Control Motor

  300

• Swivel Module Position Sensor

  300

• Headlight Screen Adjustment Solenoid

  301

• Vehicle Level Sender

  302

• LED Module for Daytime Running Light and Side Light

  302

Volkswagen Jetta 2005 Workshop Manual (372 pages)

Table of Contents

Brand: Volkswagen
|
Category: Automobile
|
Size: 9.07 MB

• Table of Contents

  3

• Jetta 2005 ➤ , Bora

  8

• Starter, Current Supply, CC

  9

  • Battery

    9

  • Fundamentals for Batteries

    9

  • Types of Battery

    9

  • Warning Notices and Safety Regulations

    10

  • Battery Terminal Connection

    12

  • Checking Battery

    13

    • Procedure When Checking the Battery

      13

• Visual Check

  13

  • Checking Battery with Magic Eye

    14

  • Checking Low Maintenance Battery

    15

  • Check no Load Voltage of Battery

    18

  • Battery Tester with Printer VAS 5097 a

    19

  • Evaluating Test Result

    22

    • Charging Battery

      23

    • Battery Charger VAS 5095 a

      23

    • Battery Charger VAS 5900

      27

    • Totally Discharged Batteries

      35

    • Disconnecting and Reconnecting Batteries

      37

    • Disconnecting Battery

      37

    • Connecting Battery

      37

    • Removing and Installing Battery

      39

    • Models with a Petrol Engine

      39

    • Models with a Diesel Engine

      40

    • Torque Settings: Battery

      44

    • Starter

      45

    • Checking Starter B

      45

    • Removing and Installing Starter, Automatic Gearbox

      46

    • Removing and Installing Starter, Automated Shift Gearboxes

      66

    • Removing and Installing Starter, Manual Gearbox

      84

    • Torque Settings: Starter

      105

    • Alternator

      106

    • Fastening B+ Wire to Alternator

      106

    • Checking Ribbed Belt (Poly V-Belt)

      106

    • Check Alternator C

      107

    • Alternator, 1.6 L Injection Engine

      107

    • Alternator, 1.6 L FSI Engine

      112

    • Alternator, 2.0 L FSI Engine

      116

    • Alternator, 2.0 L FSI Turbo Engine

      123

    • Alternator 2.5 L Injection Engine

      130

    • Alternator, 1.9 L TDI Engine

      134

    • Alternator, 2,0 L TDI Engine

      141

    • Removing and Installing Ribbed Belt (Poly V-Belt) Pulley on Alternator

      145

    • Voltage Regulator for Alternator

      150

    • Torque Settings: Alternator

      153

    • General Torque Settings for All Vehicles

      153

    • L Injection Engine and 2.0 L FSI Engine

      153

    • 2.0 L FSI Turbo Engine

      154

    • 1.9 L and 2.0 L TDI Engine

      155

    • 2.5 L Injection Engine

      156

    • Cruise Control System (CCS)

      157

  • Activating and Deactivating Cruise Control System

    157

  • Dash Panel Insert

    158

  • Jetta 2005 ➤ , Bora

    158

  • Renewing Dash Panel Insert

    158

  • Removing and Installing Dash Panel Insert

    159

  • Description of Reverse Side of Dash Panel Insert

    160

  • Warning Lamp Symbols in Dash Panel Insert

    160

  • Resetting Service Interval Display

    162

  • Service Interval Display

    162

• Instruments, GCI

  158

• Windscreen Wash/Wipe System

  163

  • Windscreen Wiper System

    163

  • Deactivating APP Function of Wiper Motors

    163

  • Removing and Installing the Windscreen Wiper System

    164

  • Removing and Installing Wiper Arms

    168

  • Adjusting Wiper Blade Park Position

    169

  • Removing and Installing Aerodynamic Wipers

    170

  • Removing and Installing Rain and Light Detector Sensor G397

    171

  • Windscreen Washer System

    173

  • Assembly Overview of Windscreen Washer System

    173

  • Removing and Installing Reservoir for Windscreen and Headlight Washer Systems

    174

  • Removing and Installing Washer Pump V5

    176

  • Removing and Installing Windscreen Washer Spray Jets

    177

  • Adjusting Front Windscreen Washer System Spray Jets

    177

  • Headlight Washer System

    178

  • Assembly Overview — Headlight Washer System

    179

  • Removing and Installing Headlight Washer System Pump V11

    179

  • Removing and Installing Pop-Up Spray Jet Cylinder

    180

  • Removing and Installing Spray Jet Assembly

    181

  • Adjusting Headlight Washer System Jets

    181

  • Bleeding the Headlight Washer System

    181

  • Wash Water Line Hose Couplings

    182

  • Windscreen and Rear Window Washer System

    182

  • Headlight Washer System

    183

  • Hose Repair

    184

  • General Description

    184

  • Repairing Smooth Pipe

    184

  • Repairing Corrugated Pipe

    184

  • Torque Settings: Windscreen Wash/Wipe System

    186

Brand: Volkswagen
|
Category: Automobile
|
Size: 12.43 MB

• Golf Variant 2007 ➤ , Jetta

  8

• Technical Data

  9

• General Information

  11

• Front Suspension

  12

• Repairing Front Suspension

  13

• Raising Wheel Suspension to Unladen Position

  14

• Subframe, Anti-Roll Bar, Suspension Links

  17

• Assembly Overview: Front Left Vehicle Level Sender G78

  22

• Repairing Thread in Longitudinal Member

  23

• Fixing Position of Subframe and Brackets

  24

• Lowering Subframe

  25

• Removing and Installing Subframe Without Steering Box

  29

• Removing and Installing Subframe with Steering Box

  31

• Repairing Subframe (Front-Wheel Drive)

  36

• Repairing Subframe (Four-Wheel Drive)

  39

• Checking Swivel Joint

  43

• Removing and Installing Swivel Joint

  44

• Removing and Installing Suspension Link with Mounting Bracket

  46

• Renewing Bonded Rubber Bush for Suspension Link

  54

• Renewing Mounting Bracket with Suspension Link Bush

  56

• Removing and Installing Anti-Roll Bar

  58

• Assembly Overview: Wheel Bearing

  63

• Removing and Installing Wheel Bearing Unit

  64

• Removing and Installing Wheel Bearing Housing

  66

• Assembly Overview: Suspension Strut

  70

• Removing and Installing Suspension Strut

  71

• Repairing Suspension Strut

  76

• Removing and Installing Drive Shafts

  78

• Loosening and Tightening 12-Point Flange Bolt Securing Drive Shaft

  79

• Removing and Installing Drive Shaft with Constant Velocity Joint

  80

• Removing and Installing Left Drive Shaft with (Push-On) Constant Velocity Slip Joint

  82

• Removing and Installing Right Drive Shaft with (Push-On) Constant Velocity Slip Joint

  86

• Removing and Installing Drive Shafts with Triple Roller Joint Aar2600I

  89

• Removing and Installing Drive Shafts with Triple Roller Joint Aar3300I

  91

• Removing and Installing Intermediate Shaft

  93

• Repairing Drive Shaft — Overview of Drive Shafts

  95

• Heat Shields for Drive Shafts

  97

• Assembly Overview: Drive Shaft with VL90 or VL100 Constant Velocity Joint

  98

• Dismantling and Assembling Drive Shaft with VL90 or VL100 Constant Velocity Joint

  100

• Checking Outer Constant Velocity Joint

  104

• Checking Inner Constant Velocity Joint

  105

• Assembly Overview: Drive Shaft with VL107 Constant Velocity Joint (Bolt-On)

  108

• Dismantling and Assembling Drive Shaft with VL107 Constant Velocity Joint

  110

• Golf Variant 2007 ➤ , Jetta

  111

• Repairing Intermediate Shaft

  115

• Assembly Overview: Drive Shaft with VL107 Constant Velocity Slip Joint (Push-On)

  117

• 10.1 Dismantling and Assembling Drive Shaft with VL107 (Push-On) Constant Velocity Slip Joint

  118

• Checking Outer Constant Velocity Joint

  120

• Assembly Overview: Drive Shaft with Triple Roller Joint Aar2600I

  122

• Dismantling and Assembling Drive Shaft with Triple Roller Joint Aar2600I

  123

• Assembly Overview: Drive Shaft with Triple Roller Joint Aar3300I

  128

• Dismantling and Assembling Drive Shaft with Triple Roller Joint Aar3300I

  130

• Appraisal of Accident Vehicles

  135

• Repairing Rear Suspension (Front-Wheel Drive)

  136

• Rear Axle in Unladen Position

  137

• Assembly Overview: Subframe, Transverse Link, Track Rod (Front-Wheel Drive)

  140

• Removing and Installing Rear Axle

  142

• Vehicle Level Sender for Vehicles with Automatic Headlight Range Control

  147

• Removing and Installing Upper Transverse Link

  148

• Removing and Installing Lower Transverse Link

  150

• Removing and Installing Track Rod

  151

• Assembly Overview: Wheel Bearing Housing, Trailing Arm (Front-Wheel Drive)

  155

• Removing and Installing Wheel Bearing Housing

  156

Brand: Volkswagen
|
Category: Automobile
|
Size: 12.2 MB

• Table of Contents

  3

• Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta

  8

• Interior Equipment

  9

  • Interior Mirror

    9

  • Tools

    9

  • Automatic Anti-Dazzle Interior Mirror

    9

  • Removing and Installing Interior Mirror with Rain Sensor

    9

  • Bonding on Retaining Plate for Interior Mirror with Rain Sensor

    10

  • Removing and Installing Interior Mirror in Vehicles with Adaptive Cruise Control

    11

  • Removing and Installing Interior Mirror

    13

  • Bonding on Retaining Plate for Interior Mirror Without Rain Sensor

    13

  • Compartments, Covers and Trims

    15

  • Tools

    15

  • Removing and Installing Basic Version Centre Console (Jetta 2010 ▸, Golf Variant 2010 ▸)

    19

  • Removing and Installing Highline Centre Console (Jetta 2005 ▸, Golf Variant 2007 ▸)

    24

  • Removing and Installing Highline Centre Console (Jetta 2010 ▸, Golf Variant 2010 ▸)

    33

  • Removing and Installing Mounting Bracket for Centre Console (Jetta 2005 ▸, Golf Variant 2007 ▸)

    43

  • Removing and Installing Mounting Bracket for Centre Console and Mounting Bracket for Footwell Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

    44

  • Removing and Installing Cup Holder in Highline Centre Console

    45

  • Repairing Cup Holder in Centre Console, Highline

    46

  • Removing and Installing Dash Panel Centre Vents (Vehicles with no Climatronic) (Jetta 2005 ▸, Golf Variant 2007 ▸)

    51

  • Removing and Installing Dash Panel Centre Vents (Vehicles with Climatronic) (Jetta 2005 ▸, Golf Variant 2007 ▸)

    53

  • Removing and Installing Centre Storage Compartment in Dash Panel (Jetta 2010 ▸, Golf Variant 2010 ▸)

    56

  • Removing and Installing Dash Panel Centre Vents (Jetta 2010 ▸, Golf Variant 2010 ▸)

    57

  • Removing and Installing Dash Panel Middle Trim (Jetta 2005 ▸, Golf Variant 2007 ▸)

    59

  • Removing and Installing Dash Panel Middle Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

    60

  • Removing and Installing Air Conditioner Controls Unit / Heater Controls Unit Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

    61

  • Removing and Installing Dash Panel End Trims

    62

  • Removing and Installing Steering Column Trim

    63

  • Removing and Installing Left Trim Panel on Driver Side with no Storage Compartment

    64

  • Removing and Installing Left Trim Panel on Driver Side with Storage Compartment

    66

  • Removing and Installing Right Trim Panel on Driver Side

    68

  • Removing and Installing Glove Compartment

    70

  • Removing and Installing Glove Compartment Lock Cylinder

    74

  • Removing and Installing Footwell Cover on Driver Side

    75

  • Removing and Installing Centre Cover (Jetta 2005 ▸, Golf Variant 2007 ▸)

    80

  • Removing and Installing Centre Cover (Jetta 2010 ▸, Golf Variant 2010 ▸)

    80

  • Removing and Installing Sun Visor

    81

  • Sill Panel Mouldings

    85

  • Removing and Installing Sill Panel Mouldings

    85

  • Removing and Installing Wheel Housing Liner (Saloon)

    86

  • Removing and Installing Wheel Housing Liner (Variant)

    87

  • Grab Handles

    89

  • Removing and Installing Roof Grab Handles

    89

  • Removing and Installing Roof Grab Handle Bracket

    90

  • Net Partition

    92

  • Removing and Installing Net Partition

    92

  • Removing and Installing Net Partition Mountings

    93

  • Removing and Installing Net Partition Bracket on Vehicles with no Panorama Sliding Roof

    94

  • Removing and Installing Net Partition Bracket on Vehicles with Panorama Sliding Roof

    95

• Passenger Protection

  96

  • Seat Belts

    96

  • General Safety Regulations When Working on Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

    97

  • Special Instructions for Belt Tensioners

    98

  • Storage, Transportation and Disposal of Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

    98

  • Assembly Overview — Front Seat Belts

    99

  • Removing and Installing Front Seat Belts

    99

  • Removing and Installing Front Belt Height Adjuster

    101

  • Removing and Installing Front Belt Buckle

    102

  • Assembly Overview — Rear Outer Seat Belts (Saloon)

    104

  • Removing and Installing Rear Outer Seat Belts (Saloon)

    104

  • Assembly Overview — Rear Outer Seat Belts (Variant)

    106

  • Removing and Installing Rear Outer Seat Belts (Variant)

    106

  • Assembly Overview — Rear Centre 3-Point Seat Belt

    108

  • Removing and Installing Rear Centre 3-Point Seat Belt

    108

  • Removing and Installing Middle Rear Seat Lap Belt

    109

  • Removing and Installing Rear Double Belt Buckle

    110

  • Inspecting Seat Belts

    112

  • Points to Check

    112

  • Checking Child Seat Anchors (ISOFIX) after an Accident

    116

  • Points to Check

    116

  • Removing and Installing Child Seat Anchorages in Rear Shelf

    116

  • Airbag

    117

  • Overview of Locations — Airbag Systems

    117

  • General Safety Regulations When Working on Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

    119

  • Special Instructions for Driver and Front Passenger Airbag

    120

  • Special Instructions for Curtain Airbag Modules

    120

  • Storage, Transportation and Disposal of Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

    120

  • Deactivating the Airbag

    120

  • Renewing Airbag Units Following an Accident

    121

  • Removing and Installing Airbag Control Unit J234

    122

  • Removing and Installing Airbag Unit on Driver Side (Jetta 2005 ▸, Golf Variant 2007 ▸)

    124

  • Removing and Installing Airbag Unit on Driver Side (Jetta 2010 ▸, Golf Variant 2010 ▸)

    128

  • Removing and Installing Airbag Coil Connector and Return Spring with Slip Ring F138

    131

  • Removing and Installing Key Operated Switch to Deactivate Front Passenger Airbag E224

    131

  • Removing and Installing Knee Airbag (Jetta 2010 ▸, Golf Variant 2010 ▸)

    132

    • Drive Vehicles

      134

    • Drive Vehicles

      136

  • Removing and Installing Return Spring with Slip Ring

    138

  • Removing and Installing Front Passenger Airbag Unit

    138

  • Removing and Installing Side Airbags on Driver and Front Passenger Sides

    143

  • Removing and Installing Rear Side-Airbag

    144

  • Removing and Installing Curtain Airbag on Driver and Passenger Side (Saloon)

    146

  • Removing and Installing Curtain Airbag on Driver and Passenger Side (Variant)

    148

  • Removing and Installing Seat Occupied Sensor, Front Passenger Side G128

    150

  • Adapting Components

    155

  • Seat Occupied Recognition (USA)

    156

  • Safety Precautions for When Working on Seat Occupied Recognition

    156

  • Procedure for Seat Belt Tensioner after an Accident and /Or Triggering of Airbag

    156

  • Assembly Overview — Seat Occupied Recognition (USA)

    157

  • Parts Repair Kit for Seat Occupied Recognition

    157

  • Removing and Installing Repair Kit for Seat Occupied Recognition on Vehicles with Manually Adjusted Seats

    158

  • Removing and Installing Repair Kit for Seat Occupied Recognition on Vehicles with Electrically Adjusted Seats

    167

  • Importers Reporting Obligation

    176

  • Crash Sensors

    178

  • Tools

    178

  • Removing and Installing Side Airbag Crash Sensor on Driver Side G179

    181

  • Variant 2010 ▸)

    181

  • Removing and Installing Side Airbag Crash Sensor on Front Passenger Side G180 (Jetta 2010 ▸, Golf Variant 2010 ▸)

    183

  • Removing and Installing Crash Sensors in Rear Wheel Housing (Saloon)

    183

  • Removing and Installing Crash Sensors in Rear Wheel Housing (Variant)

    185

Brand: Volkswagen
|
Category: Automobile
|
Size: 9.73 MB

• Table of Contents

  3

• Technical Data

  5

  • Gearbox Identification

    5

  • Location on Gearbox

    5

  • Identification Code, Assembly Allocation and Capacities

    5

  • Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta

    5

  • Overview — Power Transmission

    9

  • Calculating Overall Gear Ratio „I

    11

  • General Repair Notes

    12

  • Contact Corrosion

    12

  • Special Tools

    12

  • Components

    12

• Clutch

  16

  • Fault Finding, Power Transmission

    16

  • Repairing Clutch Mechanism

    17

  • Overview

    17

  • Assembly Overview — Pedal Cluster

    18

  • Removing and Installing Over-Centre Spring

    19

  • Removing and Installing Clutch Pedal

    23

  • Removing and Installing Mounting Bracket

    27

  • Removing and Installing Master Cylinder

    33

  • Removing and Installing Clutch Position Sender G476

    34

  • Assembly Overview — Hydraulics (LHD)

    38

  • Assembly Overview — Hydraulics (RHD)

    40

  • Bleeding Clutch System

    41

  • Repairing Clutch Release Mechanism

    43

  • Removing Pipe/Hose Line and Bleeder from and Installing on Slave Cylinder

    44

  • Removing and Installing Slave Cylinder with Release Bearing

    44

  • Removing and Installing Pipe/Hose Line or Plastic Line

    45

  • Renewing Input Shaft Seal

    47

  • Repairing Clutch — Vehicles with Turbo Diesel Engine

    49

  • Determining Clutch Manufacturer

    49

  • Removing and Installing „Sachs» Clutch

    51

  • Repairing „Sachs» Clutch

    54

  • Removing and Installing „Luk» Clutch

    54

  • Repairing „Luk» Clutch

    57

  • Repairing Clutch — Vehicles with Petrol Engine

    58

  • Repairing Clutch

    59

  • Removing and Installing Clutch

    59

• Controls, Housing

  63

  • Repairing Selector Mechanism

    63

  • Installation Position of Selector Mechanism

    63

  • Overview of Selector Mechanism

    64

  • Removing and Installing Gear Knob and Frame

    66

  • Removing and Installing Gaiter with Gear Knob and Noise Insulation

    66

  • Repairing Gear Lever and Selector Housing (through 10.06)

    68

  • Repairing Gear Lever and Selector Housing (from 11.06)

    70

  • Assembly Overview — Removing and Installing Selector Cables

    75

  • Plastic Relay Lever

    79

  • Removing and Installing Selector Mechanism

    82

  • Removing and Installing Gear Selector Cable and Gate Selector Cable

    84

  • Adjusting Selector Mechanism

    86

  • Functional Check

    88

  • Removing and Installing Gearbox in Vehicles with Turbo Diesel Engine

    89

  • Removing Gearbox

    89

  • Transporting Gearbox

    100

  • Installing Gearbox

    101

  • Specified Torques

    108

  • Removing and Installing Gearbox, Vehicles with Petrol Engine

    110

  • Removing Gearbox

    110

  • Transporting Gearbox

    120

  • Installing Gearbox

    121

  • Specified Torques

    128

  • Checking Gearbox Oil

    130

  • Dismantling and Assembling Gearbox

    132

  • Overview — Rear Final Drive

    132

  • Assembly Overview

    133

  • Removing and Installing Gearbox Housing and Selector Mechanism

    134

  • Removing and Installing Input Shaft, Output Shafts, Differential and Selector Rods

    136

  • Assembly Order, Gearbox »Without« Retaining Ring a for Input Shaft Sealing Cover

    138

  • Assembly Order, Gearbox »With« Retaining Ring a for Input Shaft Sealing Cover

    149

  • Repairing Gearbox Housing

    161

  • Repairing Clutch Housing

    171

  • Repairing Selector Unit

    176

  • Renewing Oil Seal for Selector Shaft

    177

  • Repairing Selector Forks

    179

Brand: Volkswagen
|
Category: Automobile
|
Size: 7.29 MB

• Body Repairs

  1

• Technical Data

  7

• Identification Plate

  8

• Safety Instructions

  10

• Moulded Foam Elements

  11

• Laser Welding

  12

• Galvanized Body Parts

  13

• Floor Group

  14

• High Strength Body Parts

  15

• Floor Group

  16

• Body Panel Gaps/Shut Lines

  18

• Body — Centre

  20

• Body — Rear

  21

• Body Dimensions

  24

• Body — Centre

  29

• Body — Rear

  34

• Floor Group — Front

  37

• Floor Group — Centre

  40

• Floor Group — Rear

  42

• Alignment Jig

  45

• Overview

  46

• Front Alignment Bracket

  47

• Centre Alignment Bracket

  52

• Rear Alignment Bracket

  54

• Portal Gauge

  56

• Renewing Right-Hand Bracket

  58

• Installing

  59

• Renewing Left Console

  61

• Removing

  62

• Installing

  63

• Renewing Retaining Bracket

  64

• Installing

  65

• Renewing Front Bumper Bracket

  67

• Installing

  68

• Renewing Upper Wheel Housing Longitudinal Member

  70

• Removing

  71

• Renewing Upper Longitudinal Member for Wheel Housing — Partial Renewal

  73

• Installing

  74

• Renewing Front Wheel Housing

  76

• Installing

  77

• Repairing Threads for Securing Subframe (Suspension Subframe)

  78

• Contents of Thread Repair Kit

  79

• Repairing Thread

  80

• Renewing Front Longitudinal Member

  83

• Removing

  84

• Installing

  86

• Renewing Front Longitudinal Member — Partial Replacement

  91

• Removing

  92

• Installing

  93

• Renewing Roof

  95

• Removing

  96

• Installing

  97

Brand: Volkswagen
|
Category: Automobile
|
Size: 5.89 MB

• Table of Contents

  3

• 1 Engine List

  5

  • In Litres Number of Cylinders 4

    8

  • Engine List

    9

• 2 Service Work

  10

  • Service Tables for «Rest of World» Markets

    10

  • Spark Plugs

    13

  • Service Scope for North American and Canadian Markets

    15

  • Service Scope for «Rest of World» Markets up to Model Year 2007

    21

  • Page

    21

  • Service Scope for «Rest of World» Markets from Model Year 2008

    29

    • Oil Change Service

      29

    • Interval Service

      31

    • Inspection Service

      32

  • Service Intervals for «Rest of World» Markets

    39

  • Service Intervals for North American and Canadian Markets

    39

  • Information on Longlife Service or Time or Distance Dependent Service

    40

• 3 General

  41

  • Tow Starting/Towing for North American and Canadian Markets

    41

  • Raising Vehicle with Lifting Platform and Trolley Jack

    45

  • Sticker

    45

  • Delivery Inspection

    46

  • Connecting Vehicle Diagnostic Tester

    47

  • Vehicle Identification Number

    50

  • Vehicle Data Sticker

    50

  • Countries with Elevated Sulphur Content in Diesel Fuel

    51

  • Severe Operating Conditions

    51

  • Engine Code and Engine Number

    52

  • Engine Oils for North American and Canadian Markets

    52

  • Engine Oils for «Rest of World» Markets

    52

  • RME Fuel -Biodiesel- for Vehicles up to 05.2006

    53

  • Type Plate

    53

• 4 Descriptions of Work

  55

  • Removable Towing Bracket: Check

    57

  • Swivel Joints: Visual Check

    59

  • Driving Light Assist and Cornering Light: Check Function

    59

  • Automatic Gearbox: Check ATF Level, 09G Gearbox

    60

  • Battery: Check Battery Terminal Clamps for Secure Seating

    60

  • Battery: Check Using Battery Tester with Printer VAS 5097A

    62

  • Front Passenger Front Airbag: Check Activation / Deactivation for Vehicles Without Seat

    62

  • Occupied Recognition

    62

  • Checking Tyres: Condition, Wear Pattern, Inflation Pressure, Tread Depth

    63

  • General Notes

    65

  • Brake and Clutch System: Change Brake Fluid

    71

  • Brake Fluid Level: Check

    75

  • Brake System: Perform Visual Check for Leaks and Damage

    76

  • Front and Rear Brake Pads/Linings: Check Thickness

    76

  • Front Brake Pads

    77

  • Checking Diesel Particulate Filter

    78

  • 6-Speed Dual Clutch Gearbox (DSG) 02E: Change Oil and Filter

    78

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

    79

  • Vehicle System Test: Perform Test

    79

  • Protective Bellows: Visual Check

    80

  • Renewing Rubber Buffers for Engine Cover

    81

  • Haldex Coupling (Jetta 4Motion): Change Oil

    82

  • Poly V-Belt: Adjust Tension on Engines Without Automatic Tensioning Roller

    85

  • Poly V-Belt: Check Condition

    86

  • Dash Panel Insert: Adapt Menu Language Versions

    87

  • Compass: Set Compass Zone and Calibrate Compass (for North American, Canadian and Mexican Markets)

    88

  • Multifunction Steering Wheel

    88

  • Cooling System: Check Frost Protection and Coolant Level

    92

  • Fuel Filter: Renew

    95

  • Air Filter: Clean Housing and Renew Filter Element

    99

  • Memory Seat: Perform Initialisation

    108

  • Engine and Components in Engine Compartment (from above and Below): Perform Visual Check for Leaks and Damage

    109

  • Engine Cover -Top-: Removing and Installing

    109

  • Removing and Installing Engine Compartment Cover -Bottom- (Noise Insulation)

    120

  • Engine Oil Level: Check

    121

  • Engine Oil: Drain or Extract; Renew Oil Filter and Replenish Engine Oil

    121

  • Checking Breakdown Set

    137

  • Panorama Sliding Roof: Check Function, Clean Guide Rails if Necessary and Grease with Special Grease, Clean Wind Deflector

    138

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

    139

  • Wheel Securing Bolts: Tighten to Prescribed Torque Setting

    140

  • Reading Radio Code with Fault Reader

    143

  • Radio/Navigation System: Activate Anti-Theft Coding

    144

  • Tyre Pressure Monitoring: Perform Basic Setting

    148

  • Renewing Tyre Pressure Sensors

    150

  • Dust and Pollen Filter: Clean Housing and Renew Filter Element

    150

  • Headlight Adjustment: Check

    151

  • Adjusting Headlights

    155

  • Service Interval Display: Reset

    157

  • Service Interval Display: Recode (for «Rest of World» Markets)

    158

  • Service Interval Display: Recode at Delivery Inspection

    160

  • Markets)

    160

  • Service Interval Display: Recode at First Oil Change Service (for North American and Canadian Markets)

    162

  • Sunroof: Check Function, Clean and Grease Guide Rails

    164

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

    164

  • Wiper Blades: Check Park Position

    169

  • Wiper Blade Protection: Remove

    170

  • Track Rod Ends: Check Play, Security and Boots

    173

  • Auxiliary Heater: Set Weekday in Menu of Combi-Instrument

    173

  • Door Arrester: Grease

    174

  • Transportation Mode: Switch off

    174

  • Transportation Devices: Remove Blocking Pieces from Front Axle Springs

    176

  • Underbody Sealant: Perform Visual Check for Damage to Underbody Sealant, Underbody Panels, Routing of Lines and Plugs

    176

  • Clock and Date: Set to Correct Time

    177

  • Camshaft Drive Toothed Belt: Check (TDI Unit Injector Engines)

    178

  • Toothed Belt and Toothed Belt Tensioning Roller: Renew (TDI Engines)

    178

  • Camshaft Drive Toothed Belt: Renew (2.0 L FSI and TFSI)

    179

  • Camshaft Drive Toothed Belt: Check (4-Cylinder Petrol Engines 1.4 L and 1.6 L)

    179

  • Spark Plugs: Renew

    179

Brand: Volkswagen
|
Category: Automobile
|
Size: 15.42 MB

• Table of Contents

  3

• General, Technical Data

  5

  • Transmission Identification

    5

  • Overview — Transmission

    6

  • Engine Codes, Engine Allocation

    7

  • Capacities

    8

  • Safety Precautions

    9

  • General Safety Precautions

    9

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

    9

  • Safety Precautions During Road Test with Testing Equipment

    10

  • Tow Starting and Towing Notes

    11

  • General Repair Information

    12

  • Tools

    12

  • Transmission

    12

  • Working with Vehicle Diagnostic Testers

    17

• Clutch

  19

  • Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011

    19

  • Overview — Dual Clutch, through Transmission Production Date 05/2011

    19

  • Dual Clutch, Removing, through Transmission Production Date 05/2011

    21

  • K 1″ and «K 2» Clutch Engaging Bearing Position, Adjusting, Transmission Production Date through 05/2011

    24

  • Dual Clutch, Installing, Transmission Production Date through 05/2011

    37

  • Dual Clutch, Removing and Installing, from Transmission Production Date 06/2011

    44

  • Overview — Dual Clutch, Transmission Production Date from 06/2011

    44

  • Dual Clutch, Removing, Transmission Production Date from 06/2011

    46

  • K 1″ and «K 2» Clutch Engaging Bearing Position, Adjusting, Transmission Production Date from 06/2011

    49

  • Dual Clutch, Installing, Transmission Production Date from 06/2011

    62

  • Clutch-Side Seals, Removing and Installing

    67

  • Special Tools

    70

• Controls, Housing

  74

  • Transmission Fluid, Replacing

    74

  • Selector Mechanism

    78

  • Selector Mechanism Overview, through 02/2009

    78

  • Selector Lever Cable, Removing and Installing, through 02/2009

    80

  • Selector Mechanism Overview, from 03/2009

    88

  • Selector Mechanism, Removing and Installing, Vehicles from 03/2009

    89

  • Selector Lever Cable, Checking

    97

  • Selector Lever Cable, Adjusting

    98

  • Selector Lever, Emergency Release

    100

  • Selector Lever Handle, Removing and Installing

    100

  • Button in Handle, Moving into Installation Position

    103

  • Selector Mechanism, Checking

    105

  • DSG Transmission Mechatronic J743

    107

  • DSG Transmission Mechatronic J743 Safety Precautions

    107

  • Overview — Mechatronic

    108

  • DSG Transmission Mechatronic J743 , Removing with Transmission Installed

    109

  • DSG Transmission Mechatronic J743 , Moving into «Removal Position» by Hand

    119

  • DSG Transmission Mechatronic J743 , Moving into Re- Moval Position by Hand

    119

  • DSG Transmission Mechatronic J743 , Installing

    123

  • Overview — Shift Forks with Mechatronic Removed

    129

  • Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010

    131

  • Transmissions with Different Output Shafts

    131

  • Transmission, Removing, Vehicles with 1.4L/90 Kw TFSI Engine and 1.4L/118 Kw TSI Engine

    131

  • Transmission, Removing, Vehicles with 1.6L/75 Kw MPI Engine

    139

  • Transmission, Removing, Vehicles with 1.9L 77 Kw TDI PD Engine

    147

  • Transmission, Removing, Vehicles with 1.6L/77 Kw TDI CR Engine

    154

  • Transmission, Installing, Jetta from MY 2005, Golf Wagon from MY 2007, Golf Wagon from

    161

  • Transmission to Engine» Tightening Specifications and Subframe Mount Information

    165

  • Transmission, Removing and Installing, Jetta from MY 2011

    170

  • Transmission, Removing, Jetta 2011 with 1.4L/90 Kw TFSI Engine and 1.4L/118 Kw TSI Engine

    170

  • Transmission, Removing, Jetta 2011 with 1.6L/77 Kw TDI CR Engine

    179

  • Transmission, Installing, Jetta MY 2011

    187

  • Tightening Specifications

    192

  • Transmission, Transporting and Securing to Assembly Stand

    195

  • Special Tools

    198

Brand: Volkswagen
|
Category: Automobile
|
Size: 11.23 MB

• Table of Contents

  3

• Technical Data

  5

  • Gearbox Identification

    5

  • Location on Gearbox

    5

  • Identification Code, Assembly Allocation and Capacities

    5

  • Overview — Power Transmission

    9

  • Calculating Overall Gear Ratio «I

    11

  • General Repair Notes

    12

  • Components

    12

• Clutch

  16

  • Fault Finding, Power Transmission

    16

  • Repairing Clutch Mechanism

    17

  • Overview

    17

  • Assembly Overview — Pedal Cluster

    18

  • Removing and Installing Over-Centre Spring

    19

  • Removing and Installing Clutch Pedal

    24

  • Removing and Installing Mounting Bracket

    29

  • Removing and Installing Master Cylinder

    35

  • Removing and Installing Clutch Position Sender G476

    37

  • Assembly Overview — Hydraulics (LHD Vehicles)

    41

  • Assembly Overview — Hydraulics (RHD Vehicles)

    43

  • Removing and Installing Slave Cylinder

    44

  • Bleeding Clutch System

    46

  • Repairing Clutch Release Mechanism

    48

  • Repairing Clutch, in Conjunction with Dual-Mass Flywheel

    50

  • Determining Clutch Manufacturer

    50

  • Removing and Installing Sachs Clutch

    52

  • Repairing Sachs Clutch

    54

  • Removing and Installing Luk Clutch

    54

  • Repairing Luk Clutch

    57

  • Repairing Clutch, in Conjunction with One-Piece Flywheel

    58

• Controls, Housing

  61

  • Fault Finding, Power Transmission

    61

  • Repairing Selector Mechanism

    62

  • Installation Position of Selector Mechanism

    62

  • Overview of Selector Mechanism

    63

  • Removing and Installing Gear Knob and Frame

    65

  • Removing and Installing Gaiter with Gear Knob and Noise Insulation

    65

  • Repairing Gear Lever and Selector Housing (through 10.06)

    67

  • Repairing Gear Lever and Selector Housing (from 11.06)

    69

  • Assembly Overview — Removing and Installing Selector Cables

    74

  • Plastic Relay Lever

    77

  • Removing and Installing Selector Mechanism

    79

  • Removing and Installing Gear Selector Cable and Gate Selector Cable

    82

  • Adjusting Selector Mechanism

    84

  • Functional Check

    86

  • Removing and Installing Gearbox

    88

  • Removing Gearbox

    89

  • Transporting Gearbox

    95

  • Installing Gearbox

    96

  • Specified Torques

    100

  • Checking and Topping up Gear Oil

    103

  • Preparation

    103

  • Draining Gear Oil

    104

  • Filling with Gear Oil

    105

  • Dismantling and Assembling Gearbox

    106

  • Overview — Gearbox

    106

  • Assembly Overview

    107

  • Removing and Installing Cover for Gearbox Housing and 5Th and 6Th Gear

    108

  • Removing and Installing Gearbox Housing and Shift Mechanism

    111

  • Removing and Installing Input Shaft, Output Shaft, Differential and Selector Forks

    112

  • Gear

    113

  • Assembly Sequence — Dismantling and Assembling Gearbox Completely

    119

  • Repairing Gearbox Housing and Clutch Housing

    136

  • Repairing Gearbox Housing Cover

    142

  • Repairing Selector Unit

    146

  • Dismantling and Assembling Selector Forks

    149

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: 4.24 MB

• Table of Contents

  3

• Technical Data

  5

  • Suggestions and Criticism, General Repair Notes

    5

  • Suggestions and Criticism of this Workshop Manual

    5

  • Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta

    5

  • General Repair Notes

    6

  • Gearbox

    6

  • Torque Converter

    6

  • Atf

    6

  • Automatic Gearbox Control Unit J217 with Fuzzy Logic

    6

  • Control Units in Vehicle

    6

  • Information on «09G Gearbox

    6

  • Tools

    6

  • Gearbox

    7

  • Gaskets, Seals and Oil

    8

  • Nuts and Bolts

    8

  • Electrical Components

    8

  • Guided Fault Finding, Vehicle Self-Diagnosis and Testing

    9

  • Gearbox Identification

    10

  • Gearbox Codes

    10

  • Capacities

    11

  • Planetary Gearbox and Final Drive

    11

  • Codes, Gearbox Allocation, Ratios

    12

• Torque Converter

  13

  • Identification of Torque Converter

    13

  • Draining Torque Converter

    13

  • Removing and Installing Torque Converter Oil Seal

    13

  • Installing Torque Converter

    14

• Controls, Housing

  15

  • Connecting «Tester

    15

  • Connecting Vehicle Diagnosis, Testing and Information System VAS 5051

    15

  • Electrical and Electronic Components and Their Locations

    17

  • Multifunction Switch F125

    22

  • Removing Multifunction Switch F125

    22

  • Installing Multifunction Switch F125

    23

  • Adjusting Multifunction Switch F125

    24

  • Selector Mechanism up to 02.2009

    26

  • Overview of Selector Mechanism up to 02.2009

    26

  • Removing and Installing Selector Mechanism with Selector Lever up to 02.2009

    27

  • Removing and Installing Selector Lever Cable up to 02.2009

    27

  • Checking Selector Lever Cable

    34

  • Adjusting Selector Lever Cable

    34

  • Emergency Release of Selector Lever

    35

  • Removing and Installing Knob

    36

  • Checking Selector Mechanism

    37

  • Selector Mechanism from 03.2009 Onwards

    39

  • Overview of Selector Mechanism in Vehicles from 03.2009 Onwards

    39

  • Onwards

    39

  • Emergency Release of Selector Lever

    41

  • Removing and Installing Gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008

    42

  • Removing Gearbox, Vehicles with 1.6 L — 75 Kw and 2.0 L — 110 Kw (FSI) Engines

    42

  • Installing Gearbox, Vehicles with 1.6 L — 75 Kw and 2.0 L — 110 Kw (FSI) Engines

    49

  • Removing Gearbox, Vehicles with 2.5 L, 110 Kw Engine

    49

  • Installing Gearbox, Vehicles with 2.5 L, 110 Kw Engine

    57

  • Torque Settings, Gearbox to Engine

    58

  • Removing and Installing Gearbox, Jetta 2011

    61

  • Removing Gearbox, Jetta 2011 with 2.0 L — 85 Kw Engine

    61

  • Installing Gearbox, Jetta 2011 with 2.0 L — 85 Kw Engine

    67

  • Removing Gearbox, Jetta 2011 with 2.5 L — 125 Kw Engine

    67

  • Installing Gearbox, Jetta 2011 with 2.5 L — 125 Kw Engine

    76

  • Torque Settings, Gearbox to Engine

    76

  • Transporting Gearbox

    79

  • ATF Cooler

    80

  • Assembly Overview — ATF Cooler

    80

  • Checking ATF Level and Topping up

    81

  • Checking ATF Level

    82

  • Topping up ATF

    83

  • Draining and Filling ATF

    84

Brand: Volkswagen
|
Category: Automobile
|
Size: 1.6 MB

• Table of Contents

  3

• Starter, Current Supply, CCS

  5

  • Battery a

    5

  • Fundamentals for Batteries a

    5

  • Types of Battery

    5

  • Warning Notices and Safety Regulations

    6

  • Battery Terminal Connection

    8

  • Checking Battery a

    9

  • Testing Different Battery Types

    9

  • Visual Check

    10

  • Test of Colour Display of Magic Eye

    11

  • Battery Tester with Printer VAS 5097 a

    12

  • Battery Tester with Printer VAS 6161

    17

  • Midtronics MCR340V Battery Tester (Only for Usa/Canada)

    23

  • Current Draw Test

    27

  • Checking No-Load Voltage of Battery a (Stock and Stored Vehicles)

    28

  • Charging Battery a

    30

  • Battery Charger VAS 5095 a

    30

  • Battery Charger VAS 5900

    35

  • Trickle Charging

    46

  • Battery Charger VAS 5903

    47

  • Battery Charger VAS 5906

    59

  • Midtronics INC 940 Battery Charger (Only for Usa/Canada)

    61

  • Solar Panel VAS 6102 a

    66

  • Totally Discharged Batteries a

    67

  • Cruise Control System (CCS)

    69

  • Activating and Deactivating Cruise Control System (CCS)

    69

• Gauges, Instruments

  70

• Windscreen Wash/Wipe System

  71

  • Washer Fluid Line Hose Couplings

    71

  • Windscreen and Rear Window Washer System

    71

  • Headlight Washer System

    72

  • Hose Repair

    73

  • General Description

    73

  • Repairing Smooth Pipe

    73

  • Repairing Corrugated Pipe

    73

  • Distinguishing Features of Jointless Wiper Blades

    75

• Lights, Bulbs, Switches — Exterior

  76

  • Operation and Safety Notes for Gas Discharge Bulbs

    76

• Lights, Bulbs, Switches — Interior

  79

  • Socket U5

    79

  • Removing and Installing 12 V Socket U5

    79

  • Removing and Installing Socket Illumination Bulb L42

    79

  • Cigarette Lighter U1

    80

  • General Description

    80

  • Assembly Overview

    81

  • Removing and Installing Cigarette Lighter Socket

    82

  • Removing and Installing Cigarette Lighter Illumination Bulb L28

    84

• Wiring

  86

  • Vehicle Diagnosis, Testing and Information System VAS 5051B

    86

  • Connecting Vehicle Diagnosis, Testing and Information System VAS 5051B

    86

  • Connecting Vehicle Diagnostic Tester Bora Model Year 1998 to 2003

    87

  • Repairs to Wiring Harnesses and Connectors

    89

  • Wiring Harness Repair Set

    89

  • Tool Descriptions

    90

  • General Notes Concerning Repairs to Vehicle Electrical System

    94

  • Repairs to Wiring Harnesses

    95

  • Repairs to Contact Housings and Connectors

    105

  • Releasing and Dismantling Contact Housings

    109

  • Contact Surface Cleaning Set VAS 6410

    115

  • Using the Contact Surface Cleaning Set VAS 6410

    115

  • Cleaning Battery Terminals

    118

  • Renewing Lambda Probe

    121

  • Renewing LSF Lambda Probe (4-Pin)

    121

  • Renewing LSU Lambda Probe (6-Pin)

    122

  • Types of Protective Tube on Uniform Lambda Probes

    123

Brand: Volkswagen
|
Category: Automobile
|
Size: 10.89 MB

• Table of Contents

  3

• Technical Data

  5

  • Gearbox Identification

    5

  • Code, Engine Allocation

    6

  • Capacities

    7

  • General Repair Notes

    8

  • Tools

    8

  • Gearbox

    8

  • Oil

    10

  • Working with Vehicle Diagnostic Testers

    10

• Clutch

  12

  • Removing and Installing the Dual Clutch

    12

  • Removing Dual Clutch

    12

  • Adjusting Position of Engagement Bearings «K 1 and K 2

    16

  • Installing Dual Clutch

    26

• Controls, Housing

  34

  • Renewing Gear Oil

    34

  • Selector Mechanism

    37

  • Overview — Selector Mechanism in Vehicles up to 02.2009

    37

  • Removing and Installing Selector Lever Cable — Vehicles up to 02.2009

    38

  • Overview of Selector Mechanism — Vehicles from 03.2009 Onwards

    45

  • Removing and Installing Selector Mechanism with Selector Lever and Selector Lever Cable

    46

  • Vehicles from 03.2009 Onwards

    46

  • Checking Selector Lever Cable

    47

  • Adjusting Selector Lever Cable

    47

  • Emergency Release of Selector Lever

    50

  • Removing and Installing Selector Lever Handle

    50

  • Checking Selector Mechanism

    52

  • Mechatronic Unit for Dual Clutch Gearbox J743

    54

  • Safety Note on Mechatronic Unit for Dual Clutch Gearbox J743

    54

  • Overview — Mechatronic Unit

    55

  • Removing Mechatronic Unit for Dual Clutch Gearbox J743 with Gearbox Installed

    56

  • Moving Mechatronic Unit for Dual Clutch Gearbox J743 into «Removal Position» by Hand

    66

  • Installing Mechatronic Unit for Dual Clutch Gearbox J743

    69

  • View of Selector Forks with Mechatronic Unit Removed

    76

  • Removing and Installing Gearbox

    77

  • Information about Gearboxes with Different Output Shafts

    77

  • Removing Gearbox, Vehicles with 1.4 L/90 Kw TFSI Engine and 1.4 L/118 Kw TSI Engine

    78

  • Removing Gearbox, Vehicles with 1.6 L/75 Kw MPI Engine

    85

  • Removing Gearbox — Vehicles with 1.9 L/77 Kw TDI PD Engine

    94

  • Removing Gearbox — Vehicles with 1.6 L/77 Kw TDI CR Engine

    101

  • Installing Gearbox

    108

  • Torque Settings «Gearbox to Engine» and Notes on Assembly Mounting

    111

  • Transporting Gearbox and Securing to Assembly Stand

    115

• Gears, Shafts

  117

  • Currently, no Repairs Can be Made to Gears and Shafts

    117

• Renewing Oil Seal for Right Stub Shaft

  118

• Final Drive — Front Differential

  118

  • Oil Seals

    118

• Renewing Oil Seal for Left Stub Shaft

  120

• Renewing Seal for Right Flange Shaft

  122

• Renewing Oil Seal for Left Flange Shaft

  124