Volkswagen Sharan 2011 – 2016 Workshop Manual – PDF DOWNLOAD

Volkswagen Sharan 2011 – 2016 Workshop Manual – PDF DOWNLOAD

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Volkswagen Sharan 2011 – 2016 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 8044
Downloadable : Yes
File Type : PDF
Size: 317 MB

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Volkswagen Sharan 2011 – 2016 Workshop Manual – PDF DOWNLOAD

• The Volkswagen Sharan 2011-2016 Workshop Manual is a comprehensive guide for individuals who are interested in repairing or maintaining their Volkswagen Sharan from the 2011 to 2016 model years. It provides detailed information on various components of the vehicle, including the engine, transmission, suspension, steering, brakes, electrical systems, and much more. The manual is designed to help users diagnose and troubleshoot problems with their Sharan, as well as provide information on regular maintenance procedures that can help keep the vehicle running smoothly.
• One of the key features of the Volkswagen Sharan 2011-2016 Workshop Manual is its step-by-step instructions and detailed illustrations. The manual includes clear and concise explanations for each repair or maintenance procedure, and is supported by detailed diagrams and schematics that provide a visual representation of the steps involved. The manual also includes torque specifications and other important information that can help users complete repairs and maintenance procedures accurately and efficiently.
• Another valuable aspect of the Volkswagen Sharan 2011-2016 Workshop Manual is its comprehensive coverage of the vehicle’s electrical systems. The manual includes detailed information on the Sharan’s electrical circuits and wiring diagrams, as well as information on diagnosing and troubleshooting electrical problems. This information can be especially useful for individuals who are not familiar with electrical systems, as it can help them understand the components and how they work together.
• Overall, the Volkswagen Sharan 2011-2016 Workshop Manual is an essential tool for anyone who owns or works on a Volkswagen Sharan from the 2011 to 2016 model years. It provides a wealth of information that can help users repair, maintain, and understand their vehicle, and can save them time and money by enabling them to perform tasks themselves rather than relying on a mechanic.

TABLE OF CONTENTS:

Volkswagen Sharan 2011 – 2016 Workshop Manual – PDF DOWNLOAD

Emission_test_VW…………………………………………………………………………………………………………………………………………………………………. 1
AKP 6N Polo; manual gearbox……………………………………………………………………………………………………………………………………………………. 1
AKP 6N Polo; automatic gearbox…………………………………………………………………………………………………………………………………………………. 2
AVQ 1T Touran………………………………………………………………………………………………………………………………………………………………… 3
AXA 7F Transporter……………………………………………………………………………………………………………………………………………………………. 4
AXB 7H Transporter……………………………………………………………………………………………………………………………………………………………. 5
AXC 7H Transporter……………………………………………………………………………………………………………………………………………………………. 6
AXE 7J Transporter……………………………………………………………………………………………………………………………………………………………. 7
BDL 7H Transporter……………………………………………………………………………………………………………………………………………………………. 8
BDL 7H Multivan ……………………………………………………………………………………………………………………………………………………………… 9
BJJ 2E Diesel direct injection system…………………………………………………………………………………………………………………………………………… 10
BJJ 2F Diesel direct injection system…………………………………………………………………………………………………………………………………………… 11
BPC 7J Transporter……………………………………………………………………………………………………………………………………………………………. 12
BSE 521 Golf Plus; …………………………………………………………………………………………………………………………………………………………… 13
BSE 52 Golf Plus; ……………………………………………………………………………………………………………………………………………………………. 14
BSF 521 Golf Plus;……………………………………………………………………………………………………………………………………………………………. 15
BSF 52 Golf Plus;…………………………………………………………………………………………………………………………………………………………….. 16
BSX 2C Caddy…………………………………………………………………………………………………………………………………………………………………. 17
BWS 362,365 Passat……………………………………………………………………………………………………………………………………………………………. 18
BWS 36 Passat………………………………………………………………………………………………………………………………………………………………… 19
BYD 1K Golf………………………………………………………………………………………………………………………………………………………………….. 20
BZB 35 Passat CC; injection and ignition system: Motronic MED 17.5…………………………………………………………………………………………………………………. 21
CAAA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………. 22
CAAA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………. 23
CAAA SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 24
CAAB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 25
CAAB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 26
CAAB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 27
CAAB 7F Transporter…………………………………………………………………………………………………………………………………………………………… 28
CAAB 7F Transporter…………………………………………………………………………………………………………………………………………………………… 29
CAAB SG T6 – 0GG……………………………………………………………………………………………………………………………………………………………… 30
CAAB SG T6 – 0GZ……………………………………………………………………………………………………………………………………………………………… 31
CAAB SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 32
CAAB SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………. 33
CAAB SF T6 (SF) – 0GZ…………………………………………………………………………………………………………………………………………………………. 34
CAAB SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………. 35
CAAC SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 36
CAAC SG T6 – 0GG……………………………………………………………………………………………………………………………………………………………… 37
CAAC SG T6 – 0GZ……………………………………………………………………………………………………………………………………………………………… 38
CAAC SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………. 39
CAAC SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………. 40
CAAC SF T6 (SF) – 0GZ…………………………………………………………………………………………………………………………………………………………. 41
CAAD 7E Transporter…………………………………………………………………………………………………………………………………………………………… 42
CAAD 7E Transporter…………………………………………………………………………………………………………………………………………………………… 43
CAAD 7E Transporter…………………………………………………………………………………………………………………………………………………………… 44
CAAE 7E Transporter…………………………………………………………………………………………………………………………………………………………… 45
CAAE 7E Transporter…………………………………………………………………………………………………………………………………………………………… 46
CAAE 7E Transporter…………………………………………………………………………………………………………………………………………………………… 47
CASA 7P Touareg; diesel direct injection system………………………………………………………………………………………………………………………………….. 48
CAVD 517 Golf Cabrio; MED 17.5.10………………………………………………………………………………………………………………………………………………. 49
CAVD 358 CC………………………………………………………………………………………………………………………………………………………………….. 50
CAWB 13 Scirocco; injection and ignition system: Motronic MED 17.5…………………………………………………………………………………………………………………. 51
CAWB 35 Passat CC; injection and ignition system: Motronic MED 17.5………………………………………………………………………………………………………………… 52
CAXA 362,365 Passat; MED 9…………………………………………………………………………………………………………………………………………………….. 53
CAXA 5N Tiguan; MED 9…………………………………………………………………………………………………………………………………………………………. 54
CAXA 517 Golf Cabrio; MED 9.5.10……………………………………………………………………………………………………………………………………………….. 55
CAXA 16 Jetta; MED 17.05.20……………………………………………………………………………………………………………………………………………………. 56
CAYB AJ Golf Variant………………………………………………………………………………………………………………………………………………………….. 57
CAYB 1T Touran……………………………………………………………………………………………………………………………………………………………….. 58
CAYB 52 Golf Plus…………………………………………………………………………………………………………………………………………………………….. 59
CAYC 1K Jetta………………………………………………………………………………………………………………………………………………………………… 60
CAYC AJ Golf Variant………………………………………………………………………………………………………………………………………………………….. 61
CAYC 1T Touran……………………………………………………………………………………………………………………………………………………………….. 62
CAYC 3C,362,365 Passat………………………………………………………………………………………………………………………………………………………… 63
CAYC 517 Golf convertible……………………………………………………………………………………………………………………………………………………… 64
CAYC 36 Passat……………………………………………………………………………………………………………………………………………………………….. 65
CAYC 51 Golf convertible………………………………………………………………………………………………………………………………………………………. 66
CAYC 52 Golf Plus…………………………………………………………………………………………………………………………………………………………….. 67
CAYC 5C Beetle Cabriolet………………………………………………………………………………………………………………………………………………………. 68
CAYC 16 Jetta………………………………………………………………………………………………………………………………………………………………… 69
CAYC 52 Golf Plus…………………………………………………………………………………………………………………………………………………………….. 70
CAYD 2C Caddy………………………………………………………………………………………………………………………………………………………………… 71
CAYD 2C Caddy………………………………………………………………………………………………………………………………………………………………… 72
CAYD 2C Caddy………………………………………………………………………………………………………………………………………………………………… 73
CAYD 2C Caddy………………………………………………………………………………………………………………………………………………………………… 74
CAYD SA Caddy4 – 7MJ………………………………………………………………………………………………………………………………………………………….. 75
CAYD SA Caddy4 – 7MG………………………………………………………………………………………………………………………………………………………….. 76
CAYD SA Caddy4 – 0GZ………………………………………………………………………………………………………………………………………………………….. 77
CAYD SA Caddy4 – 7MQ………………………………………………………………………………………………………………………………………………………….. 78
CAYE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 79
CAYE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 80
CAYE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 81
CAYE SA Caddy4 – 7MJ………………………………………………………………………………………………………………………………………………………….. 82
CBAC 357 CC; diesel direct injection system……………………………………………………………………………………………………………………………………… 83
CBAC 3C Passat; diesel direct injection system…………………………………………………………………………………………………………………………………… 84
CBDA 52 Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 85
CBDB 5K Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 86
CBDB 5M Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 87
CBDB 1K Golf Variant; diesel direct injection system…………………………………………………………………………………………………………………………….. 88
CBDB 52 Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 89
CBDC 3C Passat; diesel direct injection system…………………………………………………………………………………………………………………………………… 90
CBDC 5M Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 91
CBDC 52 Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 92
CBRA 1K Golf; Motronic ME 7.1.1………………………………………………………………………………………………………………………………………………… 93
CBZA AJ Golf Estate; Simos 10………………………………………………………………………………………………………………………………………………….. 94
CBZA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 95
CBZA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 96
CBZA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 97
CBZB 2C Caddy………………………………………………………………………………………………………………………………………………………………… 98
CBZB 517 Golf Cabrio; Simos 10…………………………………………………………………………………………………………………………………………………. 99
CBZB AJ5 Golf Estate; Simos 10…………………………………………………………………………………………………………………………………………………. 100
CBZB 1T Touran; Simos 10………………………………………………………………………………………………………………………………………………………. 101
CBZB 16 Jetta; Simos 10……………………………………………………………………………………………………………………………………………………….. 102
CBZB 2C Caddy………………………………………………………………………………………………………………………………………………………………… 103
CBZB 2C Caddy………………………………………………………………………………………………………………………………………………………………… 104
CBZC 6R Polo; Simos 10………………………………………………………………………………………………………………………………………………………… 105
CCHB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 106
CCSA 5M,521 Golf Plus; ……………………………………………………………………………………………………………………………………………………….. 107
CCSA 52 Golf Plus; …………………………………………………………………………………………………………………………………………………………… 108
CCZA 7N1 Sharan………………………………………………………………………………………………………………………………………………………………. 109
CCZA 7N Sharan……………………………………………………………………………………………………………………………………………………………….. 110
CCZA 35 CC…………………………………………………………………………………………………………………………………………………………………… 111
CCZA 16 Jetta………………………………………………………………………………………………………………………………………………………………… 112
CCZB 357 CC………………………………………………………………………………………………………………………………………………………………….. 113
CCZB 362,365 Passat…………………………………………………………………………………………………………………………………………………………… 114
CCZB 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 115
CCZB 36 Passat……………………………………………………………………………………………………………………………………………………………….. 116
CCZB 5N Tiguan;………………………………………………………………………………………………………………………………………………………………. 117
CCZB 35 CC…………………………………………………………………………………………………………………………………………………………………… 118
CCZB 51 Golf convertible………………………………………………………………………………………………………………………………………………………. 119
CCZD 5N Tiguan;………………………………………………………………………………………………………………………………………………………………. 120
CDAA 362,365 Passat…………………………………………………………………………………………………………………………………………………………… 121
CDAA 35 CC…………………………………………………………………………………………………………………………………………………………………… 122
CDAA 36 Passat……………………………………………………………………………………………………………………………………………………………….. 123
CDAB 362,365 Passat…………………………………………………………………………………………………………………………………………………………… 124
CDAB 35 CC…………………………………………………………………………………………………………………………………………………………………… 125
CDAB 36 Passat……………………………………………………………………………………………………………………………………………………………….. 126
CDBA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 127
CDCA 2H Diesel direct injection system………………………………………………………………………………………………………………………………………….. 128
CDCA 2H Diesel direct injection system………………………………………………………………………………………………………………………………………….. 129
CDCA 2H Diesel direct injection system………………………………………………………………………………………………………………………………………….. 130
CDGA 362, 365 Passat; MED nutural gas…………………………………………………………………………………………………………………………………………… 131
CDLA 13 Scirocco R……………………………………………………………………………………………………………………………………………………………. 132
CDLC 13 Scirocco R……………………………………………………………………………………………………………………………………………………………. 133
CDLC 5K Golf R……………………………………………………………………………………………………………………………………………………………….. 134
CDLF 5K Golf R……………………………………………………………………………………………………………………………………………………………….. 135
CDLG 5K Golf ………………………………………………………………………………………………………………………………………………………………… 136
CFCA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………. 137
CFCA SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 138
CFCA SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………. 139
CFFA 5K Golf; diesel direct injection system…………………………………………………………………………………………………………………………………….. 140
CFFA 5N Tiguan; diesel direct injection system…………………………………………………………………………………………………………………………………… 141
CFFA 1F Eos; diesel direct injection system……………………………………………………………………………………………………………………………………… 142
CFFA 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………. 143
CFFA 36 Passat; diesel direct injection system…………………………………………………………………………………………………………………………………… 144
CFFA 7N Sharan; diesel direct injection system…………………………………………………………………………………………………………………………………… 145
CFFB 5K Golf; diesel direct injection system…………………………………………………………………………………………………………………………………….. 146
CFFB 5N Tiguan; diesel direct injection system…………………………………………………………………………………………………………………………………… 147
CFFB 1F Eos; diesel direct injection system……………………………………………………………………………………………………………………………………… 148
CFFB 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………. 149
CFFB 36 Passat; diesel direct injection system…………………………………………………………………………………………………………………………………… 150
CFFB 7N Sharan; diesel direct injection system…………………………………………………………………………………………………………………………………… 151
CFFB 5C Beetle Cabriolet; diesel direct injection system………………………………………………………………………………………………………………………….. 152
CFFD 5N Tiguan; diesel direct injection system…………………………………………………………………………………………………………………………………… 153
CFFE 7N Sharan; diesel direct injection system…………………………………………………………………………………………………………………………………… 154
CFGB 7N Sharan; diesel direct injection system…………………………………………………………………………………………………………………………………… 155
CFGC 13 Scirocco; Diesel, Common Rail…………………………………………………………………………………………………………………………………………… 156
CFGC 35 CC; Diesel, Common Rail………………………………………………………………………………………………………………………………………………… 157
CFGC 36 Passat Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………. 158
CFGC 5N Tiguan; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 159
CFGC 7N Sharan; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 160
CFHB 5K Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 161
CFHB 5M Golf Plus; diesel direct injection system………………………………………………………………………………………………………………………………… 162
CFHB AJ Golf Variant; diesel direct injection system……………………………………………………………………………………………………………………………… 163
CFHB 13 Scirocco; diesel direct injection system…………………………………………………………………………………………………………………………………. 164
CFHC 5K Golf Plus; Diesel-Direkteinspritzanlage………………………………………………………………………………………………………………………………….. 165
CFHC AJ Golf Variant; diesel direct injection system……………………………………………………………………………………………………………………………… 166
CFHC 2C Caddy………………………………………………………………………………………………………………………………………………………………… 167
CFHC 13 Scirocco; diesel direct injection system…………………………………………………………………………………………………………………………………. 168
CFHC 1T Touran; diesel direct injection system…………………………………………………………………………………………………………………………………… 169
CFHC 51 Golf Cabriolet; diesel direct injection system……………………………………………………………………………………………………………………………. 170
CFHC 5M,52 Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………… 171
CFHC 52 Golf Plus; Diesel, Common Rail………………………………………………………………………………………………………………………………………….. 172
CFHC 2C Caddy………………………………………………………………………………………………………………………………………………………………… 173
CFHC 2C Caddy………………………………………………………………………………………………………………………………………………………………… 174
CFHC SA Caddy4 – 7MJ………………………………………………………………………………………………………………………………………………………….. 175
CFHE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 176
CFHE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 177
CFHE 2C Caddy………………………………………………………………………………………………………………………………………………………………… 178
CFHF 2C Caddy………………………………………………………………………………………………………………………………………………………………… 179
CFHF 1T Touran; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 180
CFHF 2C Caddy………………………………………………………………………………………………………………………………………………………………… 181
CFHF 2C Caddy………………………………………………………………………………………………………………………………………………………………… 182
CFHF SA Caddy4 – 7MJ………………………………………………………………………………………………………………………………………………………….. 183
CFJA 1T Touran; diesel direct injection system…………………………………………………………………………………………………………………………………… 184
CFJA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 185
CFJA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 186
CFJB 1T Touran; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 187
CFPA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 188
CFPA S1 AMAROK……………………………………………………………………………………………………………………………………………………………….. 189
CFPA S1 AMAROK……………………………………………………………………………………………………………………………………………………………….. 190
CFWA 60 Polo KH IN……………………………………………………………………………………………………………………………………………………………. 191
CFWA 6R Polo…………………………………………………………………………………………………………………………………………………………………. 192
CGEA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 193
CGEA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 194
CGFA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 195
CGFA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 196
CGNA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 197
CGNA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 198
CGRA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 199
CGRA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 200
CGYA 35 Passat CC; CC…………………………………………………………………………………………………………………………………………………………. 201
CHGA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 202
CHGA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 203
CHHA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 204
CHHB 5G Golf…………………………………………………………………………………………………………………………………………………………………. 205
CHPA 5G Golf; ME 17…………………………………………………………………………………………………………………………………………………………… 206
CHPA AU Golf; ME 17…………………………………………………………………………………………………………………………………………………………… 207
CHPA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 208
CHYA 121 up!…………………………………………………………………………………………………………………………………………………………………. 209
CHYA 6C Polo…………………………………………………………………………………………………………………………………………………………………. 210
CHYB 121 up!…………………………………………………………………………………………………………………………………………………………………. 211
CHYB 6C Polo…………………………………………………………………………………………………………………………………………………………………. 212
CHZB 6C Polo…………………………………………………………………………………………………………………………………………………………………. 213
CHZC 6C Polo…………………………………………………………………………………………………………………………………………………………………. 214
CHZG SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 215
CJGD 7P Touareg; diesel direct injection system………………………………………………………………………………………………………………………………….. 216
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 217
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 218
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 219
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 220
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 221
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 222
CJKA 7E Transporter…………………………………………………………………………………………………………………………………………………………… 223
CJKA SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 224
CJKA SG T6 – 7GR……………………………………………………………………………………………………………………………………………………………… 225
CJKA SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 226
CJKA SG T6 – 0GG……………………………………………………………………………………………………………………………………………………………… 227
CJKA SG T6 – 0GV……………………………………………………………………………………………………………………………………………………………… 228
CJKA SG T6 – 7MT……………………………………………………………………………………………………………………………………………………………… 229
CJKB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 230
CJKB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 231
CJKB 7E Transporter…………………………………………………………………………………………………………………………………………………………… 232
CJKB SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 233
CJKB SG T6 – 7MJ……………………………………………………………………………………………………………………………………………………………… 234
CJKB SG T6 – 7MT……………………………………………………………………………………………………………………………………………………………… 235
CJKB SG T6 – 0GG……………………………………………………………………………………………………………………………………………………………… 236
CJKB SG T6 – 0GV……………………………………………………………………………………………………………………………………………………………… 237
CJKB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………. 238
CJKB SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………. 239
CJKB SF T6 (SF) – 7MT…………………………………………………………………………………………………………………………………………………………. 240
CJKB SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………. 241
CJKB SF T6 (SF) – 0GV…………………………………………………………………………………………………………………………………………………………. 242
CJLA 60 Polo…………………………………………………………………………………………………………………………………………………………………. 243
CJMA 7P Touareg; diesel direct injection system………………………………………………………………………………………………………………………………….. 244
CJTA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 245
CJTA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 246
CJXC 5G Golf…………………………………………………………………………………………………………………………………………………………………. 247
CJZA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 248
CJZB BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 249
CJZC 6C Polo…………………………………………………………………………………………………………………………………………………………………. 250
CJZD 6C Polo…………………………………………………………………………………………………………………………………………………………………. 251
CKDA 7P Touareg; diesel direct injection system………………………………………………………………………………………………………………………………….. 252
CKFC 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 253
CKFC 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 254
CKFC BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 255
CKMA 362,365 Passat; MED 17……………………………………………………………………………………………………………………………………………………. 256
CKMA 357 Passat CC; MED 17…………………………………………………………………………………………………………………………………………………….. 257
CKMA 358 CC………………………………………………………………………………………………………………………………………………………………….. 258
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 259
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 260
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 261
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 262
CKTC 2E Crafter………………………………………………………………………………………………………………………………………………………………. 263
CKTC 2E Crafter………………………………………………………………………………………………………………………………………………………………. 264
CKTC 2F Crafter………………………………………………………………………………………………………………………………………………………………. 265
CKTC 2F Crafter………………………………………………………………………………………………………………………………………………………………. 266
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 267
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 268
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 269
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………. 270
CKUC 2E Crafter………………………………………………………………………………………………………………………………………………………………. 271
CLCA 2C Caddy………………………………………………………………………………………………………………………………………………………………… 272
CLCA 1T Touran; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 273
CLHA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 274
CLHA 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 275
CLHA BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 276
CLHB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 277
CLHB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 278
CLHB BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 279
CLJA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 280
CLJA 5N Tiguan; Diesel, Common Rail…………………………………………………………………………………………………………………………………………….. 281
CLLA 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………. 282
CLLA 36 Passat; diesel direct injection system…………………………………………………………………………………………………………………………………… 283
CLNA 60 Polo…………………………………………………………………………………………………………………………………………………………………. 284
CLPA 64 Polo…………………………………………………………………………………………………………………………………………………………………. 285
CMBA 5G Golf; ME 17…………………………………………………………………………………………………………………………………………………………… 286
CMKA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 287
CMKA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 288
CMKB 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 289
CMKB 7P Touareg………………………………………………………………………………………………………………………………………………………………. 290
CMSB 137 Scirocco; MED 9.5.10………………………………………………………………………………………………………………………………………………….. 291
CMSB 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 292
CMTA 7P5 Touareg……………………………………………………………………………………………………………………………………………………………… 293
CMTA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 294
CMVA 3D Phaeton………………………………………………………………………………………………………………………………………………………………. 295
CMXA 521 Golf Plus……………………………………………………………………………………………………………………………………………………………. 296
CMXA 5K Golf…………………………………………………………………………………………………………………………………………………………………. 297
CMXA 52 Golf Plus…………………………………………………………………………………………………………………………………………………………….. 298
CNEA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 299
CNEA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 300
CNEA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 301
CNEA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 302
CNEA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 303
CNFA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 304
CNFA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 305
CNFA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 306
CNFA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 307
CPGA 12 up!………………………………………………………………………………………………………………………………………………………………….. 308
CPTA 5G Golf; ME 17…………………………………………………………………………………………………………………………………………………………… 309
CPTA 6R Polo; ME 17…………………………………………………………………………………………………………………………………………………………… 310
CPVA 5G Golf; ME 17…………………………………………………………………………………………………………………………………………………………… 311
CPVB 5G Golf…………………………………………………………………………………………………………………………………………………………………. 312
CPVB AM Golf SV………………………………………………………………………………………………………………………………………………………………. 313
CPVB BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 314
CPWA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 315
CPWA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 316
CPWA SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 317
CRBC 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 318
CRBC 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 319
CRBC BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 320
CRCA 7P Touareg; diesel direct injection system………………………………………………………………………………………………………………………………….. 321
CRGA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 322
CRKB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 323
CRKB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 324
CRKB BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 325
CRKB AM Golf Sportsvan; Diesel, Common Rail……………………………………………………………………………………………………………………………………… 326
CRLB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 327
CRLB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 328
CRLB BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 329
CRLB 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 330
CSCA 5K XL1; Diesel…………………………………………………………………………………………………………………………………………………………… 331
CSCA 6Z XL1; Diesel check according to sticker value……………………………………………………………………………………………………………………………… 332
CSHA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 333
CSHA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 334
CSHA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 335
CSHA 2H Amarok……………………………………………………………………………………………………………………………………………………………….. 336
CSLB 2F Crafter………………………………………………………………………………………………………………………………………………………………. 337
CSNA 2E Crafter………………………………………………………………………………………………………………………………………………………………. 338
CSNA 2F Crafter………………………………………………………………………………………………………………………………………………………………. 339
CTHA 1F Eos; MED 17…………………………………………………………………………………………………………………………………………………………… 340
CTHA 5N Tiguan; MED 17………………………………………………………………………………………………………………………………………………………… 341
CTHA 7N Sharan; MED 17………………………………………………………………………………………………………………………………………………………… 342
CTHB 1T Touran; MED 17………………………………………………………………………………………………………………………………………………………… 343
CTHC 1T Touran; MED 17………………………………………………………………………………………………………………………………………………………… 344
CTHD 1F Eos; MED 17…………………………………………………………………………………………………………………………………………………………… 345
CTHD 358 CC; MED 17…………………………………………………………………………………………………………………………………………………………… 346
CTHD 36 Passat; MED 17………………………………………………………………………………………………………………………………………………………… 347
CTHD 52 Golf Plus; MED 17……………………………………………………………………………………………………………………………………………………… 348
CTHD 5K Golf; MED 17………………………………………………………………………………………………………………………………………………………….. 349
CTHD 5N Tiguan; MED 17………………………………………………………………………………………………………………………………………………………… 350
CTHE 6R Polo; MED 17………………………………………………………………………………………………………………………………………………………….. 351
CTKA 51 Golf convertible………………………………………………………………………………………………………………………………………………………. 352
CTKA 52 Golf Plus…………………………………………………………………………………………………………………………………………………………….. 353
CTKA 5K Golf…………………………………………………………………………………………………………………………………………………………………. 354
CTKA 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 355
CUAA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 356
CUKB 5G Golf…………………………………………………………………………………………………………………………………………………………………. 357
CULA 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 358
CULC 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 359
CUNA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 360
CUNA 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………. 361
CUNA BA Golf Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………… 362
CUPA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 363
CUSA 6C Polo; Diesel………………………………………………………………………………………………………………………………………………………….. 364
CUSB 6C Polo; Diesel………………………………………………………………………………………………………………………………………………………….. 365
CUTA 6C Polo; Diesel………………………………………………………………………………………………………………………………………………………….. 366
CUUA 517 Golf Cabriolet; Diesel………………………………………………………………………………………………………………………………………………… 367
CUUB 517 Golf Cabriolet; Diesel………………………………………………………………………………………………………………………………………………… 368
CUUB 138 Scirocco; Diesel……………………………………………………………………………………………………………………………………………………… 369
CUUB SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 370
CUUD SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 371
CUUE SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 372
CUUF SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 373
CUVA 7N2 Sharan; Diesel……………………………………………………………………………………………………………………………………………………….. 374
CUVC 5N2 Tiguan; Diesel……………………………………………………………………………………………………………………………………………………….. 375
CUVC 358 CC; Diesel…………………………………………………………………………………………………………………………………………………………… 376
CUVC 7N2 Sharan; Diesel……………………………………………………………………………………………………………………………………………………….. 377
CUVE 5N2 Tiguan; Diesel……………………………………………………………………………………………………………………………………………………….. 378
CUWA 5N2 Tiguan; Diesel……………………………………………………………………………………………………………………………………………………….. 379
CUWA 7N2 Sharan; Diesel……………………………………………………………………………………………………………………………………………………….. 380
CUWA 358 CC; Diesel…………………………………………………………………………………………………………………………………………………………… 381
CUWA 138 Scirocco; Diesel……………………………………………………………………………………………………………………………………………………… 382
CUXA 138 Scirocco; Diesel……………………………………………………………………………………………………………………………………………………… 383
CWVA 5G Golf ………………………………………………………………………………………………………………………………………………………………… 384
CWVA AM Golf SV………………………………………………………………………………………………………………………………………………………………. 385
CWVA BA Golf Variant …………………………………………………………………………………………………………………………………………………………. 386
CWVA 61 Polo…………………………………………………………………………………………………………………………………………………………………. 387
CWVB 6C Polo…………………………………………………………………………………………………………………………………………………………………. 388
CXEB SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 389
CXEB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………. 390
CXFA SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 391
CXGA SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 392
CXGA SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………. 393
CXGB SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 394
CXGB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………. 395
CXHA SG T6 – 7MM……………………………………………………………………………………………………………………………………………………………… 396
CXHA SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………. 397
CXSA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 398
CYJA 7P Touareg………………………………………………………………………………………………………………………………………………………………. 399
CYVA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 400
CYVA AM Golf SV………………………………………………………………………………………………………………………………………………………………. 401
CYVA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 402
CYVB 5G Golf…………………………………………………………………………………………………………………………………………………………………. 403
CYVB AM Golf SV………………………………………………………………………………………………………………………………………………………………. 404
CYVB BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 405
CYVC SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 406
CYVD 517 Golf convertible……………………………………………………………………………………………………………………………………………………… 407
CZCA 13 Scirocco……………………………………………………………………………………………………………………………………………………………… 408
CZCA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 409
CZCA AM Golf SV………………………………………………………………………………………………………………………………………………………………. 410
CZCA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 411
CZCA 3G Passat, Passat Estate………………………………………………………………………………………………………………………………………………….. 412
CZCA 517 Golf convertible……………………………………………………………………………………………………………………………………………………… 413
CZCA SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 414
CZCB SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 415
CZDA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 416
CZDA AM Golf SV………………………………………………………………………………………………………………………………………………………………. 417
CZDA BA Golf Variant………………………………………………………………………………………………………………………………………………………….. 418
CZDA 5N2 Tiguan………………………………………………………………………………………………………………………………………………………………. 419
CZDA 358 CC………………………………………………………………………………………………………………………………………………………………….. 420
CZDA 517 Golf convertible……………………………………………………………………………………………………………………………………………………… 421
CZDA 7N2 Sharan………………………………………………………………………………………………………………………………………………………………. 422
CZDB 5N2 Tiguan………………………………………………………………………………………………………………………………………………………………. 423
CZEA 5G Golf…………………………………………………………………………………………………………………………………………………………………. 424
CZEA 6C Polo…………………………………………………………………………………………………………………………………………………………………. 425
CZEA 3G Passat, Passat Estate………………………………………………………………………………………………………………………………………………….. 426
DAJA 6C Polo…………………………………………………………………………………………………………………………………………………………………. 427
DAJB 6C Polo…………………………………………………………………………………………………………………………………………………………………. 428
DCXA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 429
DDAA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………. 430
DFSC SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 431
DFSD SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 432
DFSE SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 433
DFSF SA Caddy4 – 7MM………………………………………………………………………………………………………………………………………………………….. 434
Guide_for_using_trailers………………………………………………………………………………………………………………………………………………………….. 435
00 – Technical data…………………………………………………………………………………………………………………………………………………………… 443
1 Preface………………………………………………………………………………………………………………………………………………………………… 443
1.1 Legal requirements outside Germany…………………………………………………………………………………………………………………………………… 443
2 Technical prerequisites………………………………………………………………………………………………………………………………………………….. 444
2.1 Factory fitted towing attachment…………………………………………………………………………………………………………………………………….. 444
2.2 Retrofitted towing attachment……………………………………………………………………………………………………………………………………….. 444
2.3 Ball head…………………………………………………………………………………………………………………………………………………………. 444
2.4 Trailer socket…………………………………………………………………………………………………………………………………………………….. 444
2.4.1 »7-pin« trailer socket………………………………………………………………………………………………………………………………………… 444
2.4.2 »13-pin« trailer socket……………………………………………………………………………………………………………………………………….. 445
2.5 Trailer detector control unit -J345-…………………………………………………………………………………………………………………………………. 445
2.5.1 Retrofitting trailer detector control unit -J345-………………………………………………………………………………………………………………… 445
2.5.2 Coding trailer detector control unit -J345-……………………………………………………………………………………………………………………… 446
2.6 Engine cooling…………………………………………………………………………………………………………………………………………………….. 446
2.7 Exterior mirrors…………………………………………………………………………………………………………………………………………………… 447
2.8 Uprated shock absorbers and coil springs……………………………………………………………………………………………………………………………… 447
3 Notes on operation and driving……………………………………………………………………………………………………………………………………………. 448
4 General………………………………………………………………………………………………………………………………………………………………… 449
4.1 Towing attachment type plate………………………………………………………………………………………………………………………………………… 449
4.2 Weight of vehicle and trailer combination…………………………………………………………………………………………………………………………….. 449
4.3 Tachograph………………………………………………………………………………………………………………………………………………………… 449
5 Drawbar load details…………………………………………………………………………………………………………………………………………………….. 450
6 Legal requirements………………………………………………………………………………………………………………………………………………………. 451
7 Beetle 2012 ►…………………………………………………………………………………………………………………………………………………………… 452
8 Bora 1999 ►, Bora Variant 1999 ►………………………………………………………………………………………………………………………………………….. 453
9 Eos 2006 ►……………………………………………………………………………………………………………………………………………………………… 455
10 Fox 2004 ►…………………………………………………………………………………………………………………………………………………………….. 456
11 Golf 1992 ►, Golf Variant 1994 ►…………………………………………………………………………………………………………………………………………. 457
12 Golf Cabriolet 1994 ►…………………………………………………………………………………………………………………………………………………… 459
13 Golf 1998 ►, Golf Variant 1999 ►…………………………………………………………………………………………………………………………………………. 460
13.1 Golf R32…………………………………………………………………………………………………………………………………………………………. 461
13.2 Celebration GTI…………………………………………………………………………………………………………………………………………………… 461
13.3 Golf Bi Fuel……………………………………………………………………………………………………………………………………………………… 462
14 Golf 2004 ►……………………………………………………………………………………………………………………………………………………………. 463
15 Golf Plus 2005 ►……………………………………………………………………………………………………………………………………………………….. 465
16 Golf Variant 2007 ►…………………………………………………………………………………………………………………………………………………….. 467
17 Golf 2009 ►……………………………………………………………………………………………………………………………………………………………. 468
18 Golf Plus 2009 ►, CrossGolf 2009 ►……………………………………………………………………………………………………………………………………….. 470
18.1 Golf Plus………………………………………………………………………………………………………………………………………………………… 470
18.2 Cross Golf……………………………………………………………………………………………………………………………………………………….. 471
19 Golf Variant 2010 ►…………………………………………………………………………………………………………………………………………………….. 472
20 Golf Cabriolet 2012 ►…………………………………………………………………………………………………………………………………………………… 473
21 Golf 2013 ►……………………………………………………………………………………………………………………………………………………………. 475
22 Golf Variant 2014 ►, Golf Alltrack 2015 ►…………………………………………………………………………………………………………………………………. 478
22.1 Golf Variant……………………………………………………………………………………………………………………………………………………… 478
22.2 Golf Alltrack…………………………………………………………………………………………………………………………………………………….. 479
23 e Golf 2014 ►………………………………………………………………………………………………………………………………………………………….. 481
24 Golf SV 2015 ►…………………………………………………………………………………………………………………………………………………………. 482
25 Jetta 2005 ►…………………………………………………………………………………………………………………………………………………………… 484
26 Jetta 2011 ►…………………………………………………………………………………………………………………………………………………………… 486
27 Jetta 2015 ►…………………………………………………………………………………………………………………………………………………………… 488
28 Lupo 3L, Lupo FSI, Lupo GTI 1999 ►……………………………………………………………………………………………………………………………………….. 490
29 Lupo 1999 ►……………………………………………………………………………………………………………………………………………………………. 491
30 New Beetle 1999 ►………………………………………………………………………………………………………………………………………………………. 492
31 New Beetle RSi…………………………………………………………………………………………………………………………………………………………. 494
32 New Beetle Cabriolet 2003 ►……………………………………………………………………………………………………………………………………………… 495
33 Passat saloon, estate 1994 ►…………………………………………………………………………………………………………………………………………….. 496
33.1 Passat Syncro…………………………………………………………………………………………………………………………………………………….. 497
33.1.1 Increase in trailer load……………………………………………………………………………………………………………………………………… 498
34 Passat saloon, estate 1997 ►…………………………………………………………………………………………………………………………………………….. 499
35 Passat saloon, estate 2001 ►…………………………………………………………………………………………………………………………………………….. 500
36 Passat W8 2002 ►……………………………………………………………………………………………………………………………………………………….. 501
37 Passat saloon 2006 ►……………………………………………………………………………………………………………………………………………………. 502
38 Passat Variant 2006 ►…………………………………………………………………………………………………………………………………………………… 504
39 Passat CC 2009 ►; CC 2010 ►; CC 2012 ►……………………………………………………………………………………………………………………………………. 506
40 Passat saloon 2011 ►……………………………………………………………………………………………………………………………………………………. 509
41 Passat Estate 2011 ►, Passat Alltrack 2012 ►………………………………………………………………………………………………………………………………. 511
41.1 Passat Variant……………………………………………………………………………………………………………………………………………………. 511
41.2 Passat Alltrack…………………………………………………………………………………………………………………………………………………… 513
42 Passat saloon 2015 ►……………………………………………………………………………………………………………………………………………………. 514
43 Passat Estate 2015 ►, Passat Alltrack 2016 ►………………………………………………………………………………………………………………………………. 516
43.1 Passat Variant 2015 ►……………………………………………………………………………………………………………………………………………… 516
43.2 Passat Alltrack 2016 ►…………………………………………………………………………………………………………………………………………….. 518
44 Phaeton 2003 ►…………………………………………………………………………………………………………………………………………………………. 519
45 Polo 1995 ►……………………………………………………………………………………………………………………………………………………………. 520
46 Polo Classic 1996 ►…………………………………………………………………………………………………………………………………………………….. 521
47 Polo Variant 1998 ►…………………………………………………………………………………………………………………………………………………….. 522
48 Polo 2002 ►, Polo Fun 2004 ►…………………………………………………………………………………………………………………………………………….. 523
48.1 Polo…………………………………………………………………………………………………………………………………………………………….. 523
48.2 Polo Fun…………………………………………………………………………………………………………………………………………………………. 524
48.2.1 Retrofitting a towing attachment………………………………………………………………………………………………………………………………. 525
49 Polo saloon 2004 ►……………………………………………………………………………………………………………………………………………………… 526
50 Polo 2010 ►, CrossPolo 2010 ►……………………………………………………………………………………………………………………………………………. 527
50.1 Polo…………………………………………………………………………………………………………………………………………………………….. 527
50.2 CrossPolo………………………………………………………………………………………………………………………………………………………… 528
51 Polo 2014 ►, CrossPolo 2014 ►……………………………………………………………………………………………………………………………………………. 529
51.1 Polo…………………………………………………………………………………………………………………………………………………………….. 529
51.2 CrossPolo………………………………………………………………………………………………………………………………………………………… 530
52 Scirocco 2009 ►………………………………………………………………………………………………………………………………………………………… 532
53 Scirocco 2015 ►………………………………………………………………………………………………………………………………………………………… 533
54 Sharan 1996 ►………………………………………………………………………………………………………………………………………………………….. 534
54.1 Retrofitting towing attachment on Sharan BlueMotion…………………………………………………………………………………………………………………… 535
55 Sharan 2011 ►………………………………………………………………………………………………………………………………………………………….. 536
56 Sharan 2016 ►………………………………………………………………………………………………………………………………………………………….. 537
57 Tiguan 2008 ►………………………………………………………………………………………………………………………………………………………….. 538
57.1 Tiguan Trend & Fun/Sport & Style……………………………………………………………………………………………………………………………………. 538
57.2 Tiguan Track & Field………………………………………………………………………………………………………………………………………………. 539
58 Touran 2003 ►………………………………………………………………………………………………………………………………………………………….. 542
59 CrossTouran……………………………………………………………………………………………………………………………………………………………. 544
60 Touran 2016 ►………………………………………………………………………………………………………………………………………………………….. 546
61 Touareg 2003 ►…………………………………………………………………………………………………………………………………………………………. 547
62 Touareg 2010 ►…………………………………………………………………………………………………………………………………………………………. 548
63 Touareg 2015 ►…………………………………………………………………………………………………………………………………………………………. 549
64 up! 2012 ►…………………………………………………………………………………………………………………………………………………………….. 550
65 e-up! 2014 ►…………………………………………………………………………………………………………………………………………………………… 551
66 Vento 1992 ►…………………………………………………………………………………………………………………………………………………………… 552
Sharan2011-4-cyl__direct_injection_engine_(1_8_l_and_2_0_l_4V_turbocharger__chain_drive)…………………………………………………………………………………………………. 553
00 – Technical data…………………………………………………………………………………………………………………………………………………………… 559
1 Safety instructions……………………………………………………………………………………………………………………………………………………… 559
1.1 Safety precautions when working on fuel supply system………………………………………………………………………………………………………………….. 559
1.2 Safety precautions during road tests in which test and measuring equipment is used………………………………………………………………………………………… 560
1.3 Safety precautions when working on cooling system……………………………………………………………………………………………………………………… 560
1.4 Safety precautions when working on ignition system…………………………………………………………………………………………………………………….. 561
2 Identification………………………………………………………………………………………………………………………………………………………….. 562
2.1 Engine number, engine data………………………………………………………………………………………………………………………………………….. 562
3 Repair instructions……………………………………………………………………………………………………………………………………………………… 563
3.1 Rules for cleanliness………………………………………………………………………………………………………………………………………………. 563
3.2 Foreign objects in engine…………………………………………………………………………………………………………………………………………… 563
10 – Removing and installing engine…………………………………………………………………………………………………………………………………………….. 564
1 Removing and installing engine……………………………………………………………………………………………………………………………………………. 564
1.1 Removing engine……………………………………………………………………………………………………………………………………………………. 564
1.1.1 Removing engine, Sharan……………………………………………………………………………………………………………………………………….. 564
1.1.2 Removing engine, Passat, CC and Golf Cabriolet…………………………………………………………………………………………………………………… 574
1.2 Separating engine and gearbox……………………………………………………………………………………………………………………………………….. 587
1.3 Securing engine on engine and gearbox support…………………………………………………………………………………………………………………………. 588
1.4 Installing engine………………………………………………………………………………………………………………………………………………….. 589
2 Assembly mountings………………………………………………………………………………………………………………………………………………………. 591
2.1 Assembly overview – assembly mountings……………………………………………………………………………………………………………………………….. 591
2.1.1 Assembly overview – assembly mounting, Sharan……………………………………………………………………………………………………………………. 591
2.1.2 Assembly overview – assembly mountings, Passat, CC and Golf Cabriolet………………………………………………………………………………………………. 593
2.2 Supporting engine in installation position……………………………………………………………………………………………………………………………. 595
2.2.1 Supporting engine in installation position, Sharan……………………………………………………………………………………………………………….. 595
2.2.2 Supporting engine in installation location, Passat and CC…………………………………………………………………………………………………………. 597
2.2.3 Supporting engine in installation position, Golf Cabriolet………………………………………………………………………………………………………… 599
2.3 Checking adjustment of assembly mountings (engine and gearbox mountings)…………………………………………………………………………………………………. 601
2.4 Adjusting assembly mountings………………………………………………………………………………………………………………………………………… 601
3 Engine cover panel………………………………………………………………………………………………………………………………………………………. 604
3.1 Removing and installing engine cover panel……………………………………………………………………………………………………………………………. 604
13 – Crankshaft group…………………………………………………………………………………………………………………………………………………………. 605
1 Cylinder block (pulley end)………………………………………………………………………………………………………………………………………………. 605
1.1 Assembly overview – poly V-belt drive………………………………………………………………………………………………………………………………… 605
1.2 Removing and installing poly V-belt………………………………………………………………………………………………………………………………….. 607
1.3 Removing and installing tensioner for poly V-belt……………………………………………………………………………………………………………………… 608
1.4 Removing and installing ancillary bracket…………………………………………………………………………………………………………………………….. 610
1.5 Removing and installing vibration damper……………………………………………………………………………………………………………………………… 612
1.6 Renewing oil seal for vibration damper……………………………………………………………………………………………………………………………….. 618
2 Cylinder block (gearbox end)……………………………………………………………………………………………………………………………………………… 621
2.1 Assembly overview – cylinder block, gearbox end……………………………………………………………………………………………………………………….. 621
2.2 Removing and installing flywheel…………………………………………………………………………………………………………………………………….. 622
2.3 Removing and installing sealing flange on gearbox side…………………………………………………………………………………………………………………. 623
3 Crankshaft……………………………………………………………………………………………………………………………………………………………… 626
3.1 Assembly overview – crankshaft………………………………………………………………………………………………………………………………………. 626
3.2 Renewing needle bearing in crankshaft………………………………………………………………………………………………………………………………… 627
3.3 Crankshaft dimensions………………………………………………………………………………………………………………………………………………. 630
3.4 Measuring axial clearance of crankshaft………………………………………………………………………………………………………………………………. 630
3.5 Measuring radial clearance of crankshaft……………………………………………………………………………………………………………………………… 630
3.6 Allocation of main bearing shells……………………………………………………………………………………………………………………………………. 631
3.7 Removing and installing sender wheel…………………………………………………………………………………………………………………………………. 632
4 Balance shaft…………………………………………………………………………………………………………………………………………………………… 634
4.1 Assembly overview – balance shaft……………………………………………………………………………………………………………………………………. 634
4.2 Removing and installing balance shaft for inlet camshaft……………………………………………………………………………………………………………….. 636
4.3 Removing and installing balance shaft for exhaust camshaft……………………………………………………………………………………………………………… 639
5 Pistons and conrods……………………………………………………………………………………………………………………………………………………… 642
5.1 Assembly overview – pistons and conrods………………………………………………………………………………………………………………………………. 642
5.2 Removing and installing pistons……………………………………………………………………………………………………………………………………… 643
5.3 Checking pistons and cylinder bores………………………………………………………………………………………………………………………………….. 645
5.4 Separating new conrod………………………………………………………………………………………………………………………………………………. 646
15 – Cylinder head, valve gear…………………………………………………………………………………………………………………………………………………. 647
1 Cylinder head…………………………………………………………………………………………………………………………………………………………… 647
1.1 Assembly overview – cylinder head……………………………………………………………………………………………………………………………………. 647
1.2 Removing and installing cylinder head………………………………………………………………………………………………………………………………… 651
1.2.1 Removing and installing cylinder head…………………………………………………………………………………………………………………………… 651
1.2.2 Removing and installing cylinder head and camshaft timing chain……………………………………………………………………………………………………. 673
1.3 Checking compression……………………………………………………………………………………………………………………………………………….. 684
1.4 Removing and installing vacuum pump………………………………………………………………………………………………………………………………….. 686
2 Cover for timing chain…………………………………………………………………………………………………………………………………………………… 688
2.1 Assembly overview – cover for timing chain……………………………………………………………………………………………………………………………. 688
2.2 Removing and installing upper timing chain cover………………………………………………………………………………………………………………………. 690
2.3 Removing and installing timing chain cover (bottom)……………………………………………………………………………………………………………………. 691
3 Chain drive…………………………………………………………………………………………………………………………………………………………….. 697
3.1 Assembly overview – camshaft timing chains……………………………………………………………………………………………………………………………. 697
3.2 Removing and installing camshaft timing chain…………………………………………………………………………………………………………………………. 698
3.3 Removing and installing drive chain for balance shaft………………………………………………………………………………………………………………….. 709
3.4 Checking valve timing………………………………………………………………………………………………………………………………………………. 710
4 Valve gear……………………………………………………………………………………………………………………………………………………………… 712
4.1 Assembly overview – valve gear………………………………………………………………………………………………………………………………………. 712
4.2 Removing and installing camshaft…………………………………………………………………………………………………………………………………….. 714
4.3 Removing and installing inlet camshaft control valve 1 -N205-…………………………………………………………………………………………………………… 729
4.4 Measuring axial play of camshaft…………………………………………………………………………………………………………………………………….. 729
4.5 Removing and installing valve stem seals……………………………………………………………………………………………………………………………… 730
5 Inlet and exhaust valves…………………………………………………………………………………………………………………………………………………. 735
5.1 Checking valve guides………………………………………………………………………………………………………………………………………………. 735
17 – Lubrication……………………………………………………………………………………………………………………………………………………………… 736
1 Sump, oil pump………………………………………………………………………………………………………………………………………………………….. 736
1.1 Assembly overview – sump and oil pump………………………………………………………………………………………………………………………………… 736
1.2 Removing and installing lower part of sump……………………………………………………………………………………………………………………………. 739
1.3 Removing and installing upper part of sump……………………………………………………………………………………………………………………………. 741
1.4 Removing and installing oil pump…………………………………………………………………………………………………………………………………….. 745
1.5 Engine oil………………………………………………………………………………………………………………………………………………………… 747
2 Engine oil cooler……………………………………………………………………………………………………………………………………………………….. 749
2.1 Removing and installing engine oil cooler…………………………………………………………………………………………………………………………….. 749
3 Crankcase breather………………………………………………………………………………………………………………………………………………………. 751
3.1 Removing and installing oil separator………………………………………………………………………………………………………………………………… 751
4 Oil filter, oil pressure switch…………………………………………………………………………………………………………………………………………… 752
4.1 Assembly overview – oil filter/oil pressure switch…………………………………………………………………………………………………………………….. 752
4.1.1 Assembly overview – oil filter/oil pressure switch, engine codes CCTA, CBFA…………………………………………………………………………………………. 752
4.1.2 Assembly overview – oil filter/oil pressure switch, engine codes CCZA, CCZB, CDAA, CDAB………………………………………………………………………………. 754
4.2 Removing and installing oil pressure switch…………………………………………………………………………………………………………………………… 755
4.2.1 Removing and installing oil pressure switch F1 (blue), engine codes CCZA, CCZB, CDAA, CDAB……………………………………………………………………………. 755
4.2.2 Removing and installing oil pressure switch for reduced oil pressure F378 (brown), engine codes CCZA, CCZB, CDAA, CDAB…………………………………………………… 756
4.3 Checking oil pressure and oil pressure switch…………………………………………………………………………………………………………………………. 756
4.3.1 Checking oil pressure and oil pressure switch, engine codes CCZA, CCZB, CDAA, CDAB…………………………………………………………………………………… 757
4.3.2 Checking oil pressure and oil pressure switch, engine codes CCTA, CBFA……………………………………………………………………………………………… 759
4.4 Removing and installing oil pressure control valve, engine codes CCZA, CCZB, CDAA, CDAB……………………………………………………………………………………. 761
19 – Cooling…………………………………………………………………………………………………………………………………………………………………. 763
1 Cooling system, coolant………………………………………………………………………………………………………………………………………………….. 763
1.1 Coolant hose schematic diagram………………………………………………………………………………………………………………………………………. 763
1.2 Draining and filling coolant………………………………………………………………………………………………………………………………………… 765
1.3 Checking cooling system for leaks……………………………………………………………………………………………………………………………………. 770
2 Coolant pump, regulation of cooling system…………………………………………………………………………………………………………………………………. 773
2.1 Assembly overview – coolant pump, thermostat………………………………………………………………………………………………………………………….. 773
2.2 Assembly overview – electric coolant pump…………………………………………………………………………………………………………………………….. 775
2.3 Removing and installing continued coolant circulation pump -V51-………………………………………………………………………………………………………… 775
2.4 Removing and installing coolant pump…………………………………………………………………………………………………………………………………. 776
2.5 Removing and installing toothed belt for coolant pump………………………………………………………………………………………………………………….. 778
2.6 Renewing oil seal for coolant pump drive……………………………………………………………………………………………………………………………… 780
2.7 Removing and installing thermostat…………………………………………………………………………………………………………………………………… 781
2.8 Removing and installing coolant temperature sender -G62-……………………………………………………………………………………………………………….. 783
3 Coolant pipes…………………………………………………………………………………………………………………………………………………………… 786
3.1 Assembly overview – coolant pipes……………………………………………………………………………………………………………………………………. 786
3.2 Removing and installing front coolant pipes…………………………………………………………………………………………………………………………… 786
3.3 Removing and installing small coolant pipe……………………………………………………………………………………………………………………………. 789
4 Radiator and radiator fan………………………………………………………………………………………………………………………………………………… 791
4.1 Assembly overview – radiator and radiator fan…………………………………………………………………………………………………………………………. 791
4.1.1 Assembly overview – radiator and radiator fan, Sharan…………………………………………………………………………………………………………….. 791
4.1.2 Assembly overview – radiator and radiator fan, Passat, CC and Golf Cabriolet………………………………………………………………………………………… 792
4.2 Removing and installing radiator…………………………………………………………………………………………………………………………………….. 793
4.2.1 Removing and installing radiator, Sharan………………………………………………………………………………………………………………………… 793
4.2.2 Removing and installing radiator, Passat, CC and Golf Cabriolet……………………………………………………………………………………………………. 794
4.3 Removing and installing radiator cowl………………………………………………………………………………………………………………………………… 795
4.4 Removing and installing radiator fan -V7- and radiator fan 2 -V177-……………………………………………………………………………………………………… 796
21 – Turbocharging/supercharging……………………………………………………………………………………………………………………………………………….. 798
1 Turbocharger……………………………………………………………………………………………………………………………………………………………. 798
1.1 Overview – turbocharger…………………………………………………………………………………………………………………………………………….. 798
1.2 Assembly overview – turbocharger, part I for engine codes CDAA, CDAB…………………………………………………………………………………………………….. 800
1.3 Assembly overview – turbocharger, part I for engine codes CBFA, CCTA, CCZA, CCZB………………………………………………………………………………………….. 801
1.4 Assembly overview – turbocharger, part II…………………………………………………………………………………………………………………………….. 802
1.5 Assembly overview – turbocharger, part III……………………………………………………………………………………………………………………………. 803
1.6 Assembly overview – turbocharger, part IV…………………………………………………………………………………………………………………………….. 804
1.7 Removing and installing turbocharger…………………………………………………………………………………………………………………………………. 806
1.8 Checking vacuum unit for turbocharger………………………………………………………………………………………………………………………………… 812
1.9 Adjusting vacuum unit for turbocharger……………………………………………………………………………………………………………………………….. 813
1.10 Renewing vacuum unit for turbocharger……………………………………………………………………………………………………………………………….. 817
2 Charge air system……………………………………………………………………………………………………………………………………………………….. 818
2.1 Assembly overview – charge-air hose connections……………………………………………………………………………………………………………………….. 818
2.2 Assembly overview – charge air system………………………………………………………………………………………………………………………………… 819
2.3 Schematic overview – charge air system……………………………………………………………………………………………………………………………….. 821
2.4 Removing and installing charge air cooler…………………………………………………………………………………………………………………………….. 821
2.4.1 Removing and installing charge air cooler, Passat, CC and Sharan…………………………………………………………………………………………………… 821
2.4.2 Removing and installing charge air cooler, Golf Cabriolet…………………………………………………………………………………………………………. 823
2.5 Checking charge air system for leaks…………………………………………………………………………………………………………………………………. 825
24 – Mixture preparation – injection……………………………………………………………………………………………………………………………………………. 828
1 Injection system………………………………………………………………………………………………………………………………………………………… 828
1.1 Overview of fitting locations – injection system………………………………………………………………………………………………………………………. 828
2 Injectors………………………………………………………………………………………………………………………………………………………………. 833
2.1 Assembly overview – fuel rail with injectors………………………………………………………………………………………………………………………….. 833
2.2 Removing and installing injectors……………………………………………………………………………………………………………………………………. 834
2.3 Renewing seals on injectors…………………………………………………………………………………………………………………………………………. 837
2.4 Cleaning injectors…………………………………………………………………………………………………………………………………………………. 839
3 High-pressure pump………………………………………………………………………………………………………………………………………………………. 841
3.1 Assembly overview – high-pressure pump……………………………………………………………………………………………………………………………….. 841
3.2 Removing and installing high-pressure pump……………………………………………………………………………………………………………………………. 842
4 Senders and sensors……………………………………………………………………………………………………………………………………………………… 844
4.1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Golf Cabriolet…………………………………………………………….. 844
4.2 Removing and installing air mass meter -G70-………………………………………………………………………………………………………………………….. 845
4.3 Removing and installing fuel pressure sender -G247-……………………………………………………………………………………………………………………. 845
4.4 Checking fuel pressure sender -G247-…………………………………………………………………………………………………………………………………. 846
5 Intake manifold…………………………………………………………………………………………………………………………………………………………. 850
5.1 Assembly overview – intake manifold………………………………………………………………………………………………………………………………….. 850
5.2 Removing and installing intake manifold with fuel rail…………………………………………………………………………………………………………………. 851
5.2.1 Disconnecting fuel rail from intake manifold…………………………………………………………………………………………………………………….. 857
5.3 Removing and installing throttle valve module -J338-…………………………………………………………………………………………………………………… 858
5.4 Cleaning throttle valve module -J338-………………………………………………………………………………………………………………………………… 859
5.5 Checking intake manifold change-over…………………………………………………………………………………………………………………………………. 859
6 Air filter……………………………………………………………………………………………………………………………………………………………… 862
6.1 Assembly overview – air filter housing……………………………………………………………………………………………………………………………….. 862
6.2 Removing and installing air filter housing……………………………………………………………………………………………………………………………. 863
7 Engine control unit……………………………………………………………………………………………………………………………………………………… 864
7.1 Removing and installing engine control unit…………………………………………………………………………………………………………………………… 864
7.1.1 Removing and installing engine control unit, Sharan………………………………………………………………………………………………………………. 864
7.1.2 Removing and installing engine control unit, Passat, CC and Golf Cabriolet………………………………………………………………………………………….. 865
7.2 Removing and installing engine control unit with protective housing……………………………………………………………………………………………………… 867
7.2.1 Removing and installing engine control unit with protective housing, Sharan…………………………………………………………………………………………. 867
7.2.2 Removing and installing engine control unit with protective housing, Passat, CC and Golf Cabriolet…………………………………………………………………….. 868
26 – Exhaust system…………………………………………………………………………………………………………………………………………………………… 872
1 Exhaust pipes, silencers…………………………………………………………………………………………………………………………………………………. 872
1.1 Assembly overview – silencers……………………………………………………………………………………………………………………………………….. 872
1.1.1 Assembly overview – silencer, Sharan……………………………………………………………………………………………………………………………. 872
1.1.2 Assembly overview – silencers, Passat and CC with front-wheel drive………………………………………………………………………………………………… 873
1.1.3 Assembly overview – silencers, Passat with four-wheel drive……………………………………………………………………………………………………….. 874
1.1.4 Assembly overview – silencer, Golf Cabriolet…………………………………………………………………………………………………………………….. 876
1.2 Separating exhaust pipes, silencers………………………………………………………………………………………………………………………………….. 877
1.2.1 Separating exhaust pipesand silencers, Sharan……………………………………………………………………………………………………………………. 877
1.2.2 Separating exhaust pipes and silencers, Passat and CC with front-wheel drive………………………………………………………………………………………… 878
1.2.3 Separating exhaust pipes and silencers, Passat with four-wheel drive……………………………………………………………………………………………….. 880
1.2.4 Separating exhaust pipes and silencers, Golf Cabriolet……………………………………………………………………………………………………………. 881
1.3 Aligning exhaust system free of stress……………………………………………………………………………………………………………………………….. 882
1.3.1 Aligning exhaust system free of tension, Sharan………………………………………………………………………………………………………………….. 882
1.3.2 Aligning exhaust system free of tension, Passat, CC and Golf Cabriolet……………………………………………………………………………………………… 883
1.4 Installation position of clamp………………………………………………………………………………………………………………………………………. 884
1.5 Checking exhaust system for leaks……………………………………………………………………………………………………………………………………. 885
2 Emission control………………………………………………………………………………………………………………………………………………………… 886
2.1 Assembly overview – emission control…………………………………………………………………………………………………………………………………. 886
2.1.1 Assembly overview – emission control, Sharan…………………………………………………………………………………………………………………….. 886
2.1.2 Assembly overview – emission control, Passat, CC and Golf Cabriolet………………………………………………………………………………………………… 888
2.2 Removing and installing catalytic converter…………………………………………………………………………………………………………………………… 889
2.2.1 Removing and installing catalytic converter, Passat, CC and Golf Cabriolet………………………………………………………………………………………….. 889
2.2.2 Removing and installing catalytic converter, Sharan………………………………………………………………………………………………………………. 892
3 Exhaust manifold………………………………………………………………………………………………………………………………………………………… 895
4 Secondary air system – engine code CBFA……………………………………………………………………………………………………………………………………. 896
4.1 Assembly overview – secondary air system……………………………………………………………………………………………………………………………… 896
4.2 Removing and installing secondary air pump motor -V101-………………………………………………………………………………………………………………… 896
4.3 Removing and installing secondary air inlet valve -N112-……………………………………………………………………………………………………………….. 897
28 – Ignition system………………………………………………………………………………………………………………………………………………………….. 899
1 Ignition system…………………………………………………………………………………………………………………………………………………………. 899
1.1 Assembly overview – ignition system………………………………………………………………………………………………………………………………….. 899
1.2 Removing and installing ignition coils with output stage……………………………………………………………………………………………………………….. 900
1.3 Removing and installing knock sensor I -G61-………………………………………………………………………………………………………………………….. 901
1.4 Removing and installing engine speed sender -G28-……………………………………………………………………………………………………………………… 901
1.5 Test data, spark plugs……………………………………………………………………………………………………………………………………………… 902
Sharan2011-4-cylinder_diesel_engine_(2_0_l_engine__common_rail__generation_II)………………………………………………………………………………………………………….. 904
00 – Technical data…………………………………………………………………………………………………………………………………………………………… 910
1 Technical data………………………………………………………………………………………………………………………………………………………….. 910
1.1 Engine number……………………………………………………………………………………………………………………………………………………… 910
1.2 Engine data……………………………………………………………………………………………………………………………………………………….. 910
10 – Removing and installing engine…………………………………………………………………………………………………………………………………………….. 912
1 Removing and installing engine……………………………………………………………………………………………………………………………………………. 912
1.1 Removing and installing engine cover panel……………………………………………………………………………………………………………………………. 912
1.2 Removing engine……………………………………………………………………………………………………………………………………………………. 912
1.3 Separating engine from gearbox………………………………………………………………………………………………………………………………………. 919
1.4 Separating engine from dual clutch gearbox……………………………………………………………………………………………………………………………. 921
1.5 Securing engine to assembly stand……………………………………………………………………………………………………………………………………. 923
1.6 Installing engine………………………………………………………………………………………………………………………………………………….. 925
1.6.1 Notes on installing…………………………………………………………………………………………………………………………………………… 925
1.7 Assembly mountings…………………………………………………………………………………………………………………………………………………. 927
1.8 Adjusting assembly mountings………………………………………………………………………………………………………………………………………… 928
13 – Crankshaft group…………………………………………………………………………………………………………………………………………………………. 932
1 Dismantling and assembling engine…………………………………………………………………………………………………………………………………………. 932
1.1 Poly V-belt drive with tensioning element and air conditioner compressor…………………………………………………………………………………………………. 932
1.1.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………… 932
1.1.2 Removing and installing poly V-belt…………………………………………………………………………………………………………………………….. 933
1.1.3 Removing and installing poly V-belt tensioner……………………………………………………………………………………………………………………. 934
1.2 Poly V-belt drive with tensioning roller and air conditioner compressor………………………………………………………………………………………………….. 935
1.2.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………… 935
1.2.2 Removing and installing poly V-belt…………………………………………………………………………………………………………………………….. 937
1.3 Poly V-belt drive without air conditioning compressor………………………………………………………………………………………………………………….. 939
1.3.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………… 939
1.3.2 Removing and installing poly V-belt…………………………………………………………………………………………………………………………….. 939
1.4 Removing and installing ancillary bracket…………………………………………………………………………………………………………………………….. 940
1.5 Assembly overview – toothed belt drive……………………………………………………………………………………………………………………………….. 941
1.6 Removing and installing engine bracket……………………………………………………………………………………………………………………………….. 943
1.7 Assembly overview – crankcase……………………………………………………………………………………………………………………………………….. 947
2 Removing and installing sealing flange and flywheel…………………………………………………………………………………………………………………………. 949
2.1 Assembly overview – Sealing flange, belt pulley end……………………………………………………………………………………………………………………. 949
2.2 Renewing crankshaft oil seal – pulley end…………………………………………………………………………………………………………………………….. 951
2.3 Removing and installing sealing flange – pulley end……………………………………………………………………………………………………………………. 952
2.4 Assembly overview – Dual-mass flywheel and sealing flange………………………………………………………………………………………………………………. 954
2.5 Removing and installing dual-mass flywheel……………………………………………………………………………………………………………………………. 956
2.6 Renewing crankshaft sealing flange – flywheel end……………………………………………………………………………………………………………………… 957
2.6.1 Pressing out sealing flange with sender wheel……………………………………………………………………………………………………………………. 958
2.6.2 Pressing in sealing flange with sender wheel…………………………………………………………………………………………………………………….. 959
2.7 Removing and installing engine speed sender -G28-……………………………………………………………………………………………………………………… 964
3 Pistons and conrods……………………………………………………………………………………………………………………………………………………… 966
3.1 Assembly overview – pistons and conrods………………………………………………………………………………………………………………………………. 966
3.2 Piston and cylinder dimensions………………………………………………………………………………………………………………………………………. 969
3.3 Separating new conrods……………………………………………………………………………………………………………………………………………… 969
3.4 Bearing shells – installation position……………………………………………………………………………………………………………………………….. 970
3.5 Piston and cylinder dimensions………………………………………………………………………………………………………………………………………. 970
3.6 Checking piston projection at TDC……………………………………………………………………………………………………………………………………. 970
3.7 Measuring radial clearance of conrods………………………………………………………………………………………………………………………………… 972
4 Crankshaft……………………………………………………………………………………………………………………………………………………………… 974
4.1 Assembly overview – crankshaft………………………………………………………………………………………………………………………………………. 974
4.2 Crankshaft dimensions………………………………………………………………………………………………………………………………………………. 974
4.3 Renewing needle bearing in crankshaft………………………………………………………………………………………………………………………………… 975
15 – Cylinder head, valve gear…………………………………………………………………………………………………………………………………………………. 977
1 Cylinder head…………………………………………………………………………………………………………………………………………………………… 977
1.1 Assembly overview – cylinder head cover………………………………………………………………………………………………………………………………. 977
1.2 Removing and installing cylinder head cover…………………………………………………………………………………………………………………………… 979
1.2.1 Renewing seals for injectors…………………………………………………………………………………………………………………………………… 981
1.3 Removing, installing and tensioning toothed belt………………………………………………………………………………………………………………………. 982
1.3.1 Removing…………………………………………………………………………………………………………………………………………………….. 983
1.3.2 Installing…………………………………………………………………………………………………………………………………………………… 985
1.4 Assembly overview – cylinder head……………………………………………………………………………………………………………………………………. 989
1.5 Removing and installing cylinder head………………………………………………………………………………………………………………………………… 991
1.5.1 Removing…………………………………………………………………………………………………………………………………………………….. 994
1.5.2 Installing…………………………………………………………………………………………………………………………………………………… 999
1.6 Removing and installing vacuum pump…………………………………………………………………………………………………………………………………..1000
1.7 Compression test……………………………………………………………………………………………………………………………………………………1000
2 Valve gear………………………………………………………………………………………………………………………………………………………………1003
2.1 Assembly overview – valve gear……………………………………………………………………………………………………………………………………….1003
2.2 Removing and installing camshafts…………………………………………………………………………………………………………………………………….1006
2.2.1 Removing……………………………………………………………………………………………………………………………………………………..1007
2.2.2 Installing……………………………………………………………………………………………………………………………………………………1008
2.3 Measuring axial clearance of camshaft…………………………………………………………………………………………………………………………………1012
2.4 Measuring radial clearance of camshafts……………………………………………………………………………………………………………………………….1013
2.5 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………..1013
2.6 Checking hydraulic compensation elements………………………………………………………………………………………………………………………………1015
2.7 Renewing valve stem seals with cylinder head installed………………………………………………………………………………………………………………….1016
2.8 Renewing valve stem seals with cylinder head removed……………………………………………………………………………………………………………………1019
2.9 Valves…………………………………………………………………………………………………………………………………………………………….1023
2.9.1 Valve dimensions………………………………………………………………………………………………………………………………………………1023
2.9.2 Reworking valve seats………………………………………………………………………………………………………………………………………….1023
2.9.3 Checking valve guides………………………………………………………………………………………………………………………………………….1023
2.9.4 Checking valves……………………………………………………………………………………………………………………………………………….1024
17 – Lubrication………………………………………………………………………………………………………………………………………………………………1025
1 Engine oil………………………………………………………………………………………………………………………………………………………………1025
1.1 Oil capacities……………………………………………………………………………………………………………………………………………………..1025
1.2 Checking engine oil level……………………………………………………………………………………………………………………………………………1025
2 Parts of lubrication system……………………………………………………………………………………………………………………………………………….1026
2.1 Assembly overview – oil pump, sump, balancer shaft module……………………………………………………………………………………………………………….1026
2.2 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………1030
2.3 Removing and installing oil sump……………………………………………………………………………………………………………………………………..1030
2.4 Removing and installing oil pump……………………………………………………………………………………………………………………………………..1034
2.5 Removing balancer shaft module……………………………………………………………………………………………………………………………………….1035
2.6 Installing a new balancer shaft module………………………………………………………………………………………………………………………………..1037
2.7 Installing a previously used balancer shaft module again………………………………………………………………………………………………………………..1039
3 Oil filter bracket and engine oil cooler……………………………………………………………………………………………………………………………………1041
3.1 Assembly overview – oil filter bracket and engine oil cooler…………………………………………………………………………………………………………….1041
3.2 Removing and installing oil filter bracket with engine oil cooler………………………………………………………………………………………………………..1042
3.3 Removing and installing oil pressure switch -F1-……………………………………………………………………………………………………………………….1045
3.4 Checking oil pressure switch -F1-…………………………………………………………………………………………………………………………………….1045
3.5 Checking oil pressure……………………………………………………………………………………………………………………………………………….1047
19 – Cooling………………………………………………………………………………………………………………………………………………………………….1048
1 Parts of cooling system…………………………………………………………………………………………………………………………………………………..1048
1.1 Assembly overview – parts of cooling system, body side………………………………………………………………………………………………………………….1048
1.2 Assembly overview – parts of cooling system, engine side………………………………………………………………………………………………………………..1050
1.3 Assembly overview – coolant pump and thermostat………………………………………………………………………………………………………………………..1051
1.4 Coolant hose schematic diagram……………………………………………………………………………………………………………………………………….1052
2 Repairing cooling system………………………………………………………………………………………………………………………………………………….1053
2.1 Removing and installing cowling together with radiator fan -V7- and radiator fan on right of radiator -V35-…………………………………………………………………..1053
2.2 Removing and installing radiator……………………………………………………………………………………………………………………………………..1054
2.3 Removing and installing coolant pump………………………………………………………………………………………………………………………………….1055
2.4 Removing and installing 4/2-way valve with thermostat…………………………………………………………………………………………………………………..1057
2.5 Draining and filling coolant…………………………………………………………………………………………………………………………………………1061
2.5.1 Draining……………………………………………………………………………………………………………………………………………………..1062
2.5.2 Filling………………………………………………………………………………………………………………………………………………………1064
2.6 Coolant pipes, coolant temperature sender……………………………………………………………………………………………………………………………..1065
2.6.1 Removing and installing front coolant pipe……………………………………………………………………………………………………………………….1065
2.6.2 Removing and installing upper front coolant pipe………………………………………………………………………………………………………………….1069
2.6.3 Removing and installing left coolant pipe………………………………………………………………………………………………………………………..1070
2.6.4 Removing and installing right coolant pipe……………………………………………………………………………………………………………………….1072
2.6.5 Removing and installing coolant temperature sender -G62-…………………………………………………………………………………………………………..1074
2.6.6 Removing and installing coolant temperature sender at radiator outlet -G83-………………………………………………………………………………………….1075
2.7 Checking cooling system for leaks…………………………………………………………………………………………………………………………………….1076
20 – Fuel supply system………………………………………………………………………………………………………………………………………………………..1079
1 Safety precautions when working on fuel supply system………………………………………………………………………………………………………………………..1079
2 Rules for cleanliness…………………………………………………………………………………………………………………………………………………….1080
3 Repair instructions if tank has been filled with incorrect fuel……………………………………………………………………………………………………………….1081
3.1 Step 1 (Engine was started with incorrect fuel)………………………………………………………………………………………………………………………..1081
3.2 Step 2 (Engine was not started with incorrect fuel)…………………………………………………………………………………………………………………….1082
3.3 Step 3 (There are metal particles in fuel delivery unit and fuel tank)……………………………………………………………………………………………………1083
3.4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank)…………………………………………………………………………………………………1083
3.5 Step 5 (There are metal particles in high-pressure pump)………………………………………………………………………………………………………………..1084
3.6 Step 6 (There are no metal particles in high-pressure pump)……………………………………………………………………………………………………………..1084
4 Parts of fuel supply system……………………………………………………………………………………………………………………………………………….1085
4.1 Assembly overview – fuel tank………………………………………………………………………………………………………………………………………..1085
4.2 Assembly overview – fuel delivery unit, fuel gauge sender and suction jet pump…………………………………………………………………………………………….1087
4.3 Removing and installing fuel delivery unit…………………………………………………………………………………………………………………………….1088
4.4 Removing and installing fuel gauge sender -G-………………………………………………………………………………………………………………………….1090
4.5 Emptying fuel tank………………………………………………………………………………………………………………………………………………….1091
4.5.1 Emptying fuel tank when fuel pump is defective……………………………………………………………………………………………………………………1091
4.5.2 Emptying fuel tank when fuel pump is intact………………………………………………………………………………………………………………………1093
4.6 Removing and installing fuel tank…………………………………………………………………………………………………………………………………….1093
4.6.1 Removing……………………………………………………………………………………………………………………………………………………..1094
4.6.2 Installing……………………………………………………………………………………………………………………………………………………1095
5 Repairing fuel supply…………………………………………………………………………………………………………………………………………………….1096
5.1 Assembly overview – fuel filter………………………………………………………………………………………………………………………………………1096
5.2 Removing and installing fuel filter…………………………………………………………………………………………………………………………………..1097
5.3 Checking fuel system pressurisation pump -G6-………………………………………………………………………………………………………………………….1098
5.3.1 Checking delivery pressure and quantity for fuel system pressurisation pump -G6-……………………………………………………………………………………..1098
5.4 Assembly overview – accelerator mechanism……………………………………………………………………………………………………………………………..1102
5.5 Removing and installing accelerator module…………………………………………………………………………………………………………………………….1103
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………..1106
1 Turbocharger…………………………………………………………………………………………………………………………………………………………….1106
1.1 Safety precautions………………………………………………………………………………………………………………………………………………….1106
1.2 Rules for cleanliness……………………………………………………………………………………………………………………………………………….1106
1.3 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………..1107
1.4 Removing and installing turbocharger………………………………………………………………………………………………………………………………….1109
1.5 Replacing vacuum unit with position sender for charge pressure positioner -G581-…………………………………………………………………………………………..1113
2 Charge air system………………………………………………………………………………………………………………………………………………………..1119
2.1 Installing hose connections with plug-in connectors…………………………………………………………………………………………………………………….1119
2.2 Installing hose connections with corrugated pipe connection……………………………………………………………………………………………………………..1120
2.3 Assembly overview – parts of charge air cooling………………………………………………………………………………………………………………………..1120
2.4 Removing and installing charge air cooler……………………………………………………………………………………………………………………………..1121
2.5 Checking charge air system for leaks………………………………………………………………………………………………………………………………….1122
2.6 Vacuum hose schematic diagram………………………………………………………………………………………………………………………………………..1126
2.7 Testing vacuum system……………………………………………………………………………………………………………………………………………….1126
2.7.1 Checking supply line, vacuum reservoir and non-return valve………………………………………………………………………………………………………..1127
2.7.2 Checking control line to turbocharger……………………………………………………………………………………………………………………………1128
2.7.3 Checking control line to vacuum unit for exhaust gas recirculation cooler changeover function………………………………………………………………………….1129
23 – Mixture preparation – injection…………………………………………………………………………………………………………………………………………….1130
1 Diesel direct injection system…………………………………………………………………………………………………………………………………………….1130
1.1 Safety precautions………………………………………………………………………………………………………………………………………………….1130
1.2 Rules for cleanliness……………………………………………………………………………………………………………………………………………….1130
1.3 System layout………………………………………………………………………………………………………………………………………………………1131
2 High-pressure pump……………………………………………………………………………………………………………………………………………………….1133
2.1 Assembly overview – high-pressure pump………………………………………………………………………………………………………………………………..1133
2.2 Removing and installing high-pressure pump…………………………………………………………………………………………………………………………….1134
2.3 Filling, bleeding fuel system………………………………………………………………………………………………………………………………………..1137
2.4 Checking for leaks in the fuel system…………………………………………………………………………………………………………………………………1138
3 Injectors……………………………………………………………………………………………………………………………………………………………….1139
3.1 Assembly overview – injectors………………………………………………………………………………………………………………………………………..1139
3.2 Carrying out adaptation for injector delivery calibration……………………………………………………………………………………………………………….1142
3.3 Checking for injectors sticking open………………………………………………………………………………………………………………………………….1143
3.4 Removing and installing injectors…………………………………………………………………………………………………………………………………….1144
3.5 Installing high-pressure lines……………………………………………………………………………………………………………………………………….1147
3.6 Checking fuel pressure regulating valve -N276-…………………………………………………………………………………………………………………………1149
3.7 Removing and installing fuel pressure regulating valve -N276-……………………………………………………………………………………………………………1151
3.8 Removing and installing fuel pressure sender -G247-…………………………………………………………………………………………………………………….1153
3.9 Removing and installing high-pressure accumulator (rail)………………………………………………………………………………………………………………..1155
4 Intake manifold………………………………………………………………………………………………………………………………………………………….1158
4.1 Assembly overview – intake manifold with attachments……………………………………………………………………………………………………………………1158
4.2 Removing and installing throttle valve module -J338-……………………………………………………………………………………………………………………1159
4.3 Removing and installing intake manifold……………………………………………………………………………………………………………………………….1160
5 Air filter………………………………………………………………………………………………………………………………………………………………1163
5.1 Assembly overview – air filter……………………………………………………………………………………………………………………………………….1163
5.2 Removing and installing air filter housing…………………………………………………………………………………………………………………………….1164
5.3 Removing and installing air mass meter -G70-…………………………………………………………………………………………………………………………..1166
6 Lambda probe and pressure differential sender……………………………………………………………………………………………………………………………….1167
6.1 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-…………………………………………………………………………………………………1167
6.2 Removing and installing pressure differential sender -G505-……………………………………………………………………………………………………………..1168
7 Engine control unit………………………………………………………………………………………………………………………………………………………1170
7.1 Removing and installing engine control unit -J623-……………………………………………………………………………………………………………………..1170
7.2 Removing and installing anti-theft engine control unit -J623-……………………………………………………………………………………………………………1171
26 – Exhaust system……………………………………………………………………………………………………………………………………………………………1173
1 Front exhaust pipe with particulate filter………………………………………………………………………………………………………………………………….1173
1.1 Assembly overview – front exhaust pipe with particulate filter…………………………………………………………………………………………………………..1173
1.2 Removing and installing particulate filter…………………………………………………………………………………………………………………………….1175
1.2.1 Front-wheel drive vehicles……………………………………………………………………………………………………………………………………..1175
1.2.2 Vehicles with four-wheel drive………………………………………………………………………………………………………………………………….1180
2 Silencer………………………………………………………………………………………………………………………………………………………………..1183
2.1 Assembly overview – silencers………………………………………………………………………………………………………………………………………..1183
2.2 Aligning exhaust system free of stress………………………………………………………………………………………………………………………………..1184
2.3 Installation position and specified torque of clamp…………………………………………………………………………………………………………………….1184
3 Exhaust gas temperature regulation…………………………………………………………………………………………………………………………………………1186
3.1 Assembly overview – exhaust gas temperature regulation………………………………………………………………………………………………………………….1186
3.2 Removing and installing exhaust gas temperature sender 1 -G235-………………………………………………………………………………………………………….1187
3.3 Removing and installing exhaust gas temperature sender 3 -G495-………………………………………………………………………………………………………….1188
3.4 Removing and installing exhaust gas temperature sender 4 -G648-………………………………………………………………………………………………………….1190
4 SCR system (selective catalytic reduction)………………………………………………………………………………………………………………………………….1191
4.1 Assembly overview – reduction catalytic converter………………………………………………………………………………………………………………………1191
4.2 Assembly overview – tank for reduction agent…………………………………………………………………………………………………………………………..1193
4.3 Removing and installing heater element (heater cup)…………………………………………………………………………………………………………………….1194
4.4 Removing and installing injector for reduction agent -N474-……………………………………………………………………………………………………………..1197
4.5 Emptying tank for reduction agent…………………………………………………………………………………………………………………………………….1198
4.6 Removing and installing tank for reduction agent……………………………………………………………………………………………………………………….1201
5 Exhaust gas recirculation system…………………………………………………………………………………………………………………………………………..1205
5.1 Assembly overview – exhaust gas recirculation with cooling system for exhaust gas recirculation……………………………………………………………………………..1205
5.2 Checking changeover for exhaust gas recirculation cooler………………………………………………………………………………………………………………..1206
5.3 Removing and installing exhaust gas recirculation cooler………………………………………………………………………………………………………………..1206
5.4 Checking exhaust gas recirculation cooler for leaks…………………………………………………………………………………………………………………….1209
28 – Glow plug system………………………………………………………………………………………………………………………………………………………….1214
1 Checking glow plug system…………………………………………………………………………………………………………………………………………………1214
1.1 Removing and installing glow plugs……………………………………………………………………………………………………………………………………1214
1.2 Removing and installing automatic glow period control unit -J179-………………………………………………………………………………………………………..1216
Sharan2011-6-speed_dual_clutch_gearbox_02E…………………………………………………………………………………………………………………………………………..1217
00 – Technical data……………………………………………………………………………………………………………………………………………………………1223
1 General repair notes……………………………………………………………………………………………………………………………………………………..1223
1.1 Tools……………………………………………………………………………………………………………………………………………………………..1223
1.2 Gearbox……………………………………………………………………………………………………………………………………………………………1223
1.3 Overview…………………………………………………………………………………………………………………………………………………………..1223
1.4 Seals……………………………………………………………………………………………………………………………………………………………..1224
1.5 ⇒ DSG® oil…………………………………………………………………………………………………………………………………………………………1225
1.6 Oil filter change – »Yes or no?«……………………………………………………………………………………………………………………………………..1225
1.7 Oil drain and inspection plug -A-…………………………………………………………………………………………………………………………………….1225
1.8 Nuts and bolts……………………………………………………………………………………………………………………………………………………..1226
1.9 Electrical components……………………………………………………………………………………………………………………………………………….1226
2 Fault finding……………………………………………………………………………………………………………………………………………………………1227
2.1 General notes on fault finding……………………………………………………………………………………………………………………………………….1227
2.2 Useful information about the “behaviour of the control unit in the event of a gearbox fault”………………………………………………………………………………..1227
2.3 Special notes on fault finding……………………………………………………………………………………………………………………………………….1228
3 Gearbox identification……………………………………………………………………………………………………………………………………………………1229
3.1 Reading gearbox code letters…………………………………………………………………………………………………………………………………………1229
4 Code – engine allocation………………………………………………………………………………………………………………………………………………….1231
4.1 Golf Plus 2009 ►……………………………………………………………………………………………………………………………………………………1231
4.2 Golf Plus 2005 ►……………………………………………………………………………………………………………………………………………………1231
4.3 Golf 2009 ►………………………………………………………………………………………………………………………………………………………..1232
4.4 Scirocco 2009 ►…………………………………………………………………………………………………………………………………………………….1232
4.5 Golf 2004 ►………………………………………………………………………………………………………………………………………………………..1232
4.6 Touran 2003 ►………………………………………………………………………………………………………………………………………………………1233
4.7 Passat 2006 ►………………………………………………………………………………………………………………………………………………………1234
4.8 Eos 2006 ►…………………………………………………………………………………………………………………………………………………………1234
4.9 Passat CC 2009 ►, CC 2010 ►………………………………………………………………………………………………………………………………………….1235
4.10 Sharan 2011 ►……………………………………………………………………………………………………………………………………………………..1235
5 Capacity ……………………………………………………………………………………………………………………………………………………………….1236
30 – Clutch…………………………………………………………………………………………………………………………………………………………………..1237
1 Clutch………………………………………………………………………………………………………………………………………………………………….1237
1.1 Assembly overview – dual clutch………………………………………………………………………………………………………………………………………1237
1.2 Removing and installing clutch end cover………………………………………………………………………………………………………………………………1239
1.3 Removing dual clutch………………………………………………………………………………………………………………………………………………..1245
1.4 Installing dual clutch………………………………………………………………………………………………………………………………………………1246
34 – Controls, housing…………………………………………………………………………………………………………………………………………………………1252
1 Electrical and electronic components and their locations ⇒ DSG………………………………………………………………………………………………………………..1252
1.1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed)…………………………………………………………………………………1252
1.2 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox removed)…………………………………………………………………………………..1261
1.3 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509-……………………………………………………………..1268
2 Removing and installing gearbox oil cooler………………………………………………………………………………………………………………………………….1269
3 Removing and installing oil pump…………………………………………………………………………………………………………………………………………..1272
4 Renewing selector shaft lever oil seal with gearbox removed…………………………………………………………………………………………………………………..1276
5 Emergency release of selector lever………………………………………………………………………………………………………………………………………..1278
6 Removing and installing selector lever handle……………………………………………………………………………………………………………………………….1279
6.1 Moving pushbutton to installation position in the handle………………………………………………………………………………………………………………..1281
6.1.1 Handle with pushbutton on side………………………………………………………………………………………………………………………………….1281
6.1.2 Handle with front pushbutton……………………………………………………………………………………………………………………………………1281
7 Selector mechanism up to 02.2009…………………………………………………………………………………………………………………………………………..1283
7.1 Overview of selector mechanism up to 02.2009…………………………………………………………………………………………………………………………..1283
7.2 Removing and installing selector lever cable up to 02.2009………………………………………………………………………………………………………………1284
7.3 Checking selector lever cable………………………………………………………………………………………………………………………………………..1291
7.4 Adjusting selector lever cable……………………………………………………………………………………………………………………………………….1291
8 Checking selector mechanism……………………………………………………………………………………………………………………………………………….1293
8.1 Selector lever in “P” position and ignition switched on…………………………………………………………………………………………………………………1293
8.2 Selector lever in “N” position and ignition switched on…………………………………………………………………………………………………………………1293
8.3 Selector lever in position “Tiptronic”………………………………………………………………………………………………………………………………..1293
8.4 Ignition and light switched on……………………………………………………………………………………………………………………………………….1293
8.5 Selector lever position display………………………………………………………………………………………………………………………………………1293
9 Selector mechanism from 03.2009 onwards…………………………………………………………………………………………………………………………………….1294
9.1 Overview of selector mechanism in vehicles from 03.2009 onwards………………………………………………………………………………………………………….1294
9.2 Removing and installing selector mechanism, from 03.2009………………………………………………………………………………………………………………..1295
9.2.1 Removing and installing selector mechanism with selector housing……………………………………………………………………………………………………1295
9.2.2 Removing and installing selector mechanism without selector housing…………………………………………………………………………………………………1298
10 Removing and installing gearbox…………………………………………………………………………………………………………………………………………..1300
10.1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2.0 l petrol engine…………………………………………………………………………………………………..1300
10.2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2.0 l petrol engine…………………………………………………………………………………………………1309
10.3 Removing gearbox, Golf Plus 2005 ► with 1.4 l petrol engine…………………………………………………………………………………………………………….1318
10.4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine…………………………………………………………………………………………………………….1325
10.5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine (all-wheel drive)…………………………………………………………………………………………….1335
10.6 Removing gearbox, Golf Plus 2009 ► with 2.0 l diesel engine…………………………………………………………………………………………………………….1344
10.7 Removing gearbox, Golf 2009 ► 2.0 l diesel engine……………………………………………………………………………………………………………………..1352
10.8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3.6 l – V6 engine (all-wheel drive)…………………………………………………………………………………….1359
10.9 Removing gearbox, Golf 2004 ▸ with 1.9 l und 2.0 l diesel engine………………………………………………………………………………………………………..1366
10.10 Removing gearbox, Golf 2004 ► with 125 kW – 2.0 l diesel engine………………………………………………………………………………………………………..1373
10.11 Removing gearbox, Eos 2006 ►, with 3.2 and 3.6 l – V6 engine…………………………………………………………………………………………………………..1379
10.12 Removing gearbox, Golf 2004 ►with 1.4 l petrol engine…………………………………………………………………………………………………………………1386
10.13 Removing gearbox, Golf 2004 ►with 2.0 l petrol engine…………………………………………………………………………………………………………………1392
10.14 Removing gearbox, Golf 2004 ►, with 3.2 l – V6 engine (R32 four-wheel drive)…………………………………………………………………………………………….1397
10.15 Removing gearbox, Golf Plus 2005 ► with 1.9 l and 2.0 l diesel engine, with 2.0 l petrol engine……………………………………………………………………………1406
10.16 Removing gearbox, Eos 2006 ► with 2.0 l petrol engine…………………………………………………………………………………………………………………1412
10.17 Removing gearbox, Eos 2005 ► with 2.0 l diesel engine…………………………………………………………………………………………………………………1419
10.18 Removing gearbox, Touran 2003 ►…………………………………………………………………………………………………………………………………….1427
10.19 Removing gearbox, Passat 2006 ► with 2.0 l diesel engine………………………………………………………………………………………………………………1435
10.20 Removing gearbox, Passat 2006 ► with 2.0 l petrol engine………………………………………………………………………………………………………………1443
10.21 Removing gearbox, Passat 2006 ►, with 3.6 l – V6 engine (four-wheel drive)………………………………………………………………………………………………1448
10.22 Removing gearbox, Scirocco 2009 ► with 2.0 l diesel engine…………………………………………………………………………………………………………….1454
10.23 Removing gearbox, Scirocco 2009 ► with 2.0 l petrol engine…………………………………………………………………………………………………………….1462
10.24 Removing gearbox, Sharan 2011 ► with 2.0 l diesel engine………………………………………………………………………………………………………………1471
10.25 Removing gearbox, Sharan 2011 ► with 1.8 l and 2.0 l petrol engine……………………………………………………………………………………………………..1479
10.26 Removing gearbox, Sharan 2011 ► with 1.4 l petrol engine………………………………………………………………………………………………………………1488
10.27 Installing gearbox………………………………………………………………………………………………………………………………………………..1495
11 Torque settings »gearbox to engine«……………………………………………………………………………………………………………………………………….1497
11.1 Torque settings (⇒ ELSA)……………………………………………………………………………………………………………………………………………1497
11.1.1 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1498
11.1.2 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1499
11.1.3 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1500
11.1.4 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1502
11.1.5 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1503
11.1.6 Torque settings and notes concerning engine mountings…………………………………………………………………………………………………………….1504
12 Transporting gearbox and securing to assembly stand…………………………………………………………………………………………………………………………1505
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ►……………………………………………………………………………………………………………..1506
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine………………………………………………………………………………………………1511
14.1 Specified torques………………………………………………………………………………………………………………………………………………….1517
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine…………………………………………………………………………………………….1518
16 Oil and oil filter………………………………………………………………………………………………………………………………………………………1522
16.1 Renewing oil filter………………………………………………………………………………………………………………………………………………..1522
16.2 Checking oil level and topping up……………………………………………………………………………………………………………………………………1523
16.3 Draining and filling oil……………………………………………………………………………………………………………………………………………1526
35 – Gears, shafts…………………………………………………………………………………………………………………………………………………………….1530
1 Currently, no repairs can be made to gears and shafts………………………………………………………………………………………………………………………..1530
39 – Final drive – differential…………………………………………………………………………………………………………………………………………………1531
1 Overview – seals…………………………………………………………………………………………………………………………………………………………1531
1.1 Renewing seals for right flange shaft or stub shaft – front-wheel drive…………………………………………………………………………………………………..1532
2 Renewing oil seal for left flange shaft – front and four-wheel drive…………………………………………………………………………………………………………..1534
2.1 Renewing oil seal for right flange shaft – four-wheel drive……………………………………………………………………………………………………………..1535
2.2 Dismantling and assembling flange shaft……………………………………………………………………………………………………………………………….1537
3 Renewing oil seal for propshaft drive flange at bevel box…………………………………………………………………………………………………………………….1539
4 Assembly overview – Flange shafts and seals on bevel box……………………………………………………………………………………………………………………..1545
4.1 Renewing seal on gearbox between bevel box and gearbox………………………………………………………………………………………………………………….1546
4.2 Removing and installing right flange shaft…………………………………………………………………………………………………………………………….1547
4.3 Renewing seal for right flange shaft on outside of bevel box…………………………………………………………………………………………………………….1549
4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange……………………………………………………………………………………………..1550
4.5 Renewing seal on bevel box between gearbox and bevel box………………………………………………………………………………………………………………..1552
5 Checking and topping up gear oil in bevel box……………………………………………………………………………………………………………………………….1554
5.1 Checking gear oil in bevel box……………………………………………………………………………………………………………………………………….1554
5.2 Topping up gear oil in bevel box……………………………………………………………………………………………………………………………………..1555
Sharan2011-Auxiliary_heater………………………………………………………………………………………………………………………………………………………..1558
82 – Supplementary heating……………………………………………………………………………………………………………………………………………………..1562
1 Auxiliary heater Thermo Top V……………………………………………………………………………………………………………………………………………..1562
1.1 Safety measures for working on vehicles with auxiliary heaters…………………………………………………………………………………………………………..1562
1.2 Note on auxiliary heater operation in vehicles with diesel engine………………………………………………………………………………………………………..1562
1.3 Notes for vehicles with a start-stop system……………………………………………………………………………………………………………………………1562
1.4 Safety measures for vehicles with a start-stop system…………………………………………………………………………………………………………………..1563
2 Notes on general repairs on vehicles with auxiliary heaters…………………………………………………………………………………………………………………..1564
2.1 Starting conditions for auxiliary heating (preheater)…………………………………………………………………………………………………………………..1564
2.2 Starting conditions for auxiliary heating……………………………………………………………………………………………………………………………..1564
3 Rules for cleanliness when working on the auxiliary heater and the fuel system………………………………………………………………………………………………….1566
4 Repairing auxiliary heater Thermo Top V…………………………………………………………………………………………………………………………………….1567
4.1 Repairing auxiliary heater Thermo Top V……………………………………………………………………………………………………………………………….1567
4.1.1 Manufacturer’s nameplates used for Thermo Top V…………………………………………………………………………………………………………………..1569
4.1.2 Removing and installing ambient temperature sensor -G17-…………………………………………………………………………………………………………..1570
4.1.3 Removing and installing exhaust system…………………………………………………………………………………………………………………………..1571
4.1.4 Removing and installing remote control receiver for auxiliary heater -R64-…………………………………………………………………………………………..1571
5 Removing and installing auxiliary heater Thermo Top V………………………………………………………………………………………………………………………..1573
5.1 Components of auxiliary heater Thermo Top V……………………………………………………………………………………………………………………………1573
5.1.1 Removing……………………………………………………………………………………………………………………………………………………..1573
5.1.2 Installing……………………………………………………………………………………………………………………………………………………1576
5.2 Removing ancillaries of auxiliary heater Thermo Top V…………………………………………………………………………………………………………………..1576
5.2.3 Removing circulation pump -V55-…………………………………………………………………………………………………………………………………1577
5.2.4 Installing……………………………………………………………………………………………………………………………………………………1577
6 Dismantling and assembling auxiliary heater Thermo Top V……………………………………………………………………………………………………………………..1579
6.1 Dismantling and assembling auxiliary heater Thermo Top V………………………………………………………………………………………………………………..1579
6.2 Inner components of auxiliary heater………………………………………………………………………………………………………………………………….1579
6.3 Removing and installing glow plug with flame monitoring -Q8-…………………………………………………………………………………………………………….1581
6.4 Removing and installing temperature sensor -G18- and overheating sensor -G189-…………………………………………………………………………………………….1582
6.5 Removing and installing heater coolant shut-off valve -N279-…………………………………………………………………………………………………………….1582
7 Connecting auxiliary heater Thermo Top V to coolant circuit…………………………………………………………………………………………………………………..1585
7.1 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code CAVA…………………………………………………………………………………..1585
7.2 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code CCZA…………………………………………………………………………………..1586
7.3 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CFFA, CFFB, CFGB……………………………………………………………………….1588
7.4 Coolant hose routing on vehicles with 2nd heat exchanger………………………………………………………………………………………………………………..1589
8 Fuel supply for auxiliary heater Thermo Top V……………………………………………………………………………………………………………………………….1591
8.1 Fuel supply for auxiliary heater Thermo Top V………………………………………………………………………………………………………………………….1591
8.1.1 Rules for cleanliness………………………………………………………………………………………………………………………………………….1591
8.1.2 Fuel feed to Thermo Top V………………………………………………………………………………………………………………………………………1591
8.2 Removing and installing metering pump -V54-……………………………………………………………………………………………………………………………1592
8.2.1 Removing……………………………………………………………………………………………………………………………………………………..1593
8.2.2 Installing……………………………………………………………………………………………………………………………………………………1593
8.3 Testing quantity of fuel delivered……………………………………………………………………………………………………………………………………1593
8.3.1 Test prerequisites:……………………………………………………………………………………………………………………………………………1594
8.3.2 Checking:…………………………………………………………………………………………………………………………………………………….1594
9 Regulation of auxiliary heater Thermo Top V…………………………………………………………………………………………………………………………………1596
9.1 Functional description of auxiliary heater Thermo Top V…………………………………………………………………………………………………………………1596
9.2 Preheating mode…………………………………………………………………………………………………………………………………………………….1597
9.3 Auxiliary heating mode………………………………………………………………………………………………………………………………………………1597
9.4 Switching off………………………………………………………………………………………………………………………………………………………1597
10 Connector pin assignment of auxiliary heater Thermo Top V……………………………………………………………………………………………………………………1598
10.1 Connector pin assignment of auxiliary heater Thermo Top V………………………………………………………………………………………………………………1598
11 Functional description of remote control for auxiliary heater Thermo Top V…………………………………………………………………………………………………….1599
11.1 Switching auxiliary heater on using remote control…………………………………………………………………………………………………………………….1599
11.2 Switching auxiliary heater off using remote control……………………………………………………………………………………………………………………1599
11.3 Renewing remote control battery……………………………………………………………………………………………………………………………………..1600
11.4 Warning lamp in remote control………………………………………………………………………………………………………………………………………1600
Sharan2011-Body_Repairs……………………………………………………………………………………………………………………………………………………………1601
00 – Technical data……………………………………………………………………………………………………………………………………………………………1607
1 Vehicle identification data……………………………………………………………………………………………………………………………………………….1607
1.1 Vehicle identification number………………………………………………………………………………………………………………………………………..1607
2 Safety instructions………………………………………………………………………………………………………………………………………………………1609
3 Moulded foam elements…………………………………………………………………………………………………………………………………………………….1610
4 Galvanized body parts, high- and higher-strength and hot-formed body panels…………………………………………………………………………………………………….1612
5 Laser welding……………………………………………………………………………………………………………………………………………………………1614
6 Body panel gaps/shut lines………………………………………………………………………………………………………………………………………………..1615
6.1 Body – front……………………………………………………………………………………………………………………………………………………….1615
6.2 Body – centre………………………………………………………………………………………………………………………………………………………1616
6.3 Body – rear………………………………………………………………………………………………………………………………………………………..1617
7 Body dimensions………………………………………………………………………………………………………………………………………………………….1618
7.1 Body – front……………………………………………………………………………………………………………………………………………………….1618
7.2 Body – centre………………………………………………………………………………………………………………………………………………………1621
7.3 Body – rear………………………………………………………………………………………………………………………………………………………..1626
7.4 Floor group – front…………………………………………………………………………………………………………………………………………………1627
7.5 Floor group – centre………………………………………………………………………………………………………………………………………………..1628
7.6 Floor group – rear………………………………………………………………………………………………………………………………………………….1629
8 Alignment bracket set…………………………………………………………………………………………………………………………………………………….1630
8.1 Overview…………………………………………………………………………………………………………………………………………………………..1630
9 Portal gauge…………………………………………………………………………………………………………………………………………………………….1632
9.1 Overview…………………………………………………………………………………………………………………………………………………………..1632
50 – Body – front……………………………………………………………………………………………………………………………………………………………..1634
1 Renewing engine mounting bracket…………………………………………………………………………………………………………………………………………..1634
1.1 Tools……………………………………………………………………………………………………………………………………………………………..1634
1.2 Removing…………………………………………………………………………………………………………………………………………………………..1634
1.3 Installing…………………………………………………………………………………………………………………………………………………………1636
1.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1636
1.3.2 Welding in……………………………………………………………………………………………………………………………………………………1637
2 Renewing left console…………………………………………………………………………………………………………………………………………………….1638
2.1 Tools……………………………………………………………………………………………………………………………………………………………..1638
2.2 Removing…………………………………………………………………………………………………………………………………………………………..1638
2.3 Installing…………………………………………………………………………………………………………………………………………………………1641
2.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1641
2.3.2 Welding in……………………………………………………………………………………………………………………………………………………1642
3 Renewing retaining bracket (for subframe)…………………………………………………………………………………………………………………………………..1645
3.1 Tools……………………………………………………………………………………………………………………………………………………………..1645
3.2 Removing…………………………………………………………………………………………………………………………………………………………..1645
3.3 Installing…………………………………………………………………………………………………………………………………………………………1647
3.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1647
3.3.2 Welding in……………………………………………………………………………………………………………………………………………………1649
4 Renewing bumper bracket…………………………………………………………………………………………………………………………………………………..1650
4.1 Tools……………………………………………………………………………………………………………………………………………………………..1651
4.2 Removing…………………………………………………………………………………………………………………………………………………………..1651
4.3 Installing…………………………………………………………………………………………………………………………………………………………1652
4.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1652
4.3.2 Welding in……………………………………………………………………………………………………………………………………………………1653
5 Renewing upper wheel housing longitudinal member…………………………………………………………………………………………………………………………….1654
5.1 Tools……………………………………………………………………………………………………………………………………………………………..1655
5.2 Removing…………………………………………………………………………………………………………………………………………………………..1655
5.3 Installing…………………………………………………………………………………………………………………………………………………………1657
5.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1658
5.3.2 Welding in……………………………………………………………………………………………………………………………………………………1658
6 Renewing front wheel housing………………………………………………………………………………………………………………………………………………1662
6.1 Tools……………………………………………………………………………………………………………………………………………………………..1663
6.2 Removing…………………………………………………………………………………………………………………………………………………………..1663
6.3 Installing…………………………………………………………………………………………………………………………………………………………1667
6.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1667
6.3.2 Welding in……………………………………………………………………………………………………………………………………………………1668
7 Renewing front longitudinal member…………………………………………………………………………………………………………………………………………1670
7.1 Tools……………………………………………………………………………………………………………………………………………………………..1671
7.2 Removing…………………………………………………………………………………………………………………………………………………………..1671
7.3 Installing…………………………………………………………………………………………………………………………………………………………1674
7.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1675
7.3.2 Welding in……………………………………………………………………………………………………………………………………………………1675
7.3.3 Shortening new longitudinal member with cover plate……………………………………………………………………………………………………………….1679
8 Renewing front longitudinal member – part section……………………………………………………………………………………………………………………………1683
8.1 Tools……………………………………………………………………………………………………………………………………………………………..1684
8.2 Removing…………………………………………………………………………………………………………………………………………………………..1684
8.3 Installing…………………………………………………………………………………………………………………………………………………………1687
8.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1688
8.3.2 Welding in……………………………………………………………………………………………………………………………………………………1688
9 Repairing threads for securing subframe…………………………………………………………………………………………………………………………………….1693
9.1 Tools……………………………………………………………………………………………………………………………………………………………..1694
9.2 Contents of thread repair kit………………………………………………………………………………………………………………………………………..1694
9.3 Repairing threads…………………………………………………………………………………………………………………………………………………..1695
9.3.1 Drilling thread……………………………………………………………………………………………………………………………………………….1695
9.3.2 Cutting thread………………………………………………………………………………………………………………………………………………..1696
9.3.3 Inserting thread insert………………………………………………………………………………………………………………………………………..1696
51 – Body – centre…………………………………………………………………………………………………………………………………………………………….1698
1 Renewing roof……………………………………………………………………………………………………………………………………………………………1698
1.1 Tools……………………………………………………………………………………………………………………………………………………………..1699
1.2 Removing…………………………………………………………………………………………………………………………………………………………..1700
1.3 Installing…………………………………………………………………………………………………………………………………………………………1703
1.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1703
1.3.2 Adjusting roof depth…………………………………………………………………………………………………………………………………………..1707
1.3.3 Bonding roof………………………………………………………………………………………………………………………………………………….1707
1.3.4 Welding in roof……………………………………………………………………………………………………………………………………………….1713
2 Renewing roof – vehicles with panorama sunroof………………………………………………………………………………………………………………………………1715
2.1 Tools……………………………………………………………………………………………………………………………………………………………..1716
2.2 Removing…………………………………………………………………………………………………………………………………………………………..1717
2.3 Installing…………………………………………………………………………………………………………………………………………………………1720
2.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1720
2.3.2 Adjusting roof depth…………………………………………………………………………………………………………………………………………..1724
2.3.3 Bonding roof………………………………………………………………………………………………………………………………………………….1724
2.3.4 Welding in roof……………………………………………………………………………………………………………………………………………….1729
3 Renewing front roof cross member…………………………………………………………………………………………………………………………………………..1731
3.1 Tools……………………………………………………………………………………………………………………………………………………………..1732
3.2 Removing…………………………………………………………………………………………………………………………………………………………..1732
3.3 Installing…………………………………………………………………………………………………………………………………………………………1733
3.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1733
3.3.2 Welding in……………………………………………………………………………………………………………………………………………………1734
4 Renewing roof reinforcement……………………………………………………………………………………………………………………………………………….1736
4.1 Tools……………………………………………………………………………………………………………………………………………………………..1737
4.2 Removing…………………………………………………………………………………………………………………………………………………………..1737
4.3 Installing…………………………………………………………………………………………………………………………………………………………1738
4.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1738
4.3.2 Welding in……………………………………………………………………………………………………………………………………………………1740
5 Renewing rear roof cross member……………………………………………………………………………………………………………………………………………1741
5.1 Tools……………………………………………………………………………………………………………………………………………………………..1742
5.2 Removing…………………………………………………………………………………………………………………………………………………………..1742
5.3 Installing…………………………………………………………………………………………………………………………………………………………1743
5.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1743
5.3.2 Welding in……………………………………………………………………………………………………………………………………………………1745
6 Renewing A-pillar………………………………………………………………………………………………………………………………………………………..1746
6.1 Tools……………………………………………………………………………………………………………………………………………………………..1747
6.2 Removing…………………………………………………………………………………………………………………………………………………………..1748
6.3 Installing…………………………………………………………………………………………………………………………………………………………1749
6.3.1 Authorised parting cuts on complete side panel……………………………………………………………………………………………………………………1750
6.3.2 Preparing replacement part……………………………………………………………………………………………………………………………………..1750
6.3.3 Moulded foam elements………………………………………………………………………………………………………………………………………….1751
6.3.4 Welding in……………………………………………………………………………………………………………………………………………………1751
7 Renewing A-pillar reinforcement……………………………………………………………………………………………………………………………………………1753
7.1 Tools……………………………………………………………………………………………………………………………………………………………..1754
7.2 Removing…………………………………………………………………………………………………………………………………………………………..1754
7.3 Installing…………………………………………………………………………………………………………………………………………………………1756
7.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1756
7.3.2 Moulded foam elements………………………………………………………………………………………………………………………………………….1757
7.3.3 Welding in……………………………………………………………………………………………………………………………………………………1757
8 Renewing B-pillar………………………………………………………………………………………………………………………………………………………..1759
8.1 Tools……………………………………………………………………………………………………………………………………………………………..1760
8.2 Removing…………………………………………………………………………………………………………………………………………………………..1760
8.3 Installing…………………………………………………………………………………………………………………………………………………………1762
8.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1762
8.3.2 Moulded foam elements………………………………………………………………………………………………………………………………………….1763
8.3.3 Welding in……………………………………………………………………………………………………………………………………………………1764
9 Renewing B-pillar reinforcement……………………………………………………………………………………………………………………………………………1767
9.1 Tools……………………………………………………………………………………………………………………………………………………………..1768
9.2 Removing…………………………………………………………………………………………………………………………………………………………..1768
9.3 Installing…………………………………………………………………………………………………………………………………………………………1770
9.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1770
9.3.2 Moulded foam elements………………………………………………………………………………………………………………………………………….1773
9.3.3 Welding in……………………………………………………………………………………………………………………………………………………1774
10 Renewing outer side member……………………………………………………………………………………………………………………………………………….1778
10.1 Tools…………………………………………………………………………………………………………………………………………………………….1779
10.2 Removing………………………………………………………………………………………………………………………………………………………….1779
10.2.1 Installing…………………………………………………………………………………………………………………………………………………..1780
10.2.2 Preparing replacement part…………………………………………………………………………………………………………………………………….1781
10.2.3 Welding in…………………………………………………………………………………………………………………………………………………..1781
53 – Body – rear………………………………………………………………………………………………………………………………………………………………1783
1 Renewing rear cross panel…………………………………………………………………………………………………………………………………………………1783
1.1 Tools……………………………………………………………………………………………………………………………………………………………..1784
1.2 Removing…………………………………………………………………………………………………………………………………………………………..1784
1.3 Installing…………………………………………………………………………………………………………………………………………………………1785
1.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1785
1.4 Welding in…………………………………………………………………………………………………………………………………………………………1786
2 Renewing tail light mounting………………………………………………………………………………………………………………………………………………1788
2.1 Tools……………………………………………………………………………………………………………………………………………………………..1789
2.2 Removing…………………………………………………………………………………………………………………………………………………………..1789
2.3 Installing…………………………………………………………………………………………………………………………………………………………1790
2.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1790
2.3.2 Welding in……………………………………………………………………………………………………………………………………………………1791
3 Renewing cross panel member……………………………………………………………………………………………………………………………………………….1793
3.1 Tools……………………………………………………………………………………………………………………………………………………………..1794
3.2 Removing…………………………………………………………………………………………………………………………………………………………..1794
3.3 Installing…………………………………………………………………………………………………………………………………………………………1795
3.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1795
3.3.2 Welding in……………………………………………………………………………………………………………………………………………………1797
4 Renewing luggage compartment floor…………………………………………………………………………………………………………………………………………1799
4.1 Tools……………………………………………………………………………………………………………………………………………………………..1800
4.2 Removing…………………………………………………………………………………………………………………………………………………………..1800
4.3 Installing…………………………………………………………………………………………………………………………………………………………1801
4.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1801
4.3.2 Welding in……………………………………………………………………………………………………………………………………………………1802
5 Renew longitudinal member bracket………………………………………………………………………………………………………………………………………….1804
5.1 Tools……………………………………………………………………………………………………………………………………………………………..1805
5.2 Removing…………………………………………………………………………………………………………………………………………………………..1805
5.3 Installing…………………………………………………………………………………………………………………………………………………………1806
5.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1806
5.3.2 Welding in……………………………………………………………………………………………………………………………………………………1807
6 Renewing rear longitudinal member (part section)…………………………………………………………………………………………………………………………….1808
6.1 Tools……………………………………………………………………………………………………………………………………………………………..1809
6.2 Removing…………………………………………………………………………………………………………………………………………………………..1809
6.3 Installing…………………………………………………………………………………………………………………………………………………………1810
6.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1810
6.3.2 Welding in……………………………………………………………………………………………………………………………………………………1811
7 Renewing side panel………………………………………………………………………………………………………………………………………………………1813
7.1 Tools……………………………………………………………………………………………………………………………………………………………..1814
7.2 Removing…………………………………………………………………………………………………………………………………………………………..1814
7.3 Installing…………………………………………………………………………………………………………………………………………………………1816
7.3.1 Authorised parting cuts on complete side panel……………………………………………………………………………………………………………………1816
7.3.2 Preparing replacement part……………………………………………………………………………………………………………………………………..1816
7.3.3 Moulded foam elements………………………………………………………………………………………………………………………………………….1817
7.3.4 Welding in……………………………………………………………………………………………………………………………………………………1818
8 Renewing outer wheel housing liner…………………………………………………………………………………………………………………………………………1820
8.1 Tools……………………………………………………………………………………………………………………………………………………………..1821
8.2 Removing…………………………………………………………………………………………………………………………………………………………..1821
8.3 Installing…………………………………………………………………………………………………………………………………………………………1822
8.3.1 Preparing replacement part……………………………………………………………………………………………………………………………………..1823
8.3.2 Moulded foam elements………………………………………………………………………………………………………………………………………….1823
8.3.3 Welding in……………………………………………………………………………………………………………………………………………………1824
Sharan2011-Brake_system……………………………………………………………………………………………………………………………………………………………1826
00 – Technical data……………………………………………………………………………………………………………………………………………………………1830
1 Brake allocation via PR No………………………………………………………………………………………………………………………………………………..1830
1.1 Front brakes……………………………………………………………………………………………………………………………………………………….1830
1.2 Rear brakes………………………………………………………………………………………………………………………………………………………..1831
2 Technical data for brakes…………………………………………………………………………………………………………………………………………………1832
2.1 Brake master cylinder and brake servo…………………………………………………………………………………………………………………………………1832
2.2 Front brakes……………………………………………………………………………………………………………………………………………………….1832
2.3 Rear brakes (disc brakes)……………………………………………………………………………………………………………………………………………1833
3 Brake test………………………………………………………………………………………………………………………………………………………………1834
3.1 General……………………………………………………………………………………………………………………………………………………………1834
3.2 Test for vehicles with front-wheel drive………………………………………………………………………………………………………………………………1834
3.3 Test for vehicles with four-wheel drive……………………………………………………………………………………………………………………………….1834
3.3.1 On a regulated roller dynamometer with counter-rotating rollers for four-wheel drive vehicles………………………………………………………………………….1834
3.3.2 Without roller dynamometer for four-wheel drive vehicles…………………………………………………………………………………………………………..1835
3.4 Testing the electromechanical parking brake……………………………………………………………………………………………………………………………1835
3.4.1 Vehicles with front-wheel drive:………………………………………………………………………………………………………………………………..1835
3.4.2 Checking electromechanical parking brake, vehicles with four-wheel drive:……………………………………………………………………………………………1836
45 – Anti-lock brake system…………………………………………………………………………………………………………………………………………………….1837
1 General notes on anti-lock brake system…………………………………………………………………………………………………………………………………….1837
2 Notes for repair work on anti-lock brake system……………………………………………………………………………………………………………………………..1838
3 Connecting -VAS 5051- and selecting functions……………………………………………………………………………………………………………………………….1839
4 Electrical/electronic components and locations………………………………………………………………………………………………………………………………1841
4.1 ABS TRW (ABS/EDL/TCS/ESP)……………………………………………………………………………………………………………………………………………1841
5 Assembly overview – hydraulic unit…………………………………………………………………………………………………………………………………………1843
5.1 ABS TRW (ABS/EDL/TCS/ESP), left-hand drive vehicle……………………………………………………………………………………………………………………..1843
5.1.1 Connecting brake lines from brake master cylinder to hydraulic unit…………………………………………………………………………………………………1844
5.1.2 Removing control unit and hydraulic unit…………………………………………………………………………………………………………………………1845
5.1.3 Installing control unit and hydraulic unit……………………………………………………………………………………………………………………….1848
5.2 ABS TRW (ABS/EDL/TCS/ESP), right-hand drive vehicle…………………………………………………………………………………………………………………….1849
5.2.1 Connecting brake lines from brake master cylinder to ABS hydraulic unit -N55-………………………………………………………………………………………..1851
5.2.2 Removing ABS control unit -J104- and ABS hydraulic unit -N55-………………………………………………………………………………………………………1852
5.2.3 Installing ABS control unit -J104- and ABS hydraulic unit -N55-…………………………………………………………………………………………………….1855
6 Removing and installing parts of ABS system on front and rear axle…………………………………………………………………………………………………………….1857
6.1 Removing and installing parts of ABS system on front axle……………………………………………………………………………………………………………….1857
6.1.1 Removing and installing speed sensor on front axle………………………………………………………………………………………………………………..1857
6.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive)……………………………………………………………………………………1858
6.2.1 Removing and installing speed sensor on rear axle…………………………………………………………………………………………………………………1859
7 Removing and installing parts of ESP system…………………………………………………………………………………………………………………………………1860
7.1 Removing and installing ESP sensor unit -G419-…………………………………………………………………………………………………………………………1860
7.2 Removing and installing steering angle sender -G85-…………………………………………………………………………………………………………………….1861
46 – Brakes – mechanism………………………………………………………………………………………………………………………………………………………..1862
1 Repairing front brakes……………………………………………………………………………………………………………………………………………………1862
1.1 Assembly overview – front brakes FN 3…………………………………………………………………………………………………………………………………1862
1.2 Removing and installing brake pads/linings…………………………………………………………………………………………………………………………….1863
1.2.1 Removing……………………………………………………………………………………………………………………………………………………..1864
1.2.2 Installing……………………………………………………………………………………………………………………………………………………1865
1.3 Removing and installing brake caliper…………………………………………………………………………………………………………………………………1866
1.3.1 Removing……………………………………………………………………………………………………………………………………………………..1866
1.3.2 Installing……………………………………………………………………………………………………………………………………………………1867
1.4 Assembly overview- front brakes C60…………………………………………………………………………………………………………………………………..1868
1.5 Removing and installing brake pads/linings…………………………………………………………………………………………………………………………….1869
1.5.1 Removing……………………………………………………………………………………………………………………………………………………..1869
1.5.2 Installing……………………………………………………………………………………………………………………………………………………1871
1.6 Removing and installing brake caliper…………………………………………………………………………………………………………………………………1872
1.6.1 Removing……………………………………………………………………………………………………………………………………………………..1872
1.6.2 Installing……………………………………………………………………………………………………………………………………………………1873
2 Repairing rear brakes…………………………………………………………………………………………………………………………………………………….1874
2.1 Assembly overview – rear brake CII 41…………………………………………………………………………………………………………………………………1874
2.2 Removing and installing brake pads/linings…………………………………………………………………………………………………………………………….1875
2.2.1 Removing……………………………………………………………………………………………………………………………………………………..1876
2.2.2 Installing……………………………………………………………………………………………………………………………………………………1878
2.3 Removing and installing brake caliper…………………………………………………………………………………………………………………………………1878
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..1879
2.3.2 Installing……………………………………………………………………………………………………………………………………………………1880
3 Overview of electromechanical parking brake components……………………………………………………………………………………………………………………….1881
3.1 Removing and installing control unit for electromechanical parking brake -J540-……………………………………………………………………………………………1881
3.2 Removing and installing parking brake motor……………………………………………………………………………………………………………………………1882
4 Assembly overview – brake pedal……………………………………………………………………………………………………………………………………………1885
4.1 Assembly overview – brake pedal, left-hand drive……………………………………………………………………………………………………………………….1885
4.1.1 Separating brake pedal from brake servo………………………………………………………………………………………………………………………….1885
4.1.2 Clipping brake pedal to brake servo……………………………………………………………………………………………………………………………..1886
4.1.3 Removing brake pedal…………………………………………………………………………………………………………………………………………..1886
4.1.4 Installing brake pedal…………………………………………………………………………………………………………………………………………1887
4.2 Assembly overview – brake pedal, right-hand drive………………………………………………………………………………………………………………………1887
4.2.1 Separating brake pedal from brake servo………………………………………………………………………………………………………………………….1888
4.2.2 Clipping brake pedal to brake servo……………………………………………………………………………………………………………………………..1889
4.2.3 Removing and installing brake pedal……………………………………………………………………………………………………………………………..1889
4.2.4 Removing and installing mounting bracket…………………………………………………………………………………………………………………………1893
47 – Brakes – hydraulics……………………………………………………………………………………………………………………………………………………….1895
1 Repairing front brake calipers…………………………………………………………………………………………………………………………………………….1895
1.1 Assembly overview – brake caliper FN 3………………………………………………………………………………………………………………………………..1895
1.2 Removing and installing piston for brake caliper FN 3…………………………………………………………………………………………………………………..1895
1.2.1 Removing……………………………………………………………………………………………………………………………………………………..1896
1.2.2 Installing……………………………………………………………………………………………………………………………………………………1897
1.3 Assembly overview – brake caliper C 60………………………………………………………………………………………………………………………………..1898
1.4 Removing and installing piston for brake caliper C 60…………………………………………………………………………………………………………………..1899
1.4.1 Removing……………………………………………………………………………………………………………………………………………………..1900
1.4.2 Installing……………………………………………………………………………………………………………………………………………………1900
2 Repairing rear brake calipers……………………………………………………………………………………………………………………………………………..1902
2.1 Assembly overview – brake caliper CII 41………………………………………………………………………………………………………………………………1902
2.2 Removing and installing brake caliper piston…………………………………………………………………………………………………………………………..1903
2.2.1 Removing……………………………………………………………………………………………………………………………………………………..1903
2.2.2 Installing……………………………………………………………………………………………………………………………………………………1903
2.3 Pre-bleeding brake caliper…………………………………………………………………………………………………………………………………………..1905
3 Pressurised leak test…………………………………………………………………………………………………………………………………………………….1906
3.1 Test prerequisites:…………………………………………………………………………………………………………………………………………………1906
4 Bleeding brake system…………………………………………………………………………………………………………………………………………………….1907
4.1 Bleeding brake system with the brake filling and bleeding equipment -VAS 5234-…………………………………………………………………………………………….1907
4.1.1 Pre-bleeding:…………………………………………………………………………………………………………………………………………………1908
4.1.2 Bleeding (normal):…………………………………………………………………………………………………………………………………………….1908
4.1.3 Subsequent bleeding……………………………………………………………………………………………………………………………………………1908
4.2 Changing brake fluid………………………………………………………………………………………………………………………………………………..1909
5 Assembly overview – brake servo/brake master cylinder………………………………………………………………………………………………………………………..1910
5.1 Assembly overview – brake servo/brake master cylinder (left-hand drive vehicle)……………………………………………………………………………………………1910
5.2 Assembly overview – brake servo/brake master cylinder (right-hand drive vehicle)…………………………………………………………………………………………..1912
5.3 Vacuum pump for brake servo (vehicles with diesel engine)……………………………………………………………………………………………………………….1913
5.4 Vacuum pump for brake servo (vehicles with petrol engine)……………………………………………………………………………………………………………….1914
5.5 Checking brake servo vacuum system……………………………………………………………………………………………………………………………………1914
5.5.1 Connecting vacuum gauge for brake servo -VAS 6721-………………………………………………………………………………………………………………..1915
5.5.2 Checking vacuum generation……………………………………………………………………………………………………………………………………..1915
5.5.3 Checking for leaks…………………………………………………………………………………………………………………………………………….1916
5.6 Checking non-return valve:…………………………………………………………………………………………………………………………………………..1918
5.7 Removing and installing vacuum sender -G608-…………………………………………………………………………………………………………………………..1918
5.8 Removing and installing brake light switch -F-, left-hand drive………………………………………………………………………………………………………….1918
5.9 Removing and installing brake light switch -F-, right-hand drive…………………………………………………………………………………………………………1919
6 Removing and installing brake master cylinder……………………………………………………………………………………………………………………………….1921
6.1 Removing and installing brake master cylinder, left-hand drive…………………………………………………………………………………………………………..1921
6.1.1 Removing……………………………………………………………………………………………………………………………………………………..1921
6.1.2 Installing……………………………………………………………………………………………………………………………………………………1922
6.2 Removing and installing brake master cylinder, right-hand drive vehicle…………………………………………………………………………………………………..1922
6.2.1 Removing……………………………………………………………………………………………………………………………………………………..1924
6.2.2 Installing……………………………………………………………………………………………………………………………………………………1931
7 Removing and installing brake servo ……………………………………………………………………………………………………………………………………….1935
7.1 Removing and installing brake servo, left-hand drive……………………………………………………………………………………………………………………1935
7.1.1 Removing……………………………………………………………………………………………………………………………………………………..1935
7.1.2 Installing……………………………………………………………………………………………………………………………………………………1937
7.2 Removing and installing brake servo, right-hand drive vehicle……………………………………………………………………………………………………………1937
7.2.1 Removing……………………………………………………………………………………………………………………………………………………..1941
7.2.2 Installing……………………………………………………………………………………………………………………………………………………1951
8 Brake lines……………………………………………………………………………………………………………………………………………………………..1956
8.1 Separating point on underbody………………………………………………………………………………………………………………………………………..1956
8.2 Repairing brake lines……………………………………………………………………………………………………………………………………………….1956
8.2.1 Assembly overview – flanging tool……………………………………………………………………………………………………………………………….1958
8.2.2 Work instructions……………………………………………………………………………………………………………………………………………..1958
Sharan2011-Communication (1)……………………………………………………………………………………………………………………………………………………….1961
91 – Communication…………………………………………………………………………………………………………………………………………………………….1965
1 Communication systems…………………………………………………………………………………………………………………………………………………….1965
1.1 Fault finding in communication systems………………………………………………………………………………………………………………………………..1965
2 Radio and radio navigation systems in general……………………………………………………………………………………………………………………………….1966
2.1 Removing and installing radio and radio navigation systems………………………………………………………………………………………………………………1966
2.1.2 Removing:…………………………………………………………………………………………………………………………………………………….1966
2.1.3 Installing:…………………………………………………………………………………………………………………………………………………..1968
2.2 Adapting radio components……………………………………………………………………………………………………………………………………………1969
2.2.2 Adapting radio components………………………………………………………………………………………………………………………………………1969
2.3 Adapting navigation system components…………………………………………………………………………………………………………………………………1969
2.3.2 Adapting navigation system components……………………………………………………………………………………………………………………………1969
3 Radio system “RCD 210”……………………………………………………………………………………………………………………………………………………1971
3.1 General notes………………………………………………………………………………………………………………………………………………………1971
3.2 Features of “RCD 210” radio………………………………………………………………………………………………………………………………………….1971
3.3 Assembly overview of radio system “RCD 210”……………………………………………………………………………………………………………………………1972
3.4 Overview of “RCD 210” radio system……………………………………………………………………………………………………………………………………1973
3.5 Overview of connectors on radio “RCD 210”……………………………………………………………………………………………………………………………..1974
3.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..1975
3.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………1976
4 Radio system “RCD 310”……………………………………………………………………………………………………………………………………………………1979
4.1 General notes………………………………………………………………………………………………………………………………………………………1979
4.2 Features of radio “RCD 310”………………………………………………………………………………………………………………………………………….1979
4.3 Assembly overview of radio system “RCD 310”……………………………………………………………………………………………………………………………1980
4.4 Overview of “RCD 310” radio system……………………………………………………………………………………………………………………………………1981
4.5 Overview of connectors on radio “RCD 310”……………………………………………………………………………………………………………………………..1982
4.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..1984
4.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………1985
5 Radio system “RCD 510”……………………………………………………………………………………………………………………………………………………1987
5.1 General notes………………………………………………………………………………………………………………………………………………………1987
5.2 Features of radio “RCD 510”………………………………………………………………………………………………………………………………………….1987
5.3 Assembly overview of radio system “RCD 510”……………………………………………………………………………………………………………………………1988
5.4 Overview of “RCD 510” radio system……………………………………………………………………………………………………………………………………1990
5.5 Activating/deactivating transport lock for CD changer in “RCD 510”……………………………………………………………………………………………………….1990
5.6 Overview of connectors on radio “RCD 510”……………………………………………………………………………………………………………………………..1991
5.7 Anti-theft coding…………………………………………………………………………………………………………………………………………………..1995
5.7.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………1997
6 Radio navigation system “RNS 315”………………………………………………………………………………………………………………………………………….1999
6.1 General notes………………………………………………………………………………………………………………………………………………………1999
6.2 Features of radio navigation system “RNS 315”………………………………………………………………………………………………………………………….1999
6.3 Assembly overview of the radio navigation system “RNS 315”………………………………………………………………………………………………………………2000
6.4 System overview of the radio navigation system “RNS 315”………………………………………………………………………………………………………………..2002
6.5 Overview of connectors on radio navigation system “RNS 315”……………………………………………………………………………………………………………..2003
6.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2006
6.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2008
7 Radio navigation system “RNS 510”………………………………………………………………………………………………………………………………………….2010
7.1 General notes………………………………………………………………………………………………………………………………………………………2010
7.2 Features of radio navigation system “RNS 510”………………………………………………………………………………………………………………………….2010
7.3 Assembly overview of the radio navigation system “RNS 510”………………………………………………………………………………………………………………2011
7.4 System overview of the radio navigation system “RNS 510”………………………………………………………………………………………………………………..2013
7.5 Overview of connectors on radio navigation system “RNS 510”……………………………………………………………………………………………………………..2014
7.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2017
7.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2019
8 CD changer………………………………………………………………………………………………………………………………………………………………2021
8.1 Removing and installing CD changer……………………………………………………………………………………………………………………………………2021
8.1.2 Removing:…………………………………………………………………………………………………………………………………………………….2021
8.1.3 Installing:…………………………………………………………………………………………………………………………………………………..2022
9 Sound system amplifier……………………………………………………………………………………………………………………………………………………2023
9.1 General notes………………………………………………………………………………………………………………………………………………………2023
9.2 Removing and installing amplifier…………………………………………………………………………………………………………………………………….2023
9.2.1 Removing:…………………………………………………………………………………………………………………………………………………….2023
9.2.2 Installing:…………………………………………………………………………………………………………………………………………………..2024
10 Multimedia system control unit……………………………………………………………………………………………………………………………………………2025
10.1 General notes……………………………………………………………………………………………………………………………………………………..2025
10.2 Overview of “multimedia control unit” system………………………………………………………………………………………………………………………….2025
10.3 Removing and installing multimedia control unit……………………………………………………………………………………………………………………….2026
10.3.1 Removing:……………………………………………………………………………………………………………………………………………………2026
10.3.2 Installing:………………………………………………………………………………………………………………………………………………….2027
11 Connection for external audio sources……………………………………………………………………………………………………………………………………..2028
11.1 General notes……………………………………………………………………………………………………………………………………………………..2028
11.2 Removing and installing connection for external audio sources…………………………………………………………………………………………………………..2028
11.2.1 Required special tools, testers, measuring instruments and auxiliary items………………………………………………………………………………………….2028
11.2.2 Removing:……………………………………………………………………………………………………………………………………………………2029
11.2.3 Installing:………………………………………………………………………………………………………………………………………………….2029
11.3 Contact assignment on connection for external audio sources…………………………………………………………………………………………………………….2029
12 Loudspeaker systems……………………………………………………………………………………………………………………………………………………..2030
12.1 Assembly overview of loudspeaker system………………………………………………………………………………………………………………………………2030
12.2 Removing and installing front bass loudspeakers……………………………………………………………………………………………………………………….2030
12.2.1 Removing:……………………………………………………………………………………………………………………………………………………2030
12.2.2 Installing:………………………………………………………………………………………………………………………………………………….2031
12.3 Removing and installing rear bass loudspeakers………………………………………………………………………………………………………………………..2031
12.3.1 Removing:……………………………………………………………………………………………………………………………………………………2031
12.3.2 Installing:………………………………………………………………………………………………………………………………………………….2032
12.4 Removing and installing front treble loudspeakers……………………………………………………………………………………………………………………..2032
12.4.1 Removing:……………………………………………………………………………………………………………………………………………………2032
12.4.2 Installing:………………………………………………………………………………………………………………………………………………….2033
12.5 Removing and installing rear treble loudspeakers………………………………………………………………………………………………………………………2033
12.5.1 Removing:……………………………………………………………………………………………………………………………………………………2033
12.5.2 Installing:………………………………………………………………………………………………………………………………………………….2033
13 Telephone system/mobile phone preparation………………………………………………………………………………………………………………………………….2034
13.1 General notes on “universal preparation for mobile phone UTP”…………………………………………………………………………………………………………..2034
13.1.1 Preparation for mobile phone “UTP High with Bluetooth”……………………………………………………………………………………………………………2034
13.1.2 “UHV Premium” mobile phone preparation with Bluetooth and audiostreaming……………………………………………………………………………………………2034
13.2 Overview of the UHV High mobile phone preparation system……………………………………………………………………………………………………………….2034
13.3 Overview of the UHV Premium mobile phone preparation system…………………………………………………………………………………………………………….2036
13.4 Overview of UHV mobile phone preparation system in conjunction with the “RNS 315”…………………………………………………………………………………………2037
13.5 Removing and installing telephone transmitter and receiver unit…………………………………………………………………………………………………………2037
13.5.1 Removing:……………………………………………………………………………………………………………………………………………………2037
13.5.2 Installing:………………………………………………………………………………………………………………………………………………….2038
13.6 Removing and installing emergency assistance call button……………………………………………………………………………………………………………….2038
13.6.1 Removing:……………………………………………………………………………………………………………………………………………………2039
13.6.2 Installing:………………………………………………………………………………………………………………………………………………….2039
13.7 Removing and installing telephone system microphone……………………………………………………………………………………………………………………2039
13.7.1 Removing:……………………………………………………………………………………………………………………………………………………2039
13.7.2 Installing:………………………………………………………………………………………………………………………………………………….2040
14 Aerial systems………………………………………………………………………………………………………………………………………………………….2041
14.1 General notes……………………………………………………………………………………………………………………………………………………..2041
14.2 Overview of aerial system with “RCD 210” radio………………………………………………………………………………………………………………………..2041
14.3 Overview of aerial system with “RCD 310” radio………………………………………………………………………………………………………………………..2043
14.4 Overview of aerial system with “RCD 510” radio………………………………………………………………………………………………………………………..2044
14.5 Overview of aerial system with “RCD 315” radio………………………………………………………………………………………………………………………..2045
14.6 Overview of aerial system with “RCD 510” radio………………………………………………………………………………………………………………………..2046
14.7 Removing and installing aerial modules……………………………………………………………………………………………………………………………….2046
14.7.1 Removing:……………………………………………………………………………………………………………………………………………………2046
14.7.2 Installing:………………………………………………………………………………………………………………………………………………….2047
14.8 Removing and installing roof aerial………………………………………………………………………………………………………………………………….2047
14.8.1 Removing:……………………………………………………………………………………………………………………………………………………2048
14.8.2 Installing:………………………………………………………………………………………………………………………………………………….2048
14.9 Renewal of aerial wiring……………………………………………………………………………………………………………………………………………2048
15 Multifunction steering wheel……………………………………………………………………………………………………………………………………………..2049
15.1 Removing and installing steering wheel operating unit………………………………………………………………………………………………………………….2049
15.1.1 Removing:……………………………………………………………………………………………………………………………………………………2049
15.1.2 Installing:………………………………………………………………………………………………………………………………………………….2049
15.2 Adapting multifunction steering wheel components………………………………………………………………………………………………………………………2050
16 Mobile online services…………………………………………………………………………………………………………………………………………………..2051
16.1 General notes……………………………………………………………………………………………………………………………………………………..2051
16.2 Fitting locations overview – mobile online services……………………………………………………………………………………………………………………2051
16.3 Removing and installing emergency call module control unit and communication unit -J949-…………………………………………………………………………………..2052
17 Notes on operating mobile telephones and two-way radios……………………………………………………………………………………………………………………..2054
17.1 General notes……………………………………………………………………………………………………………………………………………………..2054
17.1.1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial………………………………………………………….2054
17.1.2 Installation and operation of two-way radios with a transmitting power above 10 watts is only permissible under the following conditions:………………………………….2054
17.2 Notes on performing repair work……………………………………………………………………………………………………………………………………..2055
17.2.1 Transmitting power and possible fitting locations………………………………………………………………………………………………………………..2055
17.2.2 Voltage supply……………………………………………………………………………………………………………………………………………….2055
17.2.3 Aerial and aerial wiring………………………………………………………………………………………………………………………………………2056
17.2.4 Further additional installations……………………………………………………………………………………………………………………………….2056
17.3 Overview of battery, transmitter and receiver unit, fuse and wiring harness………………………………………………………………………………………………2056
17.4 Transmitting power and aerial fitting locations……………………………………………………………………………………………………………………….2057
17.4.1 Sharan 2011 ►………………………………………………………………………………………………………………………………………………..2057
18 Suppression measures…………………………………………………………………………………………………………………………………………………….2059
18.1 Implementation of suppression measures……………………………………………………………………………………………………………………………….2059
Sharan2011-Communication…………………………………………………………………………………………………………………………………………………………..2060
91 – Communication…………………………………………………………………………………………………………………………………………………………….2064
1 Communication systems…………………………………………………………………………………………………………………………………………………….2064
1.1 Fault finding in communication systems………………………………………………………………………………………………………………………………..2064
2 Radio and radio navigation systems in general……………………………………………………………………………………………………………………………….2065
2.1 Removing and installing radio and radio navigation systems………………………………………………………………………………………………………………2065
2.1.2 Removing:…………………………………………………………………………………………………………………………………………………….2065
2.1.3 Installing:…………………………………………………………………………………………………………………………………………………..2067
2.2 Adapting radio components……………………………………………………………………………………………………………………………………………2068
2.2.2 Adapting radio components………………………………………………………………………………………………………………………………………2068
2.3 Adapting navigation system components…………………………………………………………………………………………………………………………………2068
2.3.2 Adapting navigation system components……………………………………………………………………………………………………………………………2068
3 Radio system “RCD 210”……………………………………………………………………………………………………………………………………………………2070
3.1 General notes………………………………………………………………………………………………………………………………………………………2070
3.2 Features of “RCD 210” radio………………………………………………………………………………………………………………………………………….2070
3.3 Assembly overview of radio system “RCD 210”……………………………………………………………………………………………………………………………2071
3.4 Overview of “RCD 210” radio system……………………………………………………………………………………………………………………………………2072
3.5 Overview of connectors on radio “RCD 210”……………………………………………………………………………………………………………………………..2073
3.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2074
3.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2075
4 Radio system “RCD 310”……………………………………………………………………………………………………………………………………………………2078
4.1 General notes………………………………………………………………………………………………………………………………………………………2078
4.2 Features of radio “RCD 310”………………………………………………………………………………………………………………………………………….2078
4.3 Assembly overview of radio system “RCD 310”……………………………………………………………………………………………………………………………2079
4.4 Overview of “RCD 310” radio system……………………………………………………………………………………………………………………………………2080
4.5 Overview of connectors on radio “RCD 310”……………………………………………………………………………………………………………………………..2081
4.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2083
4.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2084
5 Radio system “RCD 510”……………………………………………………………………………………………………………………………………………………2086
5.1 General notes………………………………………………………………………………………………………………………………………………………2086
5.2 Features of radio “RCD 510”………………………………………………………………………………………………………………………………………….2086
5.3 Assembly overview of radio system “RCD 510”……………………………………………………………………………………………………………………………2087
5.4 Overview of “RCD 510” radio system……………………………………………………………………………………………………………………………………2089
5.5 Activating/deactivating transport lock for CD changer in “RCD 510”……………………………………………………………………………………………………….2089
5.6 Overview of connectors on radio “RCD 510”……………………………………………………………………………………………………………………………..2090
5.7 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2094
5.7.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2096
6 Radio navigation system “RNS 315”………………………………………………………………………………………………………………………………………….2098
6.1 General notes………………………………………………………………………………………………………………………………………………………2098
6.2 Features of radio navigation system “RNS 315”………………………………………………………………………………………………………………………….2098
6.3 Assembly overview of the radio navigation system “RNS 315”………………………………………………………………………………………………………………2099
6.4 System overview of the radio navigation system “RNS 315”………………………………………………………………………………………………………………..2101
6.5 Overview of connectors on radio navigation system “RNS 315”……………………………………………………………………………………………………………..2102
6.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2105
6.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2107
7 Radio navigation system “RNS 510”………………………………………………………………………………………………………………………………………….2109
7.1 General notes………………………………………………………………………………………………………………………………………………………2109
7.2 Features of radio navigation system “RNS 510”………………………………………………………………………………………………………………………….2109
7.3 Assembly overview of the radio navigation system “RNS 510”………………………………………………………………………………………………………………2110
7.4 System overview of the radio navigation system “RNS 510”………………………………………………………………………………………………………………..2112
7.5 Overview of connectors on radio navigation system “RNS 510”……………………………………………………………………………………………………………..2113
7.6 Anti-theft coding…………………………………………………………………………………………………………………………………………………..2116
7.6.1 Determining anti-theft code by means of VAS tester and deactivating anti-theft coding…………………………………………………………………………………2118
8 CD changer………………………………………………………………………………………………………………………………………………………………2120
8.1 Removing and installing CD changer……………………………………………………………………………………………………………………………………2120
8.1.2 Removing:…………………………………………………………………………………………………………………………………………………….2120
8.1.3 Installing:…………………………………………………………………………………………………………………………………………………..2121
9 Sound system amplifier……………………………………………………………………………………………………………………………………………………2122
9.1 General notes………………………………………………………………………………………………………………………………………………………2122
9.2 Removing and installing amplifier…………………………………………………………………………………………………………………………………….2122
9.2.1 Removing:…………………………………………………………………………………………………………………………………………………….2122
9.2.2 Installing:…………………………………………………………………………………………………………………………………………………..2123
10 Multimedia system control unit……………………………………………………………………………………………………………………………………………2124
10.1 General notes……………………………………………………………………………………………………………………………………………………..2124
10.2 Overview of “multimedia control unit” system………………………………………………………………………………………………………………………….2124
10.3 Removing and installing multimedia control unit……………………………………………………………………………………………………………………….2125
10.3.1 Removing:……………………………………………………………………………………………………………………………………………………2125
10.3.2 Installing:………………………………………………………………………………………………………………………………………………….2126
11 Connection for external audio sources……………………………………………………………………………………………………………………………………..2127
11.1 General notes……………………………………………………………………………………………………………………………………………………..2127
11.2 Removing and installing connection for external audio sources…………………………………………………………………………………………………………..2127
11.2.1 Required special tools, testers, measuring instruments and auxiliary items………………………………………………………………………………………….2127
11.2.2 Removing:……………………………………………………………………………………………………………………………………………………2128
11.2.3 Installing:………………………………………………………………………………………………………………………………………………….2128
11.3 Contact assignment on connection for external audio sources…………………………………………………………………………………………………………….2128
12 Loudspeaker systems……………………………………………………………………………………………………………………………………………………..2129
12.1 Assembly overview of loudspeaker system………………………………………………………………………………………………………………………………2129
12.2 Removing and installing front bass loudspeakers……………………………………………………………………………………………………………………….2129
12.2.1 Removing:……………………………………………………………………………………………………………………………………………………2129
12.2.2 Installing:………………………………………………………………………………………………………………………………………………….2130
12.3 Removing and installing rear bass loudspeakers………………………………………………………………………………………………………………………..2130
12.3.1 Removing:……………………………………………………………………………………………………………………………………………………2130
12.3.2 Installing:………………………………………………………………………………………………………………………………………………….2131
12.4 Removing and installing front treble loudspeakers……………………………………………………………………………………………………………………..2131
12.4.1 Removing:……………………………………………………………………………………………………………………………………………………2131
12.4.2 Installing:………………………………………………………………………………………………………………………………………………….2132
12.5 Removing and installing rear treble loudspeakers………………………………………………………………………………………………………………………2132
12.5.1 Removing:……………………………………………………………………………………………………………………………………………………2132
12.5.2 Installing:………………………………………………………………………………………………………………………………………………….2132
13 Telephone system/mobile phone preparation………………………………………………………………………………………………………………………………….2133
13.1 General notes on “universal preparation for mobile phone UTP”…………………………………………………………………………………………………………..2133
13.1.1 Preparation for mobile phone “UTP High with Bluetooth”……………………………………………………………………………………………………………2133
13.1.2 “UHV Premium” mobile phone preparation with Bluetooth and audiostreaming……………………………………………………………………………………………2133
13.2 Overview of the UHV High mobile phone preparation system……………………………………………………………………………………………………………….2133
13.3 Overview of the UHV Premium mobile phone preparation system…………………………………………………………………………………………………………….2135
13.4 Overview of UHV mobile phone preparation system in conjunction with the “RNS 315”…………………………………………………………………………………………2136
13.5 Removing and installing telephone transmitter and receiver unit…………………………………………………………………………………………………………2136
13.5.1 Removing:……………………………………………………………………………………………………………………………………………………2136
13.5.2 Installing:………………………………………………………………………………………………………………………………………………….2137
13.6 Removing and installing emergency assistance call button……………………………………………………………………………………………………………….2137
13.6.1 Removing:……………………………………………………………………………………………………………………………………………………2138
13.6.2 Installing:………………………………………………………………………………………………………………………………………………….2138
13.7 Removing and installing telephone system microphone……………………………………………………………………………………………………………………2138
13.7.1 Removing:……………………………………………………………………………………………………………………………………………………2138
13.7.2 Installing:………………………………………………………………………………………………………………………………………………….2139
14 Aerial systems………………………………………………………………………………………………………………………………………………………….2140
14.1 General notes……………………………………………………………………………………………………………………………………………………..2140
14.2 Overview of aerial system with “RCD 210” radio………………………………………………………………………………………………………………………..2140
14.3 Overview of aerial system with “RCD 310” radio………………………………………………………………………………………………………………………..2142
14.4 Overview of aerial system with “RCD 510” radio………………………………………………………………………………………………………………………..2143
14.5 Overview of aerial system with “RCD 315” radio………………………………………………………………………………………………………………………..2144
14.6 Overview of aerial system with “RCD 510” radio………………………………………………………………………………………………………………………..2145
14.7 Removing and installing aerial modules……………………………………………………………………………………………………………………………….2145
14.7.1 Removing:……………………………………………………………………………………………………………………………………………………2145
14.7.2 Installing:………………………………………………………………………………………………………………………………………………….2146
14.8 Removing and installing roof aerial………………………………………………………………………………………………………………………………….2146
14.8.1 Removing:……………………………………………………………………………………………………………………………………………………2147
14.8.2 Installing:………………………………………………………………………………………………………………………………………………….2147
14.9 Renewal of aerial wiring……………………………………………………………………………………………………………………………………………2147
15 Multifunction steering wheel……………………………………………………………………………………………………………………………………………..2148
15.1 Removing and installing steering wheel operating unit………………………………………………………………………………………………………………….2148
15.1.1 Removing:……………………………………………………………………………………………………………………………………………………2148
15.1.2 Installing:………………………………………………………………………………………………………………………………………………….2148
15.2 Adapting multifunction steering wheel components………………………………………………………………………………………………………………………2149
16 Mobile online services…………………………………………………………………………………………………………………………………………………..2150
16.1 General notes……………………………………………………………………………………………………………………………………………………..2150
16.2 Fitting locations overview – mobile online services……………………………………………………………………………………………………………………2150
16.3 Removing and installing emergency call module control unit and communication unit -J949-…………………………………………………………………………………..2151
17 Notes on operating mobile telephones and two-way radios……………………………………………………………………………………………………………………..2153
17.1 General notes……………………………………………………………………………………………………………………………………………………..2153
17.1.1 Mobile telephones or portable two-way radios may not be used in the vehicle without a separate external aerial………………………………………………………….2153
17.1.2 Installation and operation of two-way radios with a transmitting power above 10 watts is only permissible under the following conditions:………………………………….2153
17.2 Notes on performing repair work……………………………………………………………………………………………………………………………………..2154
17.2.1 Transmitting power and possible fitting locations………………………………………………………………………………………………………………..2154
17.2.2 Voltage supply……………………………………………………………………………………………………………………………………………….2154
17.2.3 Aerial and aerial wiring………………………………………………………………………………………………………………………………………2155
17.2.4 Further additional installations……………………………………………………………………………………………………………………………….2155
17.3 Overview of battery, transmitter and receiver unit, fuse and wiring harness………………………………………………………………………………………………2155
17.4 Transmitting power and aerial fitting locations……………………………………………………………………………………………………………………….2156
17.4.1 Sharan 2011 ►………………………………………………………………………………………………………………………………………………..2156
18 Suppression measures…………………………………………………………………………………………………………………………………………………….2158
18.1 Implementation of suppression measures……………………………………………………………………………………………………………………………….2158
Sharan2011-Electrical_system……………………………………………………………………………………………………………………………………………………….2159
27 – Starter, current supply, CCS……………………………………………………………………………………………………………………………………………….2167
1 Battery -A-……………………………………………………………………………………………………………………………………………………………..2167
1.1 Fundamentals for batteries…………………………………………………………………………………………………………………………………………..2167
1.2 Types of battery……………………………………………………………………………………………………………………………………………………2167
1.3 Warning notices and safety regulations………………………………………………………………………………………………………………………………..2167
1.4 Battery terminal connection………………………………………………………………………………………………………………………………………….2167
2 Checking battery…………………………………………………………………………………………………………………………………………………………2168
3 Charging battery…………………………………………………………………………………………………………………………………………………………2169
4 Disconnecting and reconnecting battery……………………………………………………………………………………………………………………………………..2170
4.1 Assembly overview…………………………………………………………………………………………………………………………………………………..2170
4.2 Disconnecting battery……………………………………………………………………………………………………………………………………………….2171
4.3 Reconnecting battery………………………………………………………………………………………………………………………………………………..2172
5 Removing and installing battery……………………………………………………………………………………………………………………………………………2174
5.1 Assembly overview…………………………………………………………………………………………………………………………………………………..2174
5.2 Removing and installing battery………………………………………………………………………………………………………………………………………2175
5.3 Battery parameterisation…………………………………………………………………………………………………………………………………………….2176
6 Starter, vehicles with manual gearbox………………………………………………………………………………………………………………………………………2177
6.1 Checking starter -B-………………………………………………………………………………………………………………………………………………..2177
6.2 Starter, vehicles with 1.4 l, 110 kW TSI engine and manual gearbox MQ200-6F……………………………………………………………………………………………….2177
6.2.1 Assembly overview……………………………………………………………………………………………………………………………………………..2177
6.2.2 Removing and installing starter, 1.4 l, 90 kW TSI engine, manual gearbox MQ 200-6F……………………………………………………………………………………2178
6.3 Starter, vehicles with 2.0 l, 103 kW TDI engine and manual gearbox MQ350-6F……………………………………………………………………………………………….2180
6.3.1 Assembly overview……………………………………………………………………………………………………………………………………………..2180
6.3.2 Removing and installing starter, 2.0 l, 103 kW TDI engine, manual gearbox MQ350-6F……………………………………………………………………………………2181
7 Starter, vehicles with dual clutch gearbox (DSG)…………………………………………………………………………………………………………………………….2185
7.1 Starter, vehicles with 2.0 l 103 kW TDI engine and dual clutch gearbox DQ250-6F……………………………………………………………………………………………2185
7.1.1 Assembly overview……………………………………………………………………………………………………………………………………………..2185
7.1.2 Removing and installing starter, 2.0 l, 103 kW TDI engine, dual clutch gearbox (DSG) DQ250-6F………………………………………………………………………….2186
8 Alternator………………………………………………………………………………………………………………………………………………………………2189
8.1 Securing B+ (battery positive) wire to alternator………………………………………………………………………………………………………………………2189
8.2 Checking poly V-belt………………………………………………………………………………………………………………………………………………..2189
8.3 Checking alternator -C-……………………………………………………………………………………………………………………………………………..2190
8.4 Alternator, 1.4 l, 110 kW TSI engine………………………………………………………………………………………………………………………………….2190
8.4.1 Assembly overview……………………………………………………………………………………………………………………………………………..2190
8.4.2 Removing and installing alternator, 1.4 l, 110 kW TSI engine……………………………………………………………………………………………………….2191
8.5 Alternator, 2.0 l, 103 kW TDI engine………………………………………………………………………………………………………………………………….2194
8.5.1 Assembly overview……………………………………………………………………………………………………………………………………………..2194
8.5.2 Removing and installing alternator, 2.0 l, 103 kW TDI engine……………………………………………………………………………………………………….2195
8.6 Removing and installing poly V-belt pulley on alternator………………………………………………………………………………………………………………..2199
8.6.1 Removing and installing poly V-belt pulley without freewheel……………………………………………………………………………………………………….2199
8.6.2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch……………………………………………………………………………………….2200
8.6.3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo……………………………………………………………………………………….2202
8.7 Voltage regulator for alternator……………………………………………………………………………………………………………………………………..2204
8.7.1 Removing and installing voltage regulator, manufacturer: Bosch……………………………………………………………………………………………………..2204
8.7.2 Removing and installing voltage regulator, manufacturer: Valeo……………………………………………………………………………………………………..2204
9 Cruise control system (CCS)……………………………………………………………………………………………………………………………………………….2207
10 Start/stop system……………………………………………………………………………………………………………………………………………………….2208
10.1 General description………………………………………………………………………………………………………………………………………………..2208
10.2 Start/stop operation switch -E693-…………………………………………………………………………………………………………………………………..2209
10.2.1 Removing and installing start/stop operation switch -E693-………………………………………………………………………………………………………..2209
10.3 Voltage stabiliser -J532-…………………………………………………………………………………………………………………………………………..2209
10.3.1 Removing and installing voltage stabiliser -J532-, ► week 22/11……………………………………………………………………………………………………2210
10.3.2 Removing and installing voltage stabiliser -J532-, week 23/11 ►……………………………………………………………………………………………………2210
90 – Gauges, instruments……………………………………………………………………………………………………………………………………………………….2211
1 Dash panel insert………………………………………………………………………………………………………………………………………………………..2211
1.1 General description…………………………………………………………………………………………………………………………………………………2211
1.2 Renewing dash panel insert…………………………………………………………………………………………………………………………………………..2212
1.3 Removing and installing dash panel insert……………………………………………………………………………………………………………………………..2212
1.4 Description of back of dash panel insert………………………………………………………………………………………………………………………………2213
1.5 Pin assignment of connectors on dash panel insert………………………………………………………………………………………………………………………2213
2 Service interval display………………………………………………………………………………………………………………………………………………….2214
2.1 Resetting service interval display……………………………………………………………………………………………………………………………………2214
92 – Windscreen wash/wipe system………………………………………………………………………………………………………………………………………………..2215
1 Windscreen wiper system…………………………………………………………………………………………………………………………………………………..2215
1.1 General description…………………………………………………………………………………………………………………………………………………2215
1.2 Deactivating APP function of wiper motor………………………………………………………………………………………………………………………………2215
1.3 Assembly overview – windscreen wiper system……………………………………………………………………………………………………………………………2216
1.4 Removing and installing windscreen wiper system………………………………………………………………………………………………………………………..2217
1.4.1 Removing windscreen wiper system………………………………………………………………………………………………………………………………..2218
1.4.3 Removing plenum chamber cover…………………………………………………………………………………………………………………………………..2219
1.4.4 Removing wiper frame with linkage and wiper motor…………………………………………………………………………………………………………………2219
1.4.7 Installing windscreen wiper system………………………………………………………………………………………………………………………………2221
1.5 Removing and installing wiper arms……………………………………………………………………………………………………………………………………2221
1.6 Adjusting wiper blade park position…………………………………………………………………………………………………………………………………..2222
1.7 Removing and installing joint-free wipers……………………………………………………………………………………………………………………………..2223
1.8 Rain and light sensor -G397-…………………………………………………………………………………………………………………………………………2224
1.8.1 Removing and installing rain and light sensor -G397-………………………………………………………………………………………………………………2224
1.8.2 Coding rain and light sensor -G397-……………………………………………………………………………………………………………………………..2227
2 Windscreen washer system………………………………………………………………………………………………………………………………………………….2228
2.1 Assembly overview, windscreen washer system……………………………………………………………………………………………………………………………2228
2.2 Removing and installing washer fluid reservoir…………………………………………………………………………………………………………………………2229
2.2.1 Removing and installing connecting pipe with filler neck on windscreen and headlight washer fluid reservoir……………………………………………………………..2229
2.2.2 Removing and installing reservoir for windscreen and headlight washer system (vehicles without headlight washer system)…………………………………………………..2229
2.2.3 Removing and installing reservoir for windscreen and headlight washer system (vehicles with headlight washer system)……………………………………………………..2231
2.3 Removing and installing windscreen and rear window washer pump -V59-……………………………………………………………………………………………………..2233
2.4 Removing and installing windscreen washer fluid level sender -G33-……………………………………………………………………………………………………….2234
2.5 Removing and installing windscreen washer system spray jets……………………………………………………………………………………………………………..2234
2.6 Adjusting windscreen washer system spray jets………………………………………………………………………………………………………………………….2235
3 Rear window wiper system………………………………………………………………………………………………………………………………………………….2236
3.1 Assembly overview – rear window wiper system…………………………………………………………………………………………………………………………..2236
3.2 Removing and installing wiper arm…………………………………………………………………………………………………………………………………….2237
3.3 Removing and installing rear window wiper motor -V12-…………………………………………………………………………………………………………………..2237
3.4 Adjusting rear window wiper park position……………………………………………………………………………………………………………………………..2238
3.5 Removing and installing joint-free wiper………………………………………………………………………………………………………………………………2239
4 Rear window washer system…………………………………………………………………………………………………………………………………………………2240
4.1 Assembly overview – rear window washer system………………………………………………………………………………………………………………………….2240
4.2 Renewing and setting spray jet……………………………………………………………………………………………………………………………………….2241
4.2.1 Renewing spray jet…………………………………………………………………………………………………………………………………………….2241
4.2.2 Adjusting spray jet……………………………………………………………………………………………………………………………………………2241
5 Headlight washer system…………………………………………………………………………………………………………………………………………………..2242
5.1 General description…………………………………………………………………………………………………………………………………………………2242
5.2 Assembly overview – headlight washer system……………………………………………………………………………………………………………………………2242
5.3 Removing and installing headlight washer system pump -V11-………………………………………………………………………………………………………………2243
5.4 Removing and installing spray jet pop-up cylinders……………………………………………………………………………………………………………………..2244
5.5 Removing and installing spray jet assembly…………………………………………………………………………………………………………………………….2245
5.6 Adjusting headlight washer system spray jets…………………………………………………………………………………………………………………………..2246
5.7 Bleeding headlight washer system……………………………………………………………………………………………………………………………………..2246
6 Washer fluid line hose couplings…………………………………………………………………………………………………………………………………………..2247
7 Hose repair……………………………………………………………………………………………………………………………………………………………..2248
94 – Lights, bulbs, switches – exterior………………………………………………………………………………………………………………………………………….2249
1 Operation and safety notes for gas discharge bulbs…………………………………………………………………………………………………………………………..2249
2 Headlights with gas discharge bulbs and cornering lights……………………………………………………………………………………………………………………..2252
2.1 General description…………………………………………………………………………………………………………………………………………………2252
2.2 Assembly overview – headlights with gas discharge bulbs and cornering lights………………………………………………………………………………………………2253
2.3 Removing and installing headlight…………………………………………………………………………………………………………………………………….2254
2.4 Adjusting headlight installation position……………………………………………………………………………………………………………………………..2254
2.5 Renewing gas discharge bulbs and cornering light bulbs in headlights……………………………………………………………………………………………………..2255
2.5.1 Renewing gas discharge bulb…………………………………………………………………………………………………………………………………….2255
2.5.2 Renewing static cornering lights -M51-/-M52-……………………………………………………………………………………………………………………..2257
2.5.3 Renewing side light bulb……………………………………………………………………………………………………………………………………….2257
2.5.4 Renewing turn signal bulb………………………………………………………………………………………………………………………………………2257
2.6 Headlight range control motor………………………………………………………………………………………………………………………………………..2258
2.6.1 Removing and installing headlight range control motor……………………………………………………………………………………………………………..2259
2.7 Headlight holder……………………………………………………………………………………………………………………………………………………2260
2.7.1 Removing and installing headlight holder…………………………………………………………………………………………………………………………2260
2.8 Dynamic cornering light control motor…………………………………………………………………………………………………………………………………2261
2.9 Swivel module position sensor………………………………………………………………………………………………………………………………………..2261
2.10 Power output module for headlight……………………………………………………………………………………………………………………………………2261
2.10.1 Removing and installing power output module for headlight…………………………………………………………………………………………………………2261
2.11 Gas discharge bulb control unit……………………………………………………………………………………………………………………………………..2262
2.11.1 Removing and installing gas discharge bulb control unit…………………………………………………………………………………………………………..2262
2.12 Cornering light and headlight range control unit -J745-………………………………………………………………………………………………………………..2263
2.12.1 Removing and installing cornering light and headlight range control unit -J745-……………………………………………………………………………………..2263
2.12.2 Coding cornering light and headlight range control unit -J745-…………………………………………………………………………………………………….2264
2.13 Vehicle level sender……………………………………………………………………………………………………………………………………………….2264
2.14 Repairing headlight retaining tabs…………………………………………………………………………………………………………………………………..2264
2.15 Converting headlights for use when driving on the left or right…………………………………………………………………………………………………………2264
2.16 Adjusting headlights……………………………………………………………………………………………………………………………………………….2265
3 Headlight with halogen bulbs………………………………………………………………………………………………………………………………………………2266
3.1 General description…………………………………………………………………………………………………………………………………………………2266
3.2 Assembly overview – headlights with halogen bulbs………………………………………………………………………………………………………………………2266
3.3 Removing and installing headlights with halogen bulbs…………………………………………………………………………………………………………………..2268
3.4 Adjusting headlight installation position……………………………………………………………………………………………………………………………..2269
3.5 Renewing headlight bulbs…………………………………………………………………………………………………………………………………………….2271
3.5.1 Renewing headlight dipped beam bulb……………………………………………………………………………………………………………………………..2271
3.5.2 Renewing headlight main beam bulb……………………………………………………………………………………………………………………………….2272
3.5.3 Renewing side light bulb……………………………………………………………………………………………………………………………………….2274
3.5.4 Renewing front turn signal bulb…………………………………………………………………………………………………………………………………2275
3.5.5 Renewing day driving light bulb…………………………………………………………………………………………………………………………………2276
3.6 Headlight range control motor………………………………………………………………………………………………………………………………………..2278
3.6.1 Removing and installing headlight range control motor……………………………………………………………………………………………………………..2278
3.7 Repairing headlight retaining tabs……………………………………………………………………………………………………………………………………2280
3.7.1 Repairing upper retaining tab…………………………………………………………………………………………………………………………………..2280
3.7.2 Repairing side retaining tab……………………………………………………………………………………………………………………………………2281
3.7.3 Repairing rear retaining tab……………………………………………………………………………………………………………………………………2281
3.8 Converting headlights for use when driving on the left or right………………………………………………………………………………………………………….2282
3.8.1 Converting headlights designed for driving on the right to driving on the left……………………………………………………………………………………….2283
3.8.2 Converting headlights designed for driving on the left to driving on the right……………………………………………………………………………………….2284
3.9 Adjusting headlights………………………………………………………………………………………………………………………………………………..2285
4 Fog lights………………………………………………………………………………………………………………………………………………………………2286
4.1 Assembly overview – fog lights……………………………………………………………………………………………………………………………………….2286
4.2 Removing and installing fog light…………………………………………………………………………………………………………………………………….2286
4.3 Removing and installing fog light / static cornering light bulb………………………………………………………………………………………………………….2288
4.4 Adjusting fog lights………………………………………………………………………………………………………………………………………………..2288
5 Turn signal repeater and entry light in exterior mirror………………………………………………………………………………………………………………………2289
5.1 General description…………………………………………………………………………………………………………………………………………………2289
5.2 Turn signal repeater bulb……………………………………………………………………………………………………………………………………………2289
5.2.1 Removing and installing turn signal repeater bulb…………………………………………………………………………………………………………………2289
5.3 Entry light in exterior mirror……………………………………………………………………………………………………………………………………….2290
5.3.1 Removing and installing drive side entry light in exterior mirror -W52-……………………………………………………………………………………………..2290
6 Tail lights (tail light cluster)…………………………………………………………………………………………………………………………………………..2292
6.1 Assembly overview – tail light (tail light cluster) in side panel………………………………………………………………………………………………………..2292
6.2 Removing and installing tail light (tail light cluster) in side panel…………………………………………………………………………………………………….2293
6.3 Removing and installing tail light (tail light cluster) bulb carrier in side panel…………………………………………………………………………………………2294
6.4 Renewing brake and tail light and turn signal bulbs in tail light (tail light cluster) in side panel…………………………………………………………………………2295
6.5 Assembly overview – tail light (tail light cluster) in rear lid………………………………………………………………………………………………………….2295
6.6 Removing and installing tail light (tail light cluster) in rear lid………………………………………………………………………………………………………2296
6.7 Removing and installing tail light (tail light cluster) bulb carrier in rear lid…………………………………………………………………………………………..2297
6.8 Renewing brake and tail light (tail light cluster) bulbs in rear lid……………………………………………………………………………………………………..2298
7 Number plate light……………………………………………………………………………………………………………………………………………………….2299
7.1 Clipped Number plate light -X-……………………………………………………………………………………………………………………………………….2299
7.1.1 Removing and installing clipped number plate light………………………………………………………………………………………………………………..2299
7.1.2 Removing and installing clipped number plate light bulb……………………………………………………………………………………………………………2299
8 Additional brake lights…………………………………………………………………………………………………………………………………………………..2301
8.1 Additional brake light bulb -M25-…………………………………………………………………………………………………………………………………….2301
8.1.1 Removing and installing additional brake light bulb -M25-………………………………………………………………………………………………………….2301
8.1.2 Checking additional brake light bulb -M25-……………………………………………………………………………………………………………………….2303
9 Steering column switch……………………………………………………………………………………………………………………………………………………2304
9.1 General description…………………………………………………………………………………………………………………………………………………2304
9.2 Assembly overview – steering column switch…………………………………………………………………………………………………………………………….2304
9.3 Removal and installation sequence of components of steering column switch…………………………………………………………………………………………………2306
9.4 Steering column electronics control unit -J527-………………………………………………………………………………………………………………………..2306
9.4.1 Removing and installing steering column electronics control unit -J527- (manufacturer: Valeo)………………………………………………………………………….2307
9.4.2 Removing and installing steering column electronics control unit -J527- (manufacturer: Kostal)…………………………………………………………………………2308
9.4.3 Coding steering column electronics control unit -J527-…………………………………………………………………………………………………………….2309
9.5 Steering column combination switch -E595-……………………………………………………………………………………………………………………………..2309
9.5.1 Removing and installing steering column combination switch -E595- (manufacturer: Valeo)……………………………………………………………………………….2310
9.5.2 Removing and installing steering column combination switch -E595- (manufacturer: Kostal)………………………………………………………………………………2310
9.6 Steering column switch base………………………………………………………………………………………………………………………………………….2311
9.6.1 Removing and installing steering column switch base (manufacturer: Valeo)……………………………………………………………………………………………2311
9.6.2 Removing and installing steering column switch base (manufacturer: Kostal)…………………………………………………………………………………………..2313
10 Steering column switch, vehicles with KESSY………………………………………………………………………………………………………………………………..2316
10.1 General description………………………………………………………………………………………………………………………………………………..2316
10.2 Assembly overview – steering column switch……………………………………………………………………………………………………………………………2316
10.3 Removal and installation sequence of components of steering column switch………………………………………………………………………………………………..2318
10.4 Steering column electronics control unit -J527-……………………………………………………………………………………………………………………….2318
10.4.1 Removing and installing steering column electronics control unit -J527- (manufacturer: Valeo)…………………………………………………………………………2319
10.4.2 Removing and installing steering column electronics control unit -J527- (manufacturer: Kostal)………………………………………………………………………..2320
10.4.3 Coding steering column electronics control unit -J527-……………………………………………………………………………………………………………2321
10.5 Steering column combination switch -E595-…………………………………………………………………………………………………………………………….2321
10.5.1 Removing and installing steering column combination switch -E595- (manufacturer: Valeo)………………………………………………………………………………2322
10.5.2 Removing and installing steering column combination switch -E595- (manufacturer: Kostal)……………………………………………………………………………..2322
10.6 Steering column switch base…………………………………………………………………………………………………………………………………………2323
10.6.1 Removing and installing steering column switch base (manufacturer: Valeo)…………………………………………………………………………………………..2323
10.6.2 Removing and installing steering column switch base (manufacturer: Kostal)………………………………………………………………………………………….2325
10.7 Electronic steering column lock control unit -J764-……………………………………………………………………………………………………………………2327
10.7.1 Removing and installing electronic steering column lock control unit -J764-…………………………………………………………………………………………2328
10.7.2 Coding electronic steering column lock control unit -J764-………………………………………………………………………………………………………..2328
11 Ignition/starter switch and lock cylinder………………………………………………………………………………………………………………………………….2329
11.1 Removing and installing steering lock housing…………………………………………………………………………………………………………………………2329
11.2 Removing and installing lock cylinder………………………………………………………………………………………………………………………………..2329
11.3 Removing and installing ignition/starter switch……………………………………………………………………………………………………………………….2331
11.3.1 Checking ignition/starter switch……………………………………………………………………………………………………………………………….2332
11.4 Removing and installing ignition/starter switch, vehicles with KESSY…………………………………………………………………………………………………….2332
11.5 Removing and installing ignition key withdrawal lock solenoid -N376-…………………………………………………………………………………………………….2333
12 Entry and start authorisation (KESSY)……………………………………………………………………………………………………………………………………..2334
12.1 General description………………………………………………………………………………………………………………………………………………..2334
12.2 Assembly overview – entry and start authorisation……………………………………………………………………………………………………………………..2335
12.3 Entry and start authorisation control unit -J518-……………………………………………………………………………………………………………………..2336
12.3.1 Removing and installing entry and start authorisation control unit -J518-…………………………………………………………………………………………..2336
12.3.2 Coding entry and start authorisation control unit -J518-………………………………………………………………………………………………………….2338
12.4 Entry and start authorisation aerials and sensors……………………………………………………………………………………………………………………..2338
12.4.1 Removing and installing front passenger side door exterior handle………………………………………………………………………………………………….2338
12.4.2 Removing and installing driver side door exterior handle………………………………………………………………………………………………………….2338
12.4.3 Removing and installing rear bumper aerial for entry and start authorisation -R136-………………………………………………………………………………….2339
12.4.4 Removing and installing luggage compartment aerial for entry and start authorisation -R137-…………………………………………………………………………..2339
12.4.5 Removing and installing interior aerial 2 for entry and start authorisation -R139-…………………………………………………………………………………..2340
12.4.6 Removing and installing interior aerial 1 for entry and start authorisation -R138-…………………………………………………………………………………..2341
12.5 Removing and installing rear lid power opening sender -G750-/-G760-……………………………………………………………………………………………………..2341
12.6 Starter button -E378-………………………………………………………………………………………………………………………………………………2343
12.6.1 Removing and installing the starter button -E378-………………………………………………………………………………………………………………..2343
13 Parking aid (PDC)……………………………………………………………………………………………………………………………………………………….2345
13.1 General description………………………………………………………………………………………………………………………………………………..2345
13.2 Assembly overview – parking aid……………………………………………………………………………………………………………………………………..2346
13.3 Park assist steering control unit -J791-……………………………………………………………………………………………………………………………..2347
13.3.1 Removing and installing park assist steering control unit -J791-…………………………………………………………………………………………………..2347
13.3.2 Coding park assist steering control unit -J791-………………………………………………………………………………………………………………….2347
13.3.3 Pin assignment of park assist steering control unit -J791-………………………………………………………………………………………………………..2347
13.3.4 Adapting lower volume request………………………………………………………………………………………………………………………………….2347
13.3.5 Adapting parking aid display…………………………………………………………………………………………………………………………………..2347
13.3.6 Adapting parking aid activation sound…………………………………………………………………………………………………………………………..2347
13.4 Front parking aid senders…………………………………………………………………………………………………………………………………………..2347
13.4.1 Removing and installing front parking aid senders………………………………………………………………………………………………………………..2348
13.4.2 Checking front parking aid sender………………………………………………………………………………………………………………………………2350
13.5 Rear parking aid senders……………………………………………………………………………………………………………………………………………2350
13.5.1 Removing and installing rear parking aid senders…………………………………………………………………………………………………………………2351
13.5.2 Checking rear parking aid senders………………………………………………………………………………………………………………………………2352
13.6 Renewing parking aid senders………………………………………………………………………………………………………………………………………..2353
13.6.1 Painting senders……………………………………………………………………………………………………………………………………………..2353
13.7 Parking aid loudspeaker…………………………………………………………………………………………………………………………………………….2353
13.7.1 Removing and installing parking aid loudspeaker -R169-……………………………………………………………………………………………………………2353
13.7.2 Removing and installing rear parking aid loudspeaker -R194-……………………………………………………………………………………………………….2354
13.7.3 Adapting loudspeaker for parking aid -R169-……………………………………………………………………………………………………………………..2355
13.8 Parking aid button -E266-…………………………………………………………………………………………………………………………………………..2355
13.8.1 Removing and installing parking aid button -E266-………………………………………………………………………………………………………………..2355
14 Park assist steering…………………………………………………………………………………………………………………………………………………….2356
14.1 General description………………………………………………………………………………………………………………………………………………..2356
14.2 Assembly overview of park assist steering…………………………………………………………………………………………………………………………….2357
14.3 Park assist steering control unit -J791-……………………………………………………………………………………………………………………………..2358
14.3.1 Removing and installing park assist steering control unit -J791-…………………………………………………………………………………………………..2358
14.3.2 Coding park assist steering control unit -J791-………………………………………………………………………………………………………………….2359
14.3.3 Adaption…………………………………………………………………………………………………………………………………………………….2359
14.4 Park assist steering senders………………………………………………………………………………………………………………………………………..2359
14.4.1 Removing and installing front park assist steering senders………………………………………………………………………………………………………..2360
14.4.2 Removing and installing rear park assist steering sender………………………………………………………………………………………………………….2361
14.4.3 Checking parking aid sender and park assist steering sender……………………………………………………………………………………………………….2363
14.5 Renewing park assist steering senders………………………………………………………………………………………………………………………………..2363
14.5.1 Painting senders……………………………………………………………………………………………………………………………………………..2363
14.6 Park assist steering loudspeaker…………………………………………………………………………………………………………………………………….2364
14.7 Park assist steering button -E581-…………………………………………………………………………………………………………………………………..2364
14.7.1 Removing and installing park assist steering button -E581-………………………………………………………………………………………………………..2364
14.7.2 Checking park assist steering button -E581-……………………………………………………………………………………………………………………..2364
15 Reversing camera system………………………………………………………………………………………………………………………………………………….2365
15.1 General description………………………………………………………………………………………………………………………………………………..2365
15.2 Assembly overview – reversing camera system…………………………………………………………………………………………………………………………..2365
15.3 Removing and installing reversing camera……………………………………………………………………………………………………………………………..2366
15.3.1 Removing handle button with reversing camera from rear lid………………………………………………………………………………………………………..2366
15.4 Reversing camera system control unit -J772-…………………………………………………………………………………………………………………………..2367
15.4.1 Removing and installing reversing camera system control unit -J772-………………………………………………………………………………………………..2367
15.4.2 Renewing reversing camera system control unit -J772-……………………………………………………………………………………………………………..2367
15.4.3 Coding reversing camera system control unit -J772-……………………………………………………………………………………………………………….2367
15.5 Calibrating reversing camera system………………………………………………………………………………………………………………………………….2367
15.5.1 Preparatory work for calibration:………………………………………………………………………………………………………………………………2368
15.5.2 Calibrating reversing camera system…………………………………………………………………………………………………………………………….2371
15.6 Renewing video cable……………………………………………………………………………………………………………………………………………….2372
15.6.1 Preparation………………………………………………………………………………………………………………………………………………….2372
15.6.2 Routing repair cable………………………………………………………………………………………………………………………………………….2372
15.6.3 Renewing video cable connector strip……………………………………………………………………………………………………………………………2374
16 Lane departure warning…………………………………………………………………………………………………………………………………………………..2375
16.1 Assembly overview – lane departure warning……………………………………………………………………………………………………………………………2375
16.2 General description………………………………………………………………………………………………………………………………………………..2375
16.3 Removing and installing front camera for driver assist systems -R242-……………………………………………………………………………………………………2376
16.4 Removing and installing windscreen heater for front sensors -Z113-………………………………………………………………………………………………………2378
96 – Lights, bulbs, switches – interior………………………………………………………………………………………………………………………………………….2379
1 Interior lights and switches………………………………………………………………………………………………………………………………………………2379
1.1 Interior monitoring deactivation switch -E267- and deactivation button for vehicle inclination sender -E360-………………………………………………………………….2379
1.1.1 Removing and installing interior monitoring deactivation switch -E267- and deactivation button for vehicle inclination sender -E360-……………………………………….2379
2 Lights and switches in engine compartment…………………………………………………………………………………………………………………………………..2381
2.1 Removing and installing bonnet contact switch -F266-……………………………………………………………………………………………………………………2381
3 Lights and switches in dash panel………………………………………………………………………………………………………………………………………….2382
3.1 Light switch -E1-…………………………………………………………………………………………………………………………………………………..2382
3.1.1 Removing and installing light switch -E1-………………………………………………………………………………………………………………………..2382
3.2 Headlight range control regulator -E102- and switch and instrument illumination regulator -E20-……………………………………………………………………………..2383
3.2.1 Removing and installing headlight range control adjuster -E102- and switch and instrument illumination regulator -E20-……………………………………………………2383
3.3 Glove compartment light -W6-…………………………………………………………………………………………………………………………………………2384
3.3.1 Removing and installing glove compartment light -W6-………………………………………………………………………………………………………………2384
3.3.2 Renewing glove compartment light -W6- bulb……………………………………………………………………………………………………………………….2385
3.4 Hazard warning light switch -E3-……………………………………………………………………………………………………………………………………..2386
3.4.1 Removing and installing hazard warning light switch -E3-…………………………………………………………………………………………………………..2386
3.4.2 Checking hazard warning light switch -E3-………………………………………………………………………………………………………………………..2387
3.5 Left footwell light -W9- and right footwell light -W10-…………………………………………………………………………………………………………………2387
3.5.1 Removing and installing footwell light…………………………………………………………………………………………………………………………..2387
3.5.2 Renewing bulb of footwell light…………………………………………………………………………………………………………………………………2388
3.6 Key operated switch to deactivate front passenger side airbag -E224-……………………………………………………………………………………………………..2389
3.6.1 Removing and installing key operated switch to deactivate front passenger side airbag -E224-…………………………………………………………………………..2389
4 Lights and switches in front doors…………………………………………………………………………………………………………………………………………2391
4.1 Driver side window regulator switch module…………………………………………………………………………………………………………………………….2391
4.1.1 Removing and installing switch module for driver side window regulator………………………………………………………………………………………………2391
4.2 Mirror adjustment switch on passenger side…………………………………………………………………………………………………………………………….2392
4.2.1 Removing and installing switch module for mirror adjustment on driver side…………………………………………………………………………………………..2393
4.3 Window regulator switch in front passenger door -E107-………………………………………………………………………………………………………………….2394
4.3.1 Removing and installing window regulator switch in front passenger door -E107-……………………………………………………………………………………….2394
4.4 Driver side interior locking button for central locking system -E308-…………………………………………………………………………………………………….2395
4.4.1 Removing and installing driver side interior locking button for central locking system -E308-………………………………………………………………………….2395
4.5 Removing and installing central locking deadlock function warning lamp -SAFE- -K133-……………………………………………………………………………………….2397
4.5.1 Removing and installing central locking deadlock function warning lamp -SAFE- -K133-………………………………………………………………………………….2397
4.6 Door warning lamps………………………………………………………………………………………………………………………………………………….2398
4.6.1 Removing and installing door warning lamps……………………………………………………………………………………………………………………….2398
4.6.2 Replace door warning lamp bulbs…………………………………………………………………………………………………………………………………2399
5 Lights and switches in rear doors………………………………………………………………………………………………………………………………………….2401
5.1 Rear right window regulator button in rear right door -E705- and rear left window regulator button in rear left door -E700-…………………………………………………….2401
5.1.1 Removing and installing rear right window regulator button in rear right door -E705- and rear left window regulator button in rear left door -E700-………………………….2401
6 Lights and switches in luggage compartment………………………………………………………………………………………………………………………………….2403
6.1 Luggage compartment light -W3-……………………………………………………………………………………………………………………………………….2403
6.1.1 Removing and installing luggage compartment light -W3-…………………………………………………………………………………………………………….2403
6.1.2 Renewing luggage compartment light -W3- bulb……………………………………………………………………………………………………………………..2404
6.2 Rear lid lock unit -F256-……………………………………………………………………………………………………………………………………………2405
6.2.1 Removing and installing rear lid locking unit -F256-………………………………………………………………………………………………………………2405
6.3 Button to close rear lid in luggage compartment -E406-………………………………………………………………………………………………………………….2405
6.3.1 Removing and installing button to close rear lid in luggage compartment -E406-……………………………………………………………………………………….2405
7 Lights and switches in roof trim…………………………………………………………………………………………………………………………………………..2407
7.1 Front interior light -W1-……………………………………………………………………………………………………………………………………………2407
7.1.1 Removing and installing front interior light -W1-…………………………………………………………………………………………………………………2407
7.1.2 Replacing front reading lights -W13- and -W19-……………………………………………………………………………………………………………………2408
7.1.3 Removing and installing front reading lights button -E457- and -E458-……………………………………………………………………………………………….2409
7.1.4 Removing and installing sunroof button -E325-…………………………………………………………………………………………………………………….2409
7.2 Rear interior light -W43-……………………………………………………………………………………………………………………………………………2410
7.2.1 Removing and installing rear interior light -W43-…………………………………………………………………………………………………………………2410
7.2.2 Renewing bulbs in rear interior light -W43-………………………………………………………………………………………………………………………2410
7.3 Left and right interior lights……………………………………………………………………………………………………………………………………….2411
7.3.1 Removing and installing left and right interior lights…………………………………………………………………………………………………………….2411
7.3.2 Renewing bulbs of left and right interior lights………………………………………………………………………………………………………………….2412
7.4 Removing and installing front passenger side illuminated vanity mirror -W14- and driver side illuminated vanity mirror -W20-……………………………………………………2413
7.4.1 Removing and installing front passenger side illuminated vanity mirror -W14- and driver side illuminated vanity mirror -W20-………………………………………………2413
7.4.2 Renewing illuminated vanity mirror bulb………………………………………………………………………………………………………………………….2414
8 Lights and switches in centre console………………………………………………………………………………………………………………………………………2416
8.1 Buttons in centre console storage compartment………………………………………………………………………………………………………………………….2416
8.1.1 Removing and installing button module in centre console stowage compartment………………………………………………………………………………………….2416
8.2 Front passenger side airbag deactivated warning lamp -K145-……………………………………………………………………………………………………………..2417
8.2.1 Removing and installing front passenger side airbag deactivated warning lamp -K145-…………………………………………………………………………………..2417
8.3 Electromechanical parking brake button and auto-hold button……………………………………………………………………………………………………………..2417
8.3.1 Removing and installing electromechanical parking brake button and auto-hold button…………………………………………………………………………………..2417
8.4 AC/DC converter with socket, 12 V-230 V -U13-………………………………………………………………………………………………………………………….2419
8.4.1 Removing and installing AC/DC converter with socket, 12 V – 230 V -U13-……………………………………………………………………………………………..2419
9 Horn……………………………………………………………………………………………………………………………………………………………………2421
9.1 Treble horn -H2- and bass horn -H7-…………………………………………………………………………………………………………………………………..2421
9.1.1 Removing and installing treble horn -H2- and bass horn -H7-………………………………………………………………………………………………………..2421
9.1.2 Checking treble horn -H2- and bass horn -H7-……………………………………………………………………………………………………………………..2422
10 Immobilizer…………………………………………………………………………………………………………………………………………………………….2423
10.1 General description………………………………………………………………………………………………………………………………………………..2423
10.2 Immobilizer control unit -J362-……………………………………………………………………………………………………………………………………..2424
10.2.1 Removing and installing immobilizer control unit -J362-…………………………………………………………………………………………………………..2424
10.2.2 Adapting immobilizer control unit -J362-………………………………………………………………………………………………………………………..2424
10.3 Ignition key………………………………………………………………………………………………………………………………………………………2424
10.3.1 Loss of the ignition key………………………………………………………………………………………………………………………………………2424
10.3.2 Adapting ignition keys………………………………………………………………………………………………………………………………………..2424
10.4 New identity on renewing all components………………………………………………………………………………………………………………………………2424
10.5 Online system test…………………………………………………………………………………………………………………………………………………2424
11 Anti-theft alarm (ATA)…………………………………………………………………………………………………………………………………………………..2425
11.1 General description………………………………………………………………………………………………………………………………………………..2425
11.2 Assembly overview – anti-theft alarm (ATA)……………………………………………………………………………………………………………………………2425
11.3 Activating and deactivating anti-theft alarm………………………………………………………………………………………………………………………….2427
11.4 Interior monitoring deactivation switch -E267- and deactivation button for vehicle inclination sender -E360-…………………………………………………………………2427
11.4.1 Removing and installing interior monitoring deactivation switch -E267- and deactivation button for vehicle inclination sender -E360-………………………………………2428
11.5 Anti-theft alarm system sensor -G578-………………………………………………………………………………………………………………………………..2428
11.5.1 Removing and installing anti-theft alarm sensor -G578-……………………………………………………………………………………………………………2428
11.6 Vehicle inclination sender -G384-……………………………………………………………………………………………………………………………………2429
11.7 Interior monitoring sensor -G273-……………………………………………………………………………………………………………………………………2429
11.8 Central locking and anti-theft alarm system aerial -R47-……………………………………………………………………………………………………………….2430
11.9 Alarm horn -H12-…………………………………………………………………………………………………………………………………………………..2430
11.9.1 Removing and installing alarm horn -H12-………………………………………………………………………………………………………………………..2430
11.9.2 Checking alarm horn -H12-……………………………………………………………………………………………………………………………………..2430
11.10 Adaptions of anti-theft alarm………………………………………………………………………………………………………………………………………2430
97 – Wiring…………………………………………………………………………………………………………………………………………………………………..2432
1 Vehicle diagnosis, testing and information systems…………………………………………………………………………………………………………………………..2432
2 Fuse holder……………………………………………………………………………………………………………………………………………………………..2433
2.1 Fuse holder in dash panel……………………………………………………………………………………………………………………………………………2433
2.1.1 Removing and installing fuse holder in dash panel…………………………………………………………………………………………………………………2433
2.2 Fuse holder in E-box………………………………………………………………………………………………………………………………………………..2434
2.2.1 Removing and installing E-box in dash panel………………………………………………………………………………………………………………………2434
3 Relay carrier……………………………………………………………………………………………………………………………………………………………2435
3.1 Relay carrier on left of dash panel…………………………………………………………………………………………………………………………………..2435
3.1.1 Removing and installing relay carrier on left of dash panel………………………………………………………………………………………………………..2435
4 Electronics boxes………………………………………………………………………………………………………………………………………………………..2436
4.1 Electronics box on left side of engine compartment (engine compartment E-box)……………………………………………………………………………………………..2436
4.1.1 Removing and installing E-box on left side of engine compartment (engine compartment E-box)……………………………………………………………………………2436
5 Control units……………………………………………………………………………………………………………………………………………………………2440
5.1 Onboard supply control unit -J519-……………………………………………………………………………………………………………………………………2440
5.1.1 General description……………………………………………………………………………………………………………………………………………2440
5.1.2 Removing and installing onboard supply control unit -J519-…………………………………………………………………………………………………………2441
5.1.3 Coding onboard supply control unit -J519-………………………………………………………………………………………………………………………..2442
5.1.4 Onboard supply control unit -J519- final control diagnosis…………………………………………………………………………………………………………2442
5.2 Driver door control unit -J386-………………………………………………………………………………………………………………………………………2443
5.2.1 Removing and installing driver door control unit -J386-……………………………………………………………………………………………………………2443
5.2.2 Coding driver door control unit -J386-…………………………………………………………………………………………………………………………..2443
5.3 Front passenger door control unit -J387-………………………………………………………………………………………………………………………………2443
5.3.1 Removing and installing front passenger door control unit -J387-……………………………………………………………………………………………………2444
5.3.2 Coding front passenger door control unit -J387-…………………………………………………………………………………………………………………..2444
5.4 Coding rear left door control unit -J388-……………………………………………………………………………………………………………………………..2444
5.4.1 Removing and installing rear left door control unit -J388-…………………………………………………………………………………………………………2444
5.4.2 Coding rear left door control unit -J388-………………………………………………………………………………………………………………………..2444
5.5 Coding rear right door control unit -J389-…………………………………………………………………………………………………………………………….2445
5.5.1 Removing and installing rear right door control unit -J389-………………………………………………………………………………………………………..2445
5.5.2 Coding rear right door control unit -J389-……………………………………………………………………………………………………………………….2445
5.6 Trailer detector control unit -J345-………………………………………………………………………………………………………………………………….2445
5.6.1 Removing and installing trailer detector control unit -J345-……………………………………………………………………………………………………….2446
5.6.2 Coding trailer detector control unit -J345-………………………………………………………………………………………………………………………2447
5.6.3 Actuator diagnosis for bulbs……………………………………………………………………………………………………………………………………2447
5.6.4 Actuator diagnosis for folding tow hitch…………………………………………………………………………………………………………………………2447
6 Wiring harness and connector repairs……………………………………………………………………………………………………………………………………….2448
Sharan2011-Electrical_System__General_Information…………………………………………………………………………………………………………………………………….2449
27 – Starter, current supply, CCS……………………………………………………………………………………………………………………………………………….2453
1 Battery…………………………………………………………………………………………………………………………………………………………………2453
1.1 Fundamentals for batteries…………………………………………………………………………………………………………………………………………..2453
1.2 Types of batteries………………………………………………………………………………………………………………………………………………….2453
1.2.1 Battery with »standard« colour indicator…………………………………………………………………………………………………………………………2453
1.2.2 Battery with »enhanced« colour indicator…………………………………………………………………………………………………………………………2454
1.2.3 Absorbent glass mat battery…………………………………………………………………………………………………………………………………….2454
1.3 Warning notices and safety regulations………………………………………………………………………………………………………………………………..2455
1.3.1 Dangers when handling vehicle batteries………………………………………………………………………………………………………………………….2455
1.3.3 Working on airbag system……………………………………………………………………………………………………………………………………….2456
1.4 Battery terminal connection………………………………………………………………………………………………………………………………………….2456
2 Checking battery…………………………………………………………………………………………………………………………………………………………2458
2.1 Checking the various types of batteries……………………………………………………………………………………………………………………………….2458
2.1.1 Checking a battery with colour indicator…………………………………………………………………………………………………………………………2458
2.1.2 Absorbent glass mat battery…………………………………………………………………………………………………………………………………….2458
2.2 Visual check……………………………………………………………………………………………………………………………………………………….2459
2.3 Checking colour indicator in battery cover…………………………………………………………………………………………………………………………….2459
2.3.1 Checking colour indicator, “3-colour”……………………………………………………………………………………………………………………………2459
2.3.2 Checking colour indicator, “2-colour”……………………………………………………………………………………………………………………………2460
2.4 Battery tester with printer -VAS 6161-………………………………………………………………………………………………………………………………..2462
2.4.2 Perform battery test with battery tester with printer -VAS 6161-……………………………………………………………………………………………………2463
2.4.3 Perform guarantee test…………………………………………………………………………………………………………………………………………2464
2.4.4 Performing maintenance test…………………………………………………………………………………………………………………………………….2464
2.4.5 Perform service test…………………………………………………………………………………………………………………………………………..2465
2.4.7 Assessing test results…………………………………………………………………………………………………………………………………………2465
2.5 Midtronics -MCR340V- battery tester only for USA/Canada vehicles…………………………………………………………………………………………………………2466
2.5.1 General description……………………………………………………………………………………………………………………………………………2466
2.5.2 Performing battery test with Midtronics -MCR340V- battery tester……………………………………………………………………………………………………2467
2.5.3 Assessing test results…………………………………………………………………………………………………………………………………………2469
2.5.4 Dealing with problems with Midtronics -MCR340V- battery tester……………………………………………………………………………………………………..2469
2.6 Current draw test…………………………………………………………………………………………………………………………………………………..2470
3 Charging battery…………………………………………………………………………………………………………………………………………………………2472
3.1 Battery charger -VAS 5095 A-…………………………………………………………………………………………………………………………………………2472
3.1.1 Description of battery charger -VAS 5095 A-………………………………………………………………………………………………………………………2472
3.1.2 Charging battery with battery charger -VAS 5095 A-………………………………………………………………………………………………………………..2473
3.1.3 Charging totally discharged battery with battery charger -VAS 5095 A-……………………………………………………………………………………………….2474
3.1.4 Charging battery in support mode with battery charger -VAS 5095A-…………………………………………………………………………………………………..2475
3.1.5 Charging battery in maintenance mode with battery charger -VAS 5095 A-………………………………………………………………………………………………2477
3.2 Battery charger -VAS 5900-…………………………………………………………………………………………………………………………………………..2477
3.2.1 Description of battery charger -VAS 5900-………………………………………………………………………………………………………………………..2478
3.2.2 Charging battery with battery charger -VAS 5900-………………………………………………………………………………………………………………….2478
3.2.3 Charging battery in service mode with battery charger -VAS 5900-……………………………………………………………………………………………………2480
3.2.4 Charging totally discharged batteries with battery charger -VAS 5900-……………………………………………………………………………………………….2483
3.2.5 Charging battery in support mode with battery charger -VAS 5900-……………………………………………………………………………………………………2485
3.2.6 Charging battery in maintenance mode with battery charger -VAS 5900-………………………………………………………………………………………………..2487
3.3 Battery charger -VAS 5903-…………………………………………………………………………………………………………………………………………..2488
3.3.1 Description of battery charger -VAS 5903-………………………………………………………………………………………………………………………..2489
3.3.2 Charging battery with battery charger -VAS 5903-………………………………………………………………………………………………………………….2489
3.3.3 Charging battery in refresh charge mode with battery charger -VAS 5903-……………………………………………………………………………………………..2491
3.3.4 Charging totally discharged battery with battery charger -VAS 5903-…………………………………………………………………………………………………2494
3.3.5 Charging battery in support mode with battery charger -VAS 5903-……………………………………………………………………………………………………2496
3.3.6 Charging battery in maintenance mode with battery charger -VAS 5903-………………………………………………………………………………………………..2498
3.4 Battery charger -VAS 5906-…………………………………………………………………………………………………………………………………………..2500
3.4.2 Charging battery with battery charger -VAS 5906-………………………………………………………………………………………………………………….2500
3.5 Midtronics -INC 940- battery charger only for USA/Canada………………………………………………………………………………………………………………..2502
3.5.1 General description of Midtronics -INC 940- battery tester…………………………………………………………………………………………………………2502
3.5.2 Charging battery………………………………………………………………………………………………………………………………………………2503
3.5.3 Dealing with problems with Midtronics -INC 940- battery tester……………………………………………………………………………………………………..2505
3.6 Solar panel -VAS 6102A-……………………………………………………………………………………………………………………………………………..2506
3.7 Totally discharged batteries…………………………………………………………………………………………………………………………………………2506
4 Cruise control system (CCS)……………………………………………………………………………………………………………………………………………….2508
4.1 Activating and deactivating cruise control system (CCS)…………………………………………………………………………………………………………………2508
90 – Gauges, instruments……………………………………………………………………………………………………………………………………………………….2509
92 – Windscreen wash/wipe system………………………………………………………………………………………………………………………………………………..2510
1 Washer fluid line hose couplings…………………………………………………………………………………………………………………………………………..2510
1.1 Windscreen and rear window washer system………………………………………………………………………………………………………………………………2510
1.2 Headlight washer system……………………………………………………………………………………………………………………………………………..2511
2 Hose repair……………………………………………………………………………………………………………………………………………………………..2512
2.1 General description…………………………………………………………………………………………………………………………………………………2512
2.2 Repairing smooth pipe……………………………………………………………………………………………………………………………………………….2512
2.3 Repairing corrugated pipe……………………………………………………………………………………………………………………………………………2512
3 Distinguishing features of jointless wiper blades……………………………………………………………………………………………………………………………2514
94 – Lights, bulbs, switches – exterior………………………………………………………………………………………………………………………………………….2515
1 Operation and safety notes for gas discharge bulbs…………………………………………………………………………………………………………………………..2515
96 – Lights, bulbs, switches – interior………………………………………………………………………………………………………………………………………….2518
1 12 V socket……………………………………………………………………………………………………………………………………………………………..2518
1.1 Removing and installing 12 V socket…………………………………………………………………………………………………………………………………..2518
1.2 Removing and installing socket illumination bulb -L42-………………………………………………………………………………………………………………….2518
2 Cigarette lighter -U1-……………………………………………………………………………………………………………………………………………………2519
2.1 General description…………………………………………………………………………………………………………………………………………………2519
2.2 Assembly overview…………………………………………………………………………………………………………………………………………………..2520
2.3 Removing and installing cigarette lighter socket……………………………………………………………………………………………………………………….2521
2.4 Removing and installing cigarette lighter illumination bulb -L28-………………………………………………………………………………………………………..2523
97 – Wiring…………………………………………………………………………………………………………………………………………………………………..2525
1 Vehicle diagnostic, testing and information systems………………………………………………………………………………………………………………………….2525
1.1 Connecting vehicle diagnostic tester………………………………………………………………………………………………………………………………….2525
1.2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003…………………………………………………………………………………………………………2527
2 Wiring harness and connector repairs……………………………………………………………………………………………………………………………………….2528
2.1 General notes concerning repairs to vehicle electrical system……………………………………………………………………………………………………………2528
2.2 Wiring harness repair set……………………………………………………………………………………………………………………………………………2531
2.2.1 Wiring harness repair set -VAS 1978-…………………………………………………………………………………………………………………………….2531
2.2.2 Upgrade kit -VAS 1978/50-………………………………………………………………………………………………………………………………………2531
2.2.3 Wiring harness repair set -VAS 1978A-……………………………………………………………………………………………………………………………2531
2.2.4 Release tool set -VAS 1978/35-………………………………………………………………………………………………………………………………….2532
2.3 Tool descriptions…………………………………………………………………………………………………………………………………………………..2532
2.3.1 Special pliers with insert……………………………………………………………………………………………………………………………………..2532
2.3.2 Release tools for contacts……………………………………………………………………………………………………………………………………..2533
2.3.3 Assembly tools for single wire seals…………………………………………………………………………………………………………………………….2533
2.3.4 Wire strippers -VAS 1978/3-…………………………………………………………………………………………………………………………………….2533
2.3.6 Crimping pliers -VAS 1978/1A-…………………………………………………………………………………………………………………………………..2534
2.4 Repairs to wiring harnesses………………………………………………………………………………………………………………………………………….2535
2.4.1 Notes on repairs to airbag and belt tensioner wiring………………………………………………………………………………………………………………2536
2.4.2 Repairs to CAN bus wiring………………………………………………………………………………………………………………………………………2538
2.4.3 Renewal of aerial wiring……………………………………………………………………………………………………………………………………….2538
2.4.4 Repairs to wiring with cross sections up to 0.35 mm2………………………………………………………………………………………………………………2539
2.4.5 Wiring open circuit with one repair position……………………………………………………………………………………………………………………..2542
2.4.6 Wiring open circuit with two repair positions…………………………………………………………………………………………………………………….2544
2.5 Repair of optical fibre conductors……………………………………………………………………………………………………………………………………2545
2.5.1 Preparing fibre optic cable…………………………………………………………………………………………………………………………………….2546
2.5.2 Detaching fibre optic cable from cable harness connector…………………………………………………………………………………………………………..2551
2.6 Repair of aerial wires………………………………………………………………………………………………………………………………………………2551
2.6.1 Repair set, aerial cable VAS 6720……………………………………………………………………………………………………………………………….2551
2.7 Repairs to contact housings and connectors…………………………………………………………………………………………………………………………….2563
2.7.1 Notes on repairs to contact housings and connectors……………………………………………………………………………………………………………….2563
2.7.2 Repairs to contacts in contact housings………………………………………………………………………………………………………………………….2563
2.7.3 Fitting single wire seals………………………………………………………………………………………………………………………………………2564
2.7.4 Repairs to contact housings using cut and clamp technique………………………………………………………………………………………………………….2566
2.8 Releasing and dismantling contact housings…………………………………………………………………………………………………………………………….2567
2.8.1 Notes on releasing and dismantling contact housings……………………………………………………………………………………………………………….2567
2.8.2 Secondary locking element………………………………………………………………………………………………………………………………………2567
2.8.3 Primary locking element………………………………………………………………………………………………………………………………………..2568
2.8.4 Round connector systems………………………………………………………………………………………………………………………………………..2568
2.8.5 Flat connector systems…………………………………………………………………………………………………………………………………………2569
2.8.6 Special connector systems………………………………………………………………………………………………………………………………………2571
3 Contact surface cleaning set -VAS 6410-…………………………………………………………………………………………………………………………………….2573
3.1 Using contact surface cleaning set -VAS 6410-………………………………………………………………………………………………………………………….2573
3.1.1 Repairing ring terminals……………………………………………………………………………………………………………………………………….2573
3.1.2 Repairing threaded connections………………………………………………………………………………………………………………………………….2575
3.1.3 Cleaning battery clamp and battery terminal………………………………………………………………………………………………………………………2576
3.1.4 Anti-corrosion treatment……………………………………………………………………………………………………………………………………….2578
4 Renewing Lambda probe…………………………………………………………………………………………………………………………………………………….2580
4.1 Renewing LSF Lambda probe (4-pin)…………………………………………………………………………………………………………………………………….2580
4.2 Renewing LSU Lambda probe (6-pin)…………………………………………………………………………………………………………………………………….2581
4.3 Types of protective tube on uniform Lambda probes………………………………………………………………………………………………………………………2582
Sharan2011-Fuel_supply_system_-_Petrol_engines (1)……………………………………………………………………………………………………………………………………2584
00 – Technical data……………………………………………………………………………………………………………………………………………………………2588
1 Safety instructions………………………………………………………………………………………………………………………………………………………2588
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………..2588
1.2 Safety precautions during road tests in which testing and measuring equipment is used………………………………………………………………………………………2588
1.3 Safety precautions when working on vehicles with a start/stop system……………………………………………………………………………………………………..2589
2 Identification…………………………………………………………………………………………………………………………………………………………..2590
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………..2590
3 General notes……………………………………………………………………………………………………………………………………………………………2591
3.1 Cleanliness specifications for working on the auxiliary heater and fuel system…………………………………………………………………………………………….2591
4 Repair instructions………………………………………………………………………………………………………………………………………………………2592
4.1 Routing and securing lines…………………………………………………………………………………………………………………………………………..2592
4.2 General repair notes………………………………………………………………………………………………………………………………………………..2592
20 – Fuel supply system………………………………………………………………………………………………………………………………………………………..2593
1 Fuel tank……………………………………………………………………………………………………………………………………………………………….2593
1.1 Assembly overview – fuel tank………………………………………………………………………………………………………………………………………..2593
1.2 Emptying fuel tank………………………………………………………………………………………………………………………………………………….2594
1.2.1 Emptying fuel tank when fuel pump is defective……………………………………………………………………………………………………………………2594
1.2.2 Emptying fuel tank when fuel pump is intact………………………………………………………………………………………………………………………2597
1.3 Removing and installing fuel tank…………………………………………………………………………………………………………………………………….2599
2 Fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………………………………………2603
2.1 Assembly overview – fuel delivery unit and fuel gauge sender…………………………………………………………………………………………………………….2603
2.1.1 Assembly overview – fuel delivery unit and fuel gauge sender……………………………………………………………………………………………………….2603
2.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heating……………………………………………………………………………..2605
2.2 Removing and installing fuel delivery unit, fuel gauge sender……………………………………………………………………………………………………………2605
2.2.1 Removing and installing fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………2605
2.2.2 Removing and installing fuel line for auxiliary/supplementary heater………………………………………………………………………………………………..2607
3 Plug-in connectors……………………………………………………………………………………………………………………………………………………….2610
3.1 Detaching plug-in connectors…………………………………………………………………………………………………………………………………………2610
4 Fuel filter……………………………………………………………………………………………………………………………………………………………..2614
4.1 Assembly overview – fuel filter………………………………………………………………………………………………………………………………………2614
4.2 Removing and installing fuel filter…………………………………………………………………………………………………………………………………..2614
5 Activated charcoal filter system…………………………………………………………………………………………………………………………………………..2616
5.1 Assembly overview – activated charcoal filter system……………………………………………………………………………………………………………………2616
5.2 Removing and installing activated charcoal filter………………………………………………………………………………………………………………………2616
5.3 Checking fuel tank breather………………………………………………………………………………………………………………………………………….2617
6 Accelerator mechanism…………………………………………………………………………………………………………………………………………………….2619
6.1 Assembly overview – accelerator module………………………………………………………………………………………………………………………………..2619
6.2 Removing and installing accelerator module -GX2-……………………………………………………………………………………………………………………….2619
7 Fuel pump……………………………………………………………………………………………………………………………………………………………….2622
7.1 Checking fuel system pressurisation pump -G6-………………………………………………………………………………………………………………………….2622
7.1.1 Checking fuel pressure…………………………………………………………………………………………………………………………………………2622
7.1.2 Checking holding pressure………………………………………………………………………………………………………………………………………2624
7.2 Removing and installing suction-jet pump………………………………………………………………………………………………………………………………2627
8 Senders and sensors………………………………………………………………………………………………………………………………………………………2629
8.1 Removing and installing fuel gauge sender -G-………………………………………………………………………………………………………………………….2629
Sharan2011-Fuel_supply_system_-_Petrol_engines……………………………………………………………………………………………………………………………………….2631
00 – Technical data……………………………………………………………………………………………………………………………………………………………2635
1 Safety instructions………………………………………………………………………………………………………………………………………………………2635
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………..2635
1.2 Safety precautions during road tests in which testing and measuring equipment is used………………………………………………………………………………………2635
1.3 Safety precautions when working on vehicles with a start/stop system……………………………………………………………………………………………………..2636
2 Identification…………………………………………………………………………………………………………………………………………………………..2637
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………..2637
3 General notes……………………………………………………………………………………………………………………………………………………………2638
3.1 Cleanliness specifications for working on the auxiliary heater and fuel system…………………………………………………………………………………………….2638
4 Repair instructions………………………………………………………………………………………………………………………………………………………2639
4.1 Routing and securing lines…………………………………………………………………………………………………………………………………………..2639
4.2 General repair notes………………………………………………………………………………………………………………………………………………..2639
20 – Fuel supply system………………………………………………………………………………………………………………………………………………………..2640
1 Fuel tank……………………………………………………………………………………………………………………………………………………………….2640
1.1 Assembly overview – fuel tank………………………………………………………………………………………………………………………………………..2640
1.2 Emptying fuel tank………………………………………………………………………………………………………………………………………………….2641
1.2.1 Emptying fuel tank when fuel pump is defective……………………………………………………………………………………………………………………2641
1.2.2 Emptying fuel tank when fuel pump is intact………………………………………………………………………………………………………………………2644
1.3 Removing and installing fuel tank…………………………………………………………………………………………………………………………………….2646
2 Fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………………………………………2650
2.1 Assembly overview – fuel delivery unit and fuel gauge sender…………………………………………………………………………………………………………….2650
2.1.1 Assembly overview – fuel delivery unit and fuel gauge sender……………………………………………………………………………………………………….2650
2.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heating……………………………………………………………………………..2652
2.2 Removing and installing fuel delivery unit, fuel gauge sender……………………………………………………………………………………………………………2652
2.2.1 Removing and installing fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………2652
2.2.2 Removing and installing fuel line for auxiliary/supplementary heater………………………………………………………………………………………………..2654
3 Plug-in connectors……………………………………………………………………………………………………………………………………………………….2657
3.1 Detaching plug-in connectors…………………………………………………………………………………………………………………………………………2657
4 Fuel filter……………………………………………………………………………………………………………………………………………………………..2661
4.1 Assembly overview – fuel filter………………………………………………………………………………………………………………………………………2661
4.2 Removing and installing fuel filter…………………………………………………………………………………………………………………………………..2661
5 Activated charcoal filter system…………………………………………………………………………………………………………………………………………..2663
5.1 Assembly overview – activated charcoal filter system……………………………………………………………………………………………………………………2663
5.2 Removing and installing activated charcoal filter………………………………………………………………………………………………………………………2663
5.3 Checking fuel tank breather………………………………………………………………………………………………………………………………………….2664
6 Accelerator mechanism…………………………………………………………………………………………………………………………………………………….2666
6.1 Assembly overview – accelerator module………………………………………………………………………………………………………………………………..2666
6.2 Removing and installing accelerator module -GX2-……………………………………………………………………………………………………………………….2666
7 Fuel pump……………………………………………………………………………………………………………………………………………………………….2669
7.1 Checking fuel system pressurisation pump -G6-………………………………………………………………………………………………………………………….2669
7.1.1 Checking fuel pressure…………………………………………………………………………………………………………………………………………2669
7.1.2 Checking holding pressure………………………………………………………………………………………………………………………………………2671
7.2 Removing and installing suction-jet pump………………………………………………………………………………………………………………………………2674
8 Senders and sensors………………………………………………………………………………………………………………………………………………………2676
8.1 Removing and installing fuel gauge sender -G-………………………………………………………………………………………………………………………….2676
Sharan2011-General_body_repairs__exterior……………………………………………………………………………………………………………………………………………2678
50 – Body – front……………………………………………………………………………………………………………………………………………………………..2686
1 Lock carrier…………………………………………………………………………………………………………………………………………………………….2686
1.1 Tools……………………………………………………………………………………………………………………………………………………………..2686
1.2 Assembly overview – lock carrier……………………………………………………………………………………………………………………………………..2687
1.3 Repairing headlight mounting…………………………………………………………………………………………………………………………………………2688
1.4 Service position……………………………………………………………………………………………………………………………………………………2689
1.4.1 Moving to service position……………………………………………………………………………………………………………………………………..2689
1.4.2 Moving from service position……………………………………………………………………………………………………………………………………2690
1.5 Removing and installing lock carrier with add-on parts………………………………………………………………………………………………………………….2691
1.5.1 Removing……………………………………………………………………………………………………………………………………………………..2691
1.5.2 Installing……………………………………………………………………………………………………………………………………………………2692
1.6 Removing and installing support………………………………………………………………………………………………………………………………………2692
1.6.1 Removing……………………………………………………………………………………………………………………………………………………..2692
1.6.2 Installing……………………………………………………………………………………………………………………………………………………2694
2 Wing……………………………………………………………………………………………………………………………………………………………………2695
2.1 Tools……………………………………………………………………………………………………………………………………………………………..2695
2.2 Assembly overview – front wing……………………………………………………………………………………………………………………………………….2695
2.3 Removing and installing wing…………………………………………………………………………………………………………………………………………2696
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..2697
2.3.2 Installing……………………………………………………………………………………………………………………………………………………2698
2.4 Foam elements and end/sealing pieces for wing………………………………………………………………………………………………………………………….2699
3 Plenum chamber bulkhead…………………………………………………………………………………………………………………………………………………..2700
4 Plenum chamber cover……………………………………………………………………………………………………………………………………………………..2701
4.1 Assembly overview – plenum chamber cover………………………………………………………………………………………………………………………………2701
4.2 Removing plenum chamber cover………………………………………………………………………………………………………………………………………..2702
4.3 Installing plenum chamber cover………………………………………………………………………………………………………………………………………2704
5 Noise insulation…………………………………………………………………………………………………………………………………………………………2706
5.1 Tools……………………………………………………………………………………………………………………………………………………………..2706
5.2 Assembly overview – short noise insulation…………………………………………………………………………………………………………………………….2706
5.3 Assembly overview – long noise insulation……………………………………………………………………………………………………………………………..2707
6 Underbody cover………………………………………………………………………………………………………………………………………………………….2708
6.1 Tools……………………………………………………………………………………………………………………………………………………………..2708
6.2 Assembly overview – underbody cover…………………………………………………………………………………………………………………………………..2708
6.3 Assembly overview – rear underbody cover………………………………………………………………………………………………………………………………2710
7 Plenum chamber bulkhead…………………………………………………………………………………………………………………………………………………..2711
7.1 Tools……………………………………………………………………………………………………………………………………………………………..2711
7.2 Materials………………………………………………………………………………………………………………………………………………………….2711
7.3 Assembly overview – bulkhead…………………………………………………………………………………………………………………………………………2712
8 Tunnel cross-piece……………………………………………………………………………………………………………………………………………………….2713
8.1 Tools……………………………………………………………………………………………………………………………………………………………..2713
8.2 Assembly overview – tunnel cross-piece………………………………………………………………………………………………………………………………..2713
55 – Bonnet, rear lid………………………………………………………………………………………………………………………………………………………….2714
1 Bonnet………………………………………………………………………………………………………………………………………………………………….2714
1.1 Tools……………………………………………………………………………………………………………………………………………………………..2714
1.2 Assembly overview – bonnet…………………………………………………………………………………………………………………………………………..2714
1.3 Removing and installing bonnet……………………………………………………………………………………………………………………………………….2716
1.3.1 Removing……………………………………………………………………………………………………………………………………………………..2716
1.3.2 Installing……………………………………………………………………………………………………………………………………………………2717
1.4 Removing and installing bonnet hinge………………………………………………………………………………………………………………………………….2717
1.4.1 Removing……………………………………………………………………………………………………………………………………………………..2718
1.4.2 Installing……………………………………………………………………………………………………………………………………………………2719
1.5 Removing gas strut………………………………………………………………………………………………………………………………………………….2720
1.6 Releasing gas from gas strut…………………………………………………………………………………………………………………………………………2720
1.7 Removing and installing insulation……………………………………………………………………………………………………………………………………2720
1.7.1 Removing……………………………………………………………………………………………………………………………………………………..2720
1.7.2 Installing……………………………………………………………………………………………………………………………………………………2722
1.8 Assembly overview – bonnet lock and release components………………………………………………………………………………………………………………….2723
1.9 Removing and installing lid lock on LHD vehicle………………………………………………………………………………………………………………………..2723
1.9.1 Removing……………………………………………………………………………………………………………………………………………………..2724
1.9.2 Installing……………………………………………………………………………………………………………………………………………………2726
1.10 Removing and installing lid lock on RHD vehicle……………………………………………………………………………………………………………………….2728
1.10.1 Removing…………………………………………………………………………………………………………………………………………………….2728
1.10.2 Installing…………………………………………………………………………………………………………………………………………………..2730
1.11 Separating and joining Bowden cable………………………………………………………………………………………………………………………………….2732
1.11.1 Separating Bowden cable……………………………………………………………………………………………………………………………………….2732
1.11.2 Joining Bowden cable………………………………………………………………………………………………………………………………………….2733
1.12 Removing and installing striker pin………………………………………………………………………………………………………………………………….2734
1.13 Release lever……………………………………………………………………………………………………………………………………………………..2735
1.13.1 Assembly overview…………………………………………………………………………………………………………………………………………….2735
1.13.2 Removing and installing……………………………………………………………………………………………………………………………………….2736
1.14 Adjusting bonnet…………………………………………………………………………………………………………………………………………………..2737
1.14.1 Adjusting bonnet lock…………………………………………………………………………………………………………………………………………2738
1.14.2 Adjusting striker pin…………………………………………………………………………………………………………………………………………2739
1.14.3 Adjusting hinges……………………………………………………………………………………………………………………………………………..2740
1.14.4 Adjusting adjustment buffer……………………………………………………………………………………………………………………………………2741
2 Rear lid………………………………………………………………………………………………………………………………………………………………..2742
2.1 Tools……………………………………………………………………………………………………………………………………………………………..2742
2.2 Assembly overview – rear lid…………………………………………………………………………………………………………………………………………2742
2.3 Removing and installing rear lid……………………………………………………………………………………………………………………………………..2744
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..2744
2.3.2 Installing……………………………………………………………………………………………………………………………………………………2746
2.4 Gas strut………………………………………………………………………………………………………………………………………………………….2747
2.4.1 Assembly overview – gas strut…………………………………………………………………………………………………………………………………..2747
2.4.2 Removing gas strut…………………………………………………………………………………………………………………………………………….2747
2.4.3 Releasing gas from gas strut……………………………………………………………………………………………………………………………………2749
2.5 Rear lid drive……………………………………………………………………………………………………………………………………………………..2749
2.5.1 Assembly overview – rear lid drive………………………………………………………………………………………………………………………………2749
2.5.2 Removing and installing rear lid drive…………………………………………………………………………………………………………………………..2751
2.5.3 Removing sensor strip………………………………………………………………………………………………………………………………………….2753
2.5.4 Installing sensor strip………………………………………………………………………………………………………………………………………..2754
2.5.5 Basic setting and coding of the tailgate electronics………………………………………………………………………………………………………………2755
2.6 Rear lid hinge……………………………………………………………………………………………………………………………………………………..2755
2.6.1 Assembly overview – rear lid hinge………………………………………………………………………………………………………………………………2755
2.6.2 Removing rear lid hinge………………………………………………………………………………………………………………………………………..2757
2.6.3 Installing rear lid hinge………………………………………………………………………………………………………………………………………2759
2.7 Removing and installing striker pin…………………………………………………………………………………………………………………………………..2760
2.8 Removing and installing adjustment buffers…………………………………………………………………………………………………………………………….2761
2.9 Adjusting rear lid………………………………………………………………………………………………………………………………………………….2762
2.9.1 Adjusting striker pin………………………………………………………………………………………………………………………………………….2763
2.9.2 Adjusting adjustment buffer…………………………………………………………………………………………………………………………………….2764
2.10 Removing and installing lid lock…………………………………………………………………………………………………………………………………….2765
2.10.1 Removing…………………………………………………………………………………………………………………………………………………….2765
2.10.2 Installing…………………………………………………………………………………………………………………………………………………..2766
2.11 Removing and installing release button……………………………………………………………………………………………………………………………….2767
2.11.1 Removing…………………………………………………………………………………………………………………………………………………….2767
2.11.2 Installing…………………………………………………………………………………………………………………………………………………..2768
2.12 Removing and installing rear lid seal………………………………………………………………………………………………………………………………..2769
2.13 Number plate carrier……………………………………………………………………………………………………………………………………………….2770
2.13.1 Protective backing……………………………………………………………………………………………………………………………………………2770
2.13.2 Number plate carrier………………………………………………………………………………………………………………………………………….2771
3 Tank flap unit…………………………………………………………………………………………………………………………………………………………..2772
3.1 Tools……………………………………………………………………………………………………………………………………………………………..2772
3.2 Assembly overview – tank flap unit and actuator………………………………………………………………………………………………………………………..2772
3.3 Removing and installing tank flap unit………………………………………………………………………………………………………………………………..2774
3.3.1 Removing……………………………………………………………………………………………………………………………………………………..2774
3.3.2 Installing……………………………………………………………………………………………………………………………………………………2776
3.4 Removing and installing actuator……………………………………………………………………………………………………………………………………..2777
3.4.1 Removing……………………………………………………………………………………………………………………………………………………..2777
3.4.2 Installing……………………………………………………………………………………………………………………………………………………2778
57 – Front doors, door components, central locking………………………………………………………………………………………………………………………………..2779
1 Front door………………………………………………………………………………………………………………………………………………………………2779
1.1 Tools……………………………………………………………………………………………………………………………………………………………..2779
1.2 Assembly overview – door hinges………………………………………………………………………………………………………………………………………2780
1.3 Removing and installing door…………………………………………………………………………………………………………………………………………2781
1.3.1 Removing……………………………………………………………………………………………………………………………………………………..2782
1.3.2 Installing……………………………………………………………………………………………………………………………………………………2782
1.4 Installing hinge after renewal of A-pillar…………………………………………………………………………………………………………………………….2783
1.5 Door alignment……………………………………………………………………………………………………………………………………………………..2784
1.5.1 Note on door adjustment………………………………………………………………………………………………………………………………………..2784
1.5.2 Door alignment – shut lines and flushness………………………………………………………………………………………………………………………..2785
1.5.3 Adjusting striker pin………………………………………………………………………………………………………………………………………….2786
2 Door components………………………………………………………………………………………………………………………………………………………….2788
2.1 Tools……………………………………………………………………………………………………………………………………………………………..2788
2.2 Assembly overview – front door……………………………………………………………………………………………………………………………………….2789
2.3 Removing and installing door cover……………………………………………………………………………………………………………………………………2790
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..2790
2.3.2 Installing……………………………………………………………………………………………………………………………………………………2791
2.4 Removing and installing door retaining strap…………………………………………………………………………………………………………………………..2792
2.5 Removing and installing striker pin…………………………………………………………………………………………………………………………………..2793
2.6 Assembly overview – door handle and door lock………………………………………………………………………………………………………………………….2794
2.7 Removing and installing lock cylinder cover cap………………………………………………………………………………………………………………………..2795
2.7.1 Removing……………………………………………………………………………………………………………………………………………………..2795
2.7.2 Installing……………………………………………………………………………………………………………………………………………………2795
2.8 Removing and installing lock cylinder…………………………………………………………………………………………………………………………………2796
2.8.1 Removing……………………………………………………………………………………………………………………………………………………..2796
2.8.2 Installing……………………………………………………………………………………………………………………………………………………2797
2.9 Removing and installing cover cap (without lock cylinder)……………………………………………………………………………………………………………….2797
2.9.1 Tools………………………………………………………………………………………………………………………………………………………..2797
2.9.2 Removing……………………………………………………………………………………………………………………………………………………..2798
2.9.3 Installing……………………………………………………………………………………………………………………………………………………2799
2.10 Removing and installing door handle………………………………………………………………………………………………………………………………….2800
2.10.1 Removing…………………………………………………………………………………………………………………………………………………….2801
2.10.2 Installing…………………………………………………………………………………………………………………………………………………..2801
2.11 Removing and installing door lock……………………………………………………………………………………………………………………………………2802
2.11.1 Removing…………………………………………………………………………………………………………………………………………………….2803
2.11.2 Installing…………………………………………………………………………………………………………………………………………………..2804
2.12 Removing and installing mounting bracket……………………………………………………………………………………………………………………………..2806
2.12.1 Removing…………………………………………………………………………………………………………………………………………………….2806
2.12.2 Installing…………………………………………………………………………………………………………………………………………………..2807
2.13 Removing and installing door inner seal………………………………………………………………………………………………………………………………2807
2.14 Removing and installing door outer seal………………………………………………………………………………………………………………………………2809
2.14.1 Removing…………………………………………………………………………………………………………………………………………………….2809
2.14.2 Installing…………………………………………………………………………………………………………………………………………………..2811
2.15 Assembly overview – insulation………………………………………………………………………………………………………………………………………2813
3 Central locking………………………………………………………………………………………………………………………………………………………….2814
3.1 Overview of fitting locations – central locking components………………………………………………………………………………………………………………2814
3.2 Adapting keys with remote control…………………………………………………………………………………………………………………………………….2815
3.3 Assembly overview – battery for folding key with remote control………………………………………………………………………………………………………….2816
3.4 Removing and installing battery for folding key with remote control………………………………………………………………………………………………………2817
3.4.1 Removing……………………………………………………………………………………………………………………………………………………..2817
3.4.2 Installing……………………………………………………………………………………………………………………………………………………2819
58 – Rear doors, door components………………………………………………………………………………………………………………………………………………..2820
1 Sliding door…………………………………………………………………………………………………………………………………………………………….2820
1.1 Tools……………………………………………………………………………………………………………………………………………………………..2820
1.2 Assembly overview – sliding door roller guides…………………………………………………………………………………………………………………………2820
1.3 Removing and installing sliding door………………………………………………………………………………………………………………………………….2822
1.3.1 Removing……………………………………………………………………………………………………………………………………………………..2822
1.3.2 Installing……………………………………………………………………………………………………………………………………………………2823
1.4 Removing and installing lower roller guide…………………………………………………………………………………………………………………………….2824
1.4.1 Removing……………………………………………………………………………………………………………………………………………………..2824
1.4.2 Installing……………………………………………………………………………………………………………………………………………………2825
1.5 Removing and installing arrester……………………………………………………………………………………………………………………………………..2826
1.5.1 Removing……………………………………………………………………………………………………………………………………………………..2826
1.5.2 Installing……………………………………………………………………………………………………………………………………………………2827
1.6 Removing and installing hinge………………………………………………………………………………………………………………………………………..2828
1.6.1 Removing……………………………………………………………………………………………………………………………………………………..2828
1.6.2 Installing……………………………………………………………………………………………………………………………………………………2829
1.7 Removing and installing upper roller guide…………………………………………………………………………………………………………………………….2830
1.7.1 Removing……………………………………………………………………………………………………………………………………………………..2830
1.7.2 Installing……………………………………………………………………………………………………………………………………………………2831
1.8 Removing and installing door arrester and end plate for lower guide rail………………………………………………………………………………………………….2832
1.8.1 Removing……………………………………………………………………………………………………………………………………………………..2832
1.8.2 Installing……………………………………………………………………………………………………………………………………………………2833
1.9 Removing and installing locking pegs and catch plates…………………………………………………………………………………………………………………..2834
1.9.1 Assembly overview……………………………………………………………………………………………………………………………………………..2834
1.9.2 Removing……………………………………………………………………………………………………………………………………………………..2835
1.9.3 Installing……………………………………………………………………………………………………………………………………………………2836
1.10 Removing and installing striker pin………………………………………………………………………………………………………………………………….2837
1.11 Adjusting sliding door……………………………………………………………………………………………………………………………………………..2837
1.11.1 Tools……………………………………………………………………………………………………………………………………………………….2837
1.11.2 General notes on adjustment of the sliding door………………………………………………………………………………………………………………….2838
1.11.3 Adjusting sliding doors – overview……………………………………………………………………………………………………………………………..2838
1.11.4 Adjusting height……………………………………………………………………………………………………………………………………………..2840
1.11.5 Adjusting flushness…………………………………………………………………………………………………………………………………………..2841
1.11.6 Adjusting shut line…………………………………………………………………………………………………………………………………………..2843
1.11.7 Adjusting locking pegs………………………………………………………………………………………………………………………………………..2844
1.12 Assembly overview – sliding door locking and release components…………………………………………………………………………………………………………2845
1.13 Removing and installing covers………………………………………………………………………………………………………………………………………2846
1.13.1 Removing…………………………………………………………………………………………………………………………………………………….2846
1.13.2 Installing…………………………………………………………………………………………………………………………………………………..2847
1.14 Removing and installing door lock……………………………………………………………………………………………………………………………………2847
1.14.1 Removing…………………………………………………………………………………………………………………………………………………….2848
1.14.2 Installing…………………………………………………………………………………………………………………………………………………..2849
1.15 Interior opening mechanism………………………………………………………………………………………………………………………………………….2850
1.15.1 Removing…………………………………………………………………………………………………………………………………………………….2850
1.15.2 Installing…………………………………………………………………………………………………………………………………………………..2851
1.16 Removing and installing cap…………………………………………………………………………………………………………………………………………2852
1.16.1 Tools……………………………………………………………………………………………………………………………………………………….2852
1.16.2 Removing…………………………………………………………………………………………………………………………………………………….2852
1.16.3 Installing…………………………………………………………………………………………………………………………………………………..2854
1.17 Removing and installing door handle………………………………………………………………………………………………………………………………….2855
1.17.1 Removing…………………………………………………………………………………………………………………………………………………….2855
1.17.2 Installing…………………………………………………………………………………………………………………………………………………..2855
1.18 Removing and installing mounting bracket……………………………………………………………………………………………………………………………..2856
1.18.1 Removing…………………………………………………………………………………………………………………………………………………….2857
1.18.2 Installing…………………………………………………………………………………………………………………………………………………..2858
1.19 Removing and installing distributing mechanism………………………………………………………………………………………………………………………..2859
1.19.1 Removing…………………………………………………………………………………………………………………………………………………….2859
1.19.2 Installing…………………………………………………………………………………………………………………………………………………..2860
1.20 Upper guide rail…………………………………………………………………………………………………………………………………………………..2860
1.20.1 Assembly overview…………………………………………………………………………………………………………………………………………….2861
1.20.2 Removing…………………………………………………………………………………………………………………………………………………….2862
1.20.3 Installing…………………………………………………………………………………………………………………………………………………..2863
1.21 Centre guide rail………………………………………………………………………………………………………………………………………………….2863
1.21.1 Assembly overview…………………………………………………………………………………………………………………………………………….2864
1.21.2 Removing…………………………………………………………………………………………………………………………………………………….2865
1.21.3 Installing…………………………………………………………………………………………………………………………………………………..2866
1.21.4 Bolting sequence……………………………………………………………………………………………………………………………………………..2867
1.22 Removing and installing guide rail cover……………………………………………………………………………………………………………………………..2868
1.22.1 Removing…………………………………………………………………………………………………………………………………………………….2868
1.22.2 Installing…………………………………………………………………………………………………………………………………………………..2869
1.23 Removing and installing retaining strip for cover……………………………………………………………………………………………………………………..2870
1.23.1 List of tools………………………………………………………………………………………………………………………………………………..2870
1.23.2 Fitting notes………………………………………………………………………………………………………………………………………………..2870
1.23.3 Removing…………………………………………………………………………………………………………………………………………………….2871
1.23.4 Installing…………………………………………………………………………………………………………………………………………………..2872
1.24 Removing and installing protective strip……………………………………………………………………………………………………………………………..2873
1.24.1 List of tools………………………………………………………………………………………………………………………………………………..2873
1.24.2 Fitting notes………………………………………………………………………………………………………………………………………………..2873
1.24.3 Removing…………………………………………………………………………………………………………………………………………………….2873
1.24.4 Installing…………………………………………………………………………………………………………………………………………………..2875
1.25 Removing and installing door inner seals……………………………………………………………………………………………………………………………..2876
1.26 Removing and installing door seal……………………………………………………………………………………………………………………………………2877
1.27 Removing and installing sill panel seal………………………………………………………………………………………………………………………………2878
1.27.1 Assembly overview…………………………………………………………………………………………………………………………………………….2878
1.27.2 Removing…………………………………………………………………………………………………………………………………………………….2879
1.27.3 Installing…………………………………………………………………………………………………………………………………………………..2880
1.28 Assembly overview – insulation………………………………………………………………………………………………………………………………………2881
2 Electrically operated sliding door…………………………………………………………………………………………………………………………………………2882
2.1 Tools……………………………………………………………………………………………………………………………………………………………..2882
2.2 Assembly overview – sliding door roller guides…………………………………………………………………………………………………………………………2882
2.3 Removing and installing sliding door………………………………………………………………………………………………………………………………….2883
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..2884
2.3.2 Installing……………………………………………………………………………………………………………………………………………………2885
2.4 Removing and installing lower roller guide…………………………………………………………………………………………………………………………….2886
2.4.1 Removing……………………………………………………………………………………………………………………………………………………..2886
2.4.2 Installing……………………………………………………………………………………………………………………………………………………2887
2.5 Removing and installing hinge………………………………………………………………………………………………………………………………………..2888
2.5.1 Removing……………………………………………………………………………………………………………………………………………………..2888
2.5.2 Installing……………………………………………………………………………………………………………………………………………………2889
2.6 Removing and installing upper roller guide…………………………………………………………………………………………………………………………….2890
2.6.1 Removing……………………………………………………………………………………………………………………………………………………..2890
2.6.2 Installing……………………………………………………………………………………………………………………………………………………2891
2.7 Removing and installing door arrester…………………………………………………………………………………………………………………………………2892
2.7.1 Removing……………………………………………………………………………………………………………………………………………………..2892
2.7.2 Installing……………………………………………………………………………………………………………………………………………………2893
2.8 Removing and installing locking pegs and catch plates…………………………………………………………………………………………………………………..2894
2.8.1 Assembly overview……………………………………………………………………………………………………………………………………………..2894
2.8.2 Removing……………………………………………………………………………………………………………………………………………………..2895
2.8.3 Installing……………………………………………………………………………………………………………………………………………………2896
2.9 Removing and installing striker pin…………………………………………………………………………………………………………………………………..2897
2.10 Adjusting sliding door……………………………………………………………………………………………………………………………………………..2897
2.10.1 Tools……………………………………………………………………………………………………………………………………………………….2897
2.10.2 General notes on adjustment of the sliding door………………………………………………………………………………………………………………….2898
2.10.3 Adjusting sliding doors – overview……………………………………………………………………………………………………………………………..2899
2.10.4 Adjusting height……………………………………………………………………………………………………………………………………………..2900
2.10.5 Adjusting flushness…………………………………………………………………………………………………………………………………………..2901
2.10.6 Adjusting shut line…………………………………………………………………………………………………………………………………………..2903
2.10.7 Adjusting striker pin…………………………………………………………………………………………………………………………………………2905
2.10.8 Adjusting locking pegs………………………………………………………………………………………………………………………………………..2906
2.11 Assembly overview – sliding door locking and release components…………………………………………………………………………………………………………2907
2.12 Removing and installing cover……………………………………………………………………………………………………………………………………….2908
2.12.1 Removing…………………………………………………………………………………………………………………………………………………….2908
2.12.2 Installing…………………………………………………………………………………………………………………………………………………..2909
2.13 Removing and installing door lock……………………………………………………………………………………………………………………………………2909
2.13.1 Removing…………………………………………………………………………………………………………………………………………………….2910
2.13.2 Installing…………………………………………………………………………………………………………………………………………………..2911
2.14 Removing and installing power latching system…………………………………………………………………………………………………………………………2912
2.14.1 Removing…………………………………………………………………………………………………………………………………………………….2912
2.14.2 Installing…………………………………………………………………………………………………………………………………………………..2913
2.15 Removing and installing interior opening mechanism…………………………………………………………………………………………………………………….2914
2.15.1 Removing…………………………………………………………………………………………………………………………………………………….2914
2.15.2 Installing…………………………………………………………………………………………………………………………………………………..2915
2.16 Removing and installing cap…………………………………………………………………………………………………………………………………………2916
2.16.1 Tools……………………………………………………………………………………………………………………………………………………….2916
2.16.2 Removing…………………………………………………………………………………………………………………………………………………….2916
2.16.3 Installing…………………………………………………………………………………………………………………………………………………..2917
2.17 Removing and installing door handle………………………………………………………………………………………………………………………………….2919
2.17.1 Removing…………………………………………………………………………………………………………………………………………………….2919
2.17.2 Installing…………………………………………………………………………………………………………………………………………………..2919
2.18 Removing and installing mounting bracket……………………………………………………………………………………………………………………………..2920
2.18.1 Removing…………………………………………………………………………………………………………………………………………………….2921
2.18.2 Installing…………………………………………………………………………………………………………………………………………………..2922
2.19 Motor for electrically operated sliding door………………………………………………………………………………………………………………………….2923
2.19.1 Removing…………………………………………………………………………………………………………………………………………………….2923
2.19.2 Installing…………………………………………………………………………………………………………………………………………………..2924
2.20 Removing and installing sliding door control unit……………………………………………………………………………………………………………………..2925
2.21 Basic setting of the sliding door electronics…………………………………………………………………………………………………………………………2926
2.22 Customer service mode………………………………………………………………………………………………………………………………………………2926
2.23 Upper guide rail…………………………………………………………………………………………………………………………………………………..2927
2.23.1 Assembly overview…………………………………………………………………………………………………………………………………………….2927
2.23.2 Removing…………………………………………………………………………………………………………………………………………………….2929
2.23.3 Installing…………………………………………………………………………………………………………………………………………………..2930
2.24 Centre guide rail………………………………………………………………………………………………………………………………………………….2930
2.24.1 Assembly overview…………………………………………………………………………………………………………………………………………….2931
2.24.2 Removing…………………………………………………………………………………………………………………………………………………….2932
2.24.3 Installing…………………………………………………………………………………………………………………………………………………..2933
2.24.4 Bolting sequence……………………………………………………………………………………………………………………………………………..2934
2.25 Removing and installing guide rail cover……………………………………………………………………………………………………………………………..2935
2.25.1 Removing…………………………………………………………………………………………………………………………………………………….2935
2.25.2 Installing…………………………………………………………………………………………………………………………………………………..2936
2.26 Removing and installing retaining strip for cover……………………………………………………………………………………………………………………..2937
2.26.1 List of tools………………………………………………………………………………………………………………………………………………..2937
2.26.2 Fitting notes………………………………………………………………………………………………………………………………………………..2937
2.26.3 Removing…………………………………………………………………………………………………………………………………………………….2938
2.26.4 Installing…………………………………………………………………………………………………………………………………………………..2939
2.27 Removing and installing protective strip……………………………………………………………………………………………………………………………..2940
2.27.1 List of tools………………………………………………………………………………………………………………………………………………..2940
2.27.2 Fitting notes………………………………………………………………………………………………………………………………………………..2940
2.27.3 Removing…………………………………………………………………………………………………………………………………………………….2940
2.27.4 Installing…………………………………………………………………………………………………………………………………………………..2942
2.28 Removing and installing door inner seals……………………………………………………………………………………………………………………………..2943
2.29 Removing and installing door seal with sensor strip……………………………………………………………………………………………………………………2944
2.29.1 Assembly overview…………………………………………………………………………………………………………………………………………….2944
2.29.2 Removing…………………………………………………………………………………………………………………………………………………….2946
2.29.3 Installing…………………………………………………………………………………………………………………………………………………..2947
2.30 Removing and installing sill panel seal………………………………………………………………………………………………………………………………2947
2.30.1 Assembly overview…………………………………………………………………………………………………………………………………………….2948
2.30.2 Removing…………………………………………………………………………………………………………………………………………………….2949
2.30.3 Installing…………………………………………………………………………………………………………………………………………………..2950
2.31 Assembly overview – insulation………………………………………………………………………………………………………………………………………2951
60 – Sunroof………………………………………………………………………………………………………………………………………………………………….2952
1 Panorama sliding sunroof (Arvin-Meritor)……………………………………………………………………………………………………………………………………2952
1.1 Tools……………………………………………………………………………………………………………………………………………………………..2952
1.2 Function…………………………………………………………………………………………………………………………………………………………..2952
1.3 Basic setting, panoramic sliding sunroof………………………………………………………………………………………………………………………………2953
1.4 Assembly overview – panoramic sliding roof…………………………………………………………………………………………………………………………….2953
1.5 Removing and installing front glass panel……………………………………………………………………………………………………………………………..2955
1.5.1 Removing……………………………………………………………………………………………………………………………………………………..2955
1.5.2 Installing……………………………………………………………………………………………………………………………………………………2957
1.6 Removing and installing rear glass panel………………………………………………………………………………………………………………………………2959
1.6.1 Removing……………………………………………………………………………………………………………………………………………………..2959
1.6.2 Installing……………………………………………………………………………………………………………………………………………………2960
1.7 Adjusting height of front and rear glass panel…………………………………………………………………………………………………………………………2961
1.7.1 Checking height adjustment……………………………………………………………………………………………………………………………………..2961
1.7.2 Adjusting front glass panel…………………………………………………………………………………………………………………………………….2962
1.7.3 Adjusting rear glass panel……………………………………………………………………………………………………………………………………..2962
1.8 Renewing seals for rear glass panel…………………………………………………………………………………………………………………………………..2963
1.8.1 Removing exterior seal…………………………………………………………………………………………………………………………………………2963
1.8.2 Installing exterior seal……………………………………………………………………………………………………………………………………….2964
1.8.3 Removing interior seal…………………………………………………………………………………………………………………………………………2965
1.8.4 Installing interior seal……………………………………………………………………………………………………………………………………….2966
1.9 Removing and installing the exterior seal……………………………………………………………………………………………………………………………..2967
1.9.1 Removing exterior seal…………………………………………………………………………………………………………………………………………2967
1.9.2 Installing exterior seal……………………………………………………………………………………………………………………………………….2968
1.10 Removing and installing interior seal………………………………………………………………………………………………………………………………..2969
1.10.1 Removing interior seal………………………………………………………………………………………………………………………………………..2969
1.10.2 Installing interior seal………………………………………………………………………………………………………………………………………2970
1.11 Removing and installing wind deflector……………………………………………………………………………………………………………………………….2971
1.11.1 Removing…………………………………………………………………………………………………………………………………………………….2971
1.11.2 Installing…………………………………………………………………………………………………………………………………………………..2972
1.11.3 Removing and installing wind deflector bracket…………………………………………………………………………………………………………………..2973
1.12 Removing and installing preselector for glass panel and sun blind……………………………………………………………………………………………………….2974
1.13 Removing and installing sliding sunroof motor…………………………………………………………………………………………………………………………2975
1.13.1 Removing…………………………………………………………………………………………………………………………………………………….2975
1.13.2 Installing…………………………………………………………………………………………………………………………………………………..2976
1.14 Removing and installing sun blind motor………………………………………………………………………………………………………………………………2978
1.14.1 Removing…………………………………………………………………………………………………………………………………………………….2978
1.14.2 Installing…………………………………………………………………………………………………………………………………………………..2979
1.15 Removing and installing sun blind……………………………………………………………………………………………………………………………………2981
1.15.1 Removing…………………………………………………………………………………………………………………………………………………….2981
1.15.2 Installing…………………………………………………………………………………………………………………………………………………..2985
1.16 Assembly overview – assembly frame…………………………………………………………………………………………………………………………………..2991
1.17 Removing and installing sun blind Bowden cable………………………………………………………………………………………………………………………..2992
1.17.1 Removing…………………………………………………………………………………………………………………………………………………….2992
1.17.2 Installing…………………………………………………………………………………………………………………………………………………..2995
1.18 Removing and installing assembly frame……………………………………………………………………………………………………………………………….2996
1.18.1 Removing…………………………………………………………………………………………………………………………………………………….2996
1.18.2 Installing…………………………………………………………………………………………………………………………………………………..2997
1.19 Removing and installing rear part……………………………………………………………………………………………………………………………………2999
1.19.1 Removing…………………………………………………………………………………………………………………………………………………….2999
1.19.2 Installing…………………………………………………………………………………………………………………………………………………..3001
1.20 Removing and installing front motor plate…………………………………………………………………………………………………………………………….3003
1.20.1 Removing…………………………………………………………………………………………………………………………………………………….3003
1.20.2 Installing…………………………………………………………………………………………………………………………………………………..3005
1.21 Removing and installing tilting mechanism and front glass panel cable……………………………………………………………………………………………………3006
1.21.1 Removing…………………………………………………………………………………………………………………………………………………….3006
1.21.2 Installing…………………………………………………………………………………………………………………………………………………..3008
1.22 Maintenance and care……………………………………………………………………………………………………………………………………………….3010
1.23 Operating without current…………………………………………………………………………………………………………………………………………..3011
1.23.1 Glass panel………………………………………………………………………………………………………………………………………………….3011
1.23.2 Sun blind……………………………………………………………………………………………………………………………………………………3012
1.24 Cleaning water drain hoses………………………………………………………………………………………………………………………………………….3012
1.24.1 Tools……………………………………………………………………………………………………………………………………………………….3012
1.24.2 Front water drain hoses……………………………………………………………………………………………………………………………………….3013
1.24.3 Rear water drain hoses………………………………………………………………………………………………………………………………………..3014
63 – Bumpers………………………………………………………………………………………………………………………………………………………………….3015
1 Front bumper cover……………………………………………………………………………………………………………………………………………………….3015
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3015
1.2 Repairing front bumper cover…………………………………………………………………………………………………………………………………………3015
1.3 Installing brackets for parking aid system…………………………………………………………………………………………………………………………….3016
1.3.1 Tools………………………………………………………………………………………………………………………………………………………..3016
1.3.2 Materials…………………………………………………………………………………………………………………………………………………….3016
1.3.3 Installing brackets……………………………………………………………………………………………………………………………………………3016
1.3.4 Minimum curing period………………………………………………………………………………………………………………………………………….3020
1.4 Front bumper cover………………………………………………………………………………………………………………………………………………….3021
1.4.1 Assembly overview……………………………………………………………………………………………………………………………………………..3021
1.4.2 Removing……………………………………………………………………………………………………………………………………………………..3022
1.4.3 Installing……………………………………………………………………………………………………………………………………………………3023
1.5 Front bumper cover add-on parts………………………………………………………………………………………………………………………………………3024
1.6 Front bumper cover substructure parts…………………………………………………………………………………………………………………………………3025
1.7 Front bumper carrier………………………………………………………………………………………………………………………………………………..3026
1.7.1 Assembly overview……………………………………………………………………………………………………………………………………………..3026
1.8 Number plate carrier………………………………………………………………………………………………………………………………………………..3027
1.8.1 Assembly overview – number plate carrier…………………………………………………………………………………………………………………………3027
1.8.2 Removing number plate carrier…………………………………………………………………………………………………………………………………..3028
1.8.3 Installing number plate carrier…………………………………………………………………………………………………………………………………3029
2 Rear bumper cover………………………………………………………………………………………………………………………………………………………..3031
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3031
2.2 Repairing rear bumper cover………………………………………………………………………………………………………………………………………….3031
2.3 Installing brackets for parking aid system…………………………………………………………………………………………………………………………….3032
2.3.1 Tools………………………………………………………………………………………………………………………………………………………..3032
2.3.2 Materials…………………………………………………………………………………………………………………………………………………….3032
2.3.3 Installing brackets……………………………………………………………………………………………………………………………………………3032
2.3.4 Minimum curing period………………………………………………………………………………………………………………………………………….3036
2.4 Rear bumper cover…………………………………………………………………………………………………………………………………………………..3037
2.4.1 Assembly overview……………………………………………………………………………………………………………………………………………..3037
2.4.2 Removing……………………………………………………………………………………………………………………………………………………..3038
2.4.3 Installing……………………………………………………………………………………………………………………………………………………3039
2.5 Rear bumper cover add-on parts……………………………………………………………………………………………………………………………………….3040
2.6 Rear bumper cover substructure parts………………………………………………………………………………………………………………………………….3041
2.7 Rear bumper carrier…………………………………………………………………………………………………………………………………………………3042
3 Towing bracket…………………………………………………………………………………………………………………………………………………………..3043
3.1 Assembly overview – towing bracket……………………………………………………………………………………………………………………………………3043
3.1.1 Remove Bowden cable……………………………………………………………………………………………………………………………………………3044
3.1.2 Install Bowden cable…………………………………………………………………………………………………………………………………………..3045
64 – Glazing………………………………………………………………………………………………………………………………………………………………….3046
1 Flush bonded windows……………………………………………………………………………………………………………………………………………………..3046
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3046
1.2 Materials………………………………………………………………………………………………………………………………………………………….3048
1.3 Assembly overview – windscreen……………………………………………………………………………………………………………………………………….3048
1.4 Removing windscreen…………………………………………………………………………………………………………………………………………………3050
1.5 Installing windscreen……………………………………………………………………………………………………………………………………………….3052
1.6 Assembly overview – rear window………………………………………………………………………………………………………………………………………3052
1.7 Removing undamaged rear window……………………………………………………………………………………………………………………………………….3054
1.8 Removing broken rear window………………………………………………………………………………………………………………………………………….3055
1.9 Installing rear window………………………………………………………………………………………………………………………………………………3056
1.10 Assembly overview – rear side window…………………………………………………………………………………………………………………………………3056
1.11 Removing undamaged rear side window………………………………………………………………………………………………………………………………….3057
1.12 Removing broken rear side window…………………………………………………………………………………………………………………………………….3058
1.13 Installing rear side window…………………………………………………………………………………………………………………………………………3058
1.14 Assembly overview – front side window………………………………………………………………………………………………………………………………..3058
1.15 Removing undamaged front side window…………………………………………………………………………………………………………………………………3060
1.16 Removing broken front side window……………………………………………………………………………………………………………………………………3061
1.17 Installing front side window………………………………………………………………………………………………………………………………………..3061
1.18 Preparing old undamaged window for glazing……………………………………………………………………………………………………………………………3062
1.18.1 Cutting back adhesive bead…………………………………………………………………………………………………………………………………….3062
1.19 Preparing new window without precoating for glazing……………………………………………………………………………………………………………………3062
1.20 Preparing body flange for glazing……………………………………………………………………………………………………………………………………3063
1.21 Installation instructions…………………………………………………………………………………………………………………………………………..3065
1.21.1 Installation instructions for all windows……………………………………………………………………………………………………………………….3065
1.22 Minimum curing period………………………………………………………………………………………………………………………………………………3065
1.23 Touching up paint damage……………………………………………………………………………………………………………………………………………3066
1.24 Cleaning off excess adhesive sealing material…………………………………………………………………………………………………………………………3066
2 Front door window………………………………………………………………………………………………………………………………………………………..3067
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3067
2.2 Assembly overview – front door window…………………………………………………………………………………………………………………………………3068
2.3 Removing and installing door window…………………………………………………………………………………………………………………………………..3069
2.3.1 Removing……………………………………………………………………………………………………………………………………………………..3069
2.3.2 Installing……………………………………………………………………………………………………………………………………………………3071
2.4 Removing and installing window regulator motor…………………………………………………………………………………………………………………………3073
2.4.1 Removing……………………………………………………………………………………………………………………………………………………..3073
2.4.2 Installing……………………………………………………………………………………………………………………………………………………3074
2.5 Removing and installing window regulator………………………………………………………………………………………………………………………………3075
2.5.1 Removing window lifters………………………………………………………………………………………………………………………………………..3075
2.5.2 Installing window lifters………………………………………………………………………………………………………………………………………3076
2.6 Removing and installing window channel………………………………………………………………………………………………………………………………..3077
2.6.1 Removing window channel………………………………………………………………………………………………………………………………………..3077
2.6.2 Installing window channel………………………………………………………………………………………………………………………………………3079
2.7 Inner and outer window slot seals…………………………………………………………………………………………………………………………………….3080
3 Rear door window…………………………………………………………………………………………………………………………………………………………3081
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3081
3.2 Assembly overview – rear door window………………………………………………………………………………………………………………………………….3082
3.3 Removing and installing door window…………………………………………………………………………………………………………………………………..3083
3.3.1 Removing door window…………………………………………………………………………………………………………………………………………..3083
3.3.2 Installing door window…………………………………………………………………………………………………………………………………………3084
3.4 Removing and installing window regulator motor…………………………………………………………………………………………………………………………3085
3.4.1 Removing……………………………………………………………………………………………………………………………………………………..3085
3.4.2 Installing……………………………………………………………………………………………………………………………………………………3086
3.5 Removing and installing window regulator………………………………………………………………………………………………………………………………3087
3.5.1 Removing window lifters………………………………………………………………………………………………………………………………………..3087
3.5.2 Installing window lifters………………………………………………………………………………………………………………………………………3088
3.6 Removing and installing window channel………………………………………………………………………………………………………………………………..3090
3.6.1 Removing window channel………………………………………………………………………………………………………………………………………..3090
3.6.2 Installing window channel………………………………………………………………………………………………………………………………………3091
3.7 Inner and outer window slot seals…………………………………………………………………………………………………………………………………….3092
66 – Exterior equipment………………………………………………………………………………………………………………………………………………………..3093
1 Wheel housing liner………………………………………………………………………………………………………………………………………………………3093
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3093
1.2 Front wheel housing liner……………………………………………………………………………………………………………………………………………3093
1.2.1 Assembly overview……………………………………………………………………………………………………………………………………………..3093
1.2.2 Removing……………………………………………………………………………………………………………………………………………………..3095
1.2.3 Installing……………………………………………………………………………………………………………………………………………………3096
1.2.4 Screw tightening sequence………………………………………………………………………………………………………………………………………3097
1.3 Rear wheel housing liner…………………………………………………………………………………………………………………………………………….3097
1.3.1 Assembly overview……………………………………………………………………………………………………………………………………………..3098
1.3.2 Removing……………………………………………………………………………………………………………………………………………………..3099
1.3.3 Installing……………………………………………………………………………………………………………………………………………………3100
1.3.4 Screw tightening sequence………………………………………………………………………………………………………………………………………3101
1.4 Side member cover…………………………………………………………………………………………………………………………………………………..3102
2 Exterior mirror………………………………………………………………………………………………………………………………………………………….3103
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3103
2.2 Assembly overview – exterior mirror…………………………………………………………………………………………………………………………………..3103
2.3 Removing and installing mirror glass………………………………………………………………………………………………………………………………….3104
2.4 Removing and installing adjustment unit with motor……………………………………………………………………………………………………………………..3106
2.5 Removing and installing frame………………………………………………………………………………………………………………………………………..3107
2.6 Removing and installing mirror housing and assembly component……………………………………………………………………………………………………………3108
2.7 Removing and installing exterior mirror……………………………………………………………………………………………………………………………….3109
2.7.1 Removing……………………………………………………………………………………………………………………………………………………..3109
2.7.2 Installing……………………………………………………………………………………………………………………………………………………3110
3 Radiator grille………………………………………………………………………………………………………………………………………………………….3111
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3111
3.2 Assembly overview – radiator grille…………………………………………………………………………………………………………………………………..3111
3.3 Removing and installing radiator grille……………………………………………………………………………………………………………………………….3112
3.3.1 Removing……………………………………………………………………………………………………………………………………………………..3112
3.3.2 Installing……………………………………………………………………………………………………………………………………………………3113
3.4 Removing and installing emblem, vehicles ►06.15………………………………………………………………………………………………………………………..3114
3.4.1 Removing……………………………………………………………………………………………………………………………………………………..3114
3.4.2 Installing……………………………………………………………………………………………………………………………………………………3115
3.5 Removing and installing emblem, vehicles 07.15 ►……………………………………………………………………………………………………………………….3116
3.5.1 Removing……………………………………………………………………………………………………………………………………………………..3116
3.5.2 Installing……………………………………………………………………………………………………………………………………………………3117
4 Roof railing…………………………………………………………………………………………………………………………………………………………….3118
4.1 Tools……………………………………………………………………………………………………………………………………………………………..3118
4.2 Assembly overview – roof railing……………………………………………………………………………………………………………………………………..3118
4.3 Removing and installing roof railing………………………………………………………………………………………………………………………………….3119
4.3.1 Removing……………………………………………………………………………………………………………………………………………………..3119
4.3.2 Installing……………………………………………………………………………………………………………………………………………………3120
4.4 Removing and installing roof railing retaining bracket………………………………………………………………………………………………………………….3121
4.4.1 Removing retaining bracket……………………………………………………………………………………………………………………………………..3121
4.4.2 Installing retaining bracket……………………………………………………………………………………………………………………………………3122
4.4.3 Installing new retaining bracket………………………………………………………………………………………………………………………………..3124
5 Mouldings and trims………………………………………………………………………………………………………………………………………………………3125
5.1 Water deflector…………………………………………………………………………………………………………………………………………………….3125
5.1.1 Assembly overview……………………………………………………………………………………………………………………………………………..3125
5.1.2 Removing……………………………………………………………………………………………………………………………………………………..3126
5.1.3 Installing……………………………………………………………………………………………………………………………………………………3127
5.1.4 Retaining strip for water deflector……………………………………………………………………………………………………………………………..3128
5.2 Front and rear door covers…………………………………………………………………………………………………………………………………………..3129
5.2.1 Tools………………………………………………………………………………………………………………………………………………………..3129
5.2.2 Fitting notes…………………………………………………………………………………………………………………………………………………3129
5.2.3 Removing front door cover………………………………………………………………………………………………………………………………………3130
5.2.4 Installing front door cover…………………………………………………………………………………………………………………………………….3131
5.2.5 Removing rear door cover……………………………………………………………………………………………………………………………………….3132
5.2.6 Installing rear door cover……………………………………………………………………………………………………………………………………..3133
5.3 Front and rear door trim panel……………………………………………………………………………………………………………………………………….3134
5.3.1 Removing front door trim panel………………………………………………………………………………………………………………………………….3134
5.3.2 Installing front door trim panel………………………………………………………………………………………………………………………………..3135
5.3.3 Removing rear door trim panels………………………………………………………………………………………………………………………………….3136
5.3.4 Installing rear door trim panels………………………………………………………………………………………………………………………………..3137
5.4 Front and rear window channel trim strip………………………………………………………………………………………………………………………………3138
5.4.1 Removing and installing front window channel trim strip……………………………………………………………………………………………………………3138
5.4.2 Removing and installing rear window channel trim strip…………………………………………………………………………………………………………….3139
5.5 Front and rear window trim strip……………………………………………………………………………………………………………………………………..3140
5.5.1 Tools………………………………………………………………………………………………………………………………………………………..3140
5.5.2 Removing and installing front side window trim strip………………………………………………………………………………………………………………3140
5.5.3 Removing and installing rear side window trim strip……………………………………………………………………………………………………………….3142
6 Noise insulation…………………………………………………………………………………………………………………………………………………………3143
7 Lettering and emblems…………………………………………………………………………………………………………………………………………………….3144
7.1 Tools……………………………………………………………………………………………………………………………………………………………..3144
7.2 Fitting notes………………………………………………………………………………………………………………………………………………………3144
7.3 Removing and installing emblem on rear lid…………………………………………………………………………………………………………………………….3144
7.4 Rear lettering – dimensions………………………………………………………………………………………………………………………………………….3146
7.5 »STYLE« emblem on B-pillar…………………………………………………………………………………………………………………………………………..3147
8 Scuff protection film…………………………………………………………………………………………………………………………………………………….3148
8.1 Scuff protection film at front and rear……………………………………………………………………………………………………………………………….3148
8.1.1 Tools………………………………………………………………………………………………………………………………………………………..3148
8.1.2 Fitting notes…………………………………………………………………………………………………………………………………………………3148
8.1.3 Renewing scuff protection film………………………………………………………………………………………………………………………………….3149
Sharan2011-General_body_repairs__interior……………………………………………………………………………………………………………………………………………3151
68 – Interior equipment………………………………………………………………………………………………………………………………………………………..3157
1 Interior mirror………………………………………………………………………………………………………………………………………………………….3157
1.1 Removing and installing interior mirror, basic version………………………………………………………………………………………………………………….3157
1.1.1 Removing……………………………………………………………………………………………………………………………………………………..3157
1.1.2 Installing……………………………………………………………………………………………………………………………………………………3157
1.2 Bonding on retaining plate for interior mirror without rain sensor……………………………………………………………………………………………………….3158
1.2.1 Materials:……………………………………………………………………………………………………………………………………………………3158
1.3 Removing and installing interior mirror with rain and light sensor -G397-…………………………………………………………………………………………………3159
1.4 Removing and installing front camera for driver assist systems -R242-…………………………………………………………………………………………………….3159
1.5 Bonding retaining plate for interior mirror with rain and light sensor -G397-……………………………………………………………………………………………..3160
1.5.1 Preparing windscreen…………………………………………………………………………………………………………………………………………..3160
1.5.2 Preparing detached or new retaining plate………………………………………………………………………………………………………………………..3160
1.5.3 Bonding retaining plate………………………………………………………………………………………………………………………………………..3160
1.5.4 Cleaning and removing excessive adhesive…………………………………………………………………………………………………………………………3160
1.5.5 Installing rain sensor and mirror……………………………………………………………………………………………………………………………….3160
2 Compartments, covers and trims…………………………………………………………………………………………………………………………………………….3161
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3161
2.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3161
2.2 Removing and installing centre console………………………………………………………………………………………………………………………………..3161
2.3 Removing and installing centre console extension……………………………………………………………………………………………………………………….3164
2.4 Removing and installing centre armrest………………………………………………………………………………………………………………………………..3165
2.5 Removing and installing rear centre console trim……………………………………………………………………………………………………………………….3166
2.6 Removing and installing switch unit holder, centre console………………………………………………………………………………………………………………3167
2.7 Removing and installing cover for centre console……………………………………………………………………………………………………………………….3168
2.8 Removing and installing side panel trims for footwell…………………………………………………………………………………………………………………..3169
2.9 Removing and installing dash panel end trims…………………………………………………………………………………………………………………………..3170
2.10 Removing and installing trim for heating and air-conditioning control system……………………………………………………………………………………………..3170
2.11 Removing and installing trim strip with integrated warning light switch -E3-……………………………………………………………………………………………..3171
2.12 Removing and installing trim strip on driver’s side……………………………………………………………………………………………………………………3172
2.13 Removing and installing light switch -E1- trim………………………………………………………………………………………………………………………..3172
2.14 Removing and installing vent trim, dash panel…………………………………………………………………………………………………………………………3172
2.15 Removing and installing centre dash panel compartment………………………………………………………………………………………………………………….3174
2.16 Removing and installing steering column trim………………………………………………………………………………………………………………………….3175
2.17 Removing and installing footwell cover……………………………………………………………………………………………………………………………….3177
2.18 Removing and installing storage tray in middle of dash panel……………………………………………………………………………………………………………3178
2.19 Removing and installing spectacles holder in moulded headliner………………………………………………………………………………………………………….3179
2.20 Removing and installing glove compartment…………………………………………………………………………………………………………………………….3180
2.21 Removing and installing sun visor……………………………………………………………………………………………………………………………………3181
3 Grab handles…………………………………………………………………………………………………………………………………………………………….3183
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3183
3.2 Removing and installing roof grab handles……………………………………………………………………………………………………………………………..3183
3.3 Removing and installing roof grab handles for 2nd row of seats…………………………………………………………………………………………………………..3184
3.4 Removing and installing A-pillar grab handles………………………………………………………………………………………………………………………….3185
3.5 Removing and installing A-pillar grab handle brackets…………………………………………………………………………………………………………………..3185
4 Sill panel strips………………………………………………………………………………………………………………………………………………………..3186
4.1 Tools……………………………………………………………………………………………………………………………………………………………..3186
4.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3186
4.2 Removing and installing connecting piece between sill panel strip and luggage compartment trim………………………………………………………………………………3186
4.3 Removing and installing sill panel strips……………………………………………………………………………………………………………………………..3186
4.4 Removing and installing mounting of front sill panel strip………………………………………………………………………………………………………………3187
4.5 Removing and installing mounting of rear sill panel strip……………………………………………………………………………………………………………….3188
69 – Passenger protection………………………………………………………………………………………………………………………………………………………3189
1 Seat belts………………………………………………………………………………………………………………………………………………………………3189
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3189
1.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3189
1.2 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components)………………………………………………………….3190
1.3 Special instructions for belt tensioners………………………………………………………………………………………………………………………………3191
1.4 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)…………………………………………………………….3191
1.5 Removing and installing front seat belts………………………………………………………………………………………………………………………………3191
1.6 Removing and installing front belt height adjusters…………………………………………………………………………………………………………………….3193
1.7 Removing and installing front belt buckles…………………………………………………………………………………………………………………………….3194
1.8 Removing and installing seat belts for outer seats, 2nd row……………………………………………………………………………………………………………..3195
1.9 Removing and installing belt buckles for outer seats, 2nd row……………………………………………………………………………………………………………3196
1.10 Removing and installing seat belts for middle seat, 2nd row…………………………………………………………………………………………………………….3197
1.11 Removing and installing belt buckles for middle seat, 2nd row…………………………………………………………………………………………………………..3197
1.12 Removing and installing seat belts for 3rd row………………………………………………………………………………………………………………………..3198
1.13 Removing and installing belt buckles for 3rd row………………………………………………………………………………………………………………………3199
2 Airbag………………………………………………………………………………………………………………………………………………………………….3200
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3200
2.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3200
2.2 General safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components)………………………………………………………….3201
2.3 Special instructions for driver and front passenger airbag………………………………………………………………………………………………………………3202
2.4 Special instructions for curtain airbag modules………………………………………………………………………………………………………………………..3202
2.5 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)…………………………………………………………….3203
2.6 Renewing airbag units following an accident……………………………………………………………………………………………………………………………3203
2.6.1 Accident with airbag triggering…………………………………………………………………………………………………………………………………3203
2.6.2 Accident without airbag triggering………………………………………………………………………………………………………………………………3203
2.7 Removing and installing airbag control unit -J234-……………………………………………………………………………………………………………………..3204
2.8 Removing and installing airbag unit on driver side, Sharan 2011►…………………………………………………………………………………………………………3205
2.9 Removing and installing airbag unit on driver side, Sharan 2016►…………………………………………………………………………………………………………3208
2.10 Removing and installing front passenger airbag unit……………………………………………………………………………………………………………………3213
2.11 Removing and installing side airbags on driver and front passenger sides…………………………………………………………………………………………………3214
2.12 Removing and installing side airbag for 2nd row of seats……………………………………………………………………………………………………………….3216
2.13 Removing and installing knee airbag………………………………………………………………………………………………………………………………….3219
2.14 Removing and installing curtain airbag……………………………………………………………………………………………………………………………….3221
2.15 Removing and installing seat occupied sensor, front passenger side -G128-………………………………………………………………………………………………..3223
3 Crash sensors……………………………………………………………………………………………………………………………………………………………3227
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3227
3.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3227
3.2 Removing and installing crash sensor for front airbag -G190-…………………………………………………………………………………………………………….3227
3.3 Removing and installing side airbag crash sensor, driver side -G179-……………………………………………………………………………………………………..3228
3.4 Side airbag crash sensor, front passenger side -G180-…………………………………………………………………………………………………………………..3229
3.5 Removing and installing rear side-airbag crash sensor, driver side -G256-…………………………………………………………………………………………………3229
3.6 Removing and installing rear side-airbag crash sensor, front passenger side -G257-…………………………………………………………………………………………3230
70 – Trim, insulation………………………………………………………………………………………………………………………………………………………….3231
1 Dash panel………………………………………………………………………………………………………………………………………………………………3231
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3231
1.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3231
1.2 Removing and installing dash panel……………………………………………………………………………………………………………………………………3231
1.3 Removing and installing dash panel cross member………………………………………………………………………………………………………………………..3237
1.4 Removing and installing dash panel vents………………………………………………………………………………………………………………………………3240
2 Door trims………………………………………………………………………………………………………………………………………………………………3243
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3243
2.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3243
2.2 Removing and installing door trim at front…………………………………………………………………………………………………………………………….3243
2.3 Removing and installing cover for mirror triangle………………………………………………………………………………………………………………………3247
2.4 Removing and installing sliding door trim……………………………………………………………………………………………………………………………..3247
2.5 Removing and installing sunblind of sliding door……………………………………………………………………………………………………………………….3250
2.6 Repairing sunblind of sliding door……………………………………………………………………………………………………………………………………3251
3 Pillar trims…………………………………………………………………………………………………………………………………………………………….3253
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3253
3.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3253
3.2 Removing and installing upper A-pillar trims…………………………………………………………………………………………………………………………..3253
3.3 Removing and installing lower A-pillar trims…………………………………………………………………………………………………………………………..3254
3.4 Detaching and attaching upper B-pillar trims…………………………………………………………………………………………………………………………..3255
3.5 Removing and installing upper B-pillar trims…………………………………………………………………………………………………………………………..3256
3.6 Removing and installing lower B-pillar trims…………………………………………………………………………………………………………………………..3256
3.7 Releasing and securing C-pillar trims…………………………………………………………………………………………………………………………………3257
3.8 Removing and installing C-pillar trims………………………………………………………………………………………………………………………………..3257
3.9 Removing and installing D-pillar trims………………………………………………………………………………………………………………………………..3258
4 Rear lid trim……………………………………………………………………………………………………………………………………………………………3259
4.1 Tools……………………………………………………………………………………………………………………………………………………………..3259
4.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3259
4.2 Removing and installing rear lid trim…………………………………………………………………………………………………………………………………3259
4.3 Removing and installing window frame trims…………………………………………………………………………………………………………………………….3260
5 Luggage compartment trims…………………………………………………………………………………………………………………………………………………3263
5.1 Tools……………………………………………………………………………………………………………………………………………………………..3263
5.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items…………………………………………………………………………….3263
5.2 Removing and installing lock carrier cover…………………………………………………………………………………………………………………………….3263
5.3 Removing and installing side panel trims for luggage compartment…………………………………………………………………………………………………………3264
5.4 Removing and installing luggage compartment floor (5-seater)…………………………………………………………………………………………………………….3269
5.5 Removing and installing luggage compartment floor support (5-seater)……………………………………………………………………………………………………..3269
6 Roof trims………………………………………………………………………………………………………………………………………………………………3270
6.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items………………………………………………………………………………….3270
6.2 Removing and installing roof end strip………………………………………………………………………………………………………………………………..3271
6.3 Removing and installing moulded headliner……………………………………………………………………………………………………………………………..3271
6.4 Removing and installing insulation and roof reinforcements………………………………………………………………………………………………………………3274
72 – Seat frames………………………………………………………………………………………………………………………………………………………………3277
1 Front seats, general……………………………………………………………………………………………………………………………………………………..3277
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3277
1.2 Removing and installing seat…………………………………………………………………………………………………………………………………………3278
1.3 Removing and installing trim on tunnel side……………………………………………………………………………………………………………………………3281
1.4 Removing and installing backrest adjustment wheel………………………………………………………………………………………………………………………3282
1.5 Removing and installing drawer mounting……………………………………………………………………………………………………………………………….3283
1.6 Removing and installing heated front seats control unit -J774-…………………………………………………………………………………………………………..3284
1.7 Removing and installing lumbar adjustment lever………………………………………………………………………………………………………………………..3285
1.8 Removing and installing backrest folding table…………………………………………………………………………………………………………………………3286
1.9 Removing and installing head restraint………………………………………………………………………………………………………………………………..3286
1.10 Removing head restraint guides………………………………………………………………………………………………………………………………………3287
1.11 Removing and installing backrest…………………………………………………………………………………………………………………………………….3289
2 Front seats with manual height adjustment…………………………………………………………………………………………………………………………………..3292
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3292
2.2 Removing and installing trim on sill side……………………………………………………………………………………………………………………………..3293
2.3 Removing and installing trim bracket on sill side………………………………………………………………………………………………………………………3294
2.4 Removing and installing height adjustment lever………………………………………………………………………………………………………………………..3295
2.5 Removing and installing height adjustment element………………………………………………………………………………………………………………………3295
2.6 Removing and installing lumbar support (2-way, manual)………………………………………………………………………………………………………………….3296
3 Front passenger seat without height adjustment………………………………………………………………………………………………………………………………3298
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3298
3.2 Removing and installing trim on sill side……………………………………………………………………………………………………………………………..3299
4 Front passenger seat with through-loading aperture…………………………………………………………………………………………………………………………..3301
4.1 Removing and installing trim on sill side……………………………………………………………………………………………………………………………..3301
4.2 Removing and installing trim bracket on sill side………………………………………………………………………………………………………………………3303
4.3 Removing and installing height adjustment lever………………………………………………………………………………………………………………………..3304
4.4 Removing and installing height adjustment element………………………………………………………………………………………………………………………3304
4.5 Removing and installing lumbar support (2-way, manual)………………………………………………………………………………………………………………….3305
4.6 Removing and installing folding backrest release unit…………………………………………………………………………………………………………………..3306
5 Driver seat, electrically adjustable……………………………………………………………………………………………………………………………………….3308
5.1 Tools……………………………………………………………………………………………………………………………………………………………..3308
5.2 Removing and installing trim on sill side……………………………………………………………………………………………………………………………..3309
5.3 Removing and installing switches……………………………………………………………………………………………………………………………………..3309
5.4 Removing and installing trim bracket on sill side………………………………………………………………………………………………………………………3309
5.5 Removing and installing seat longitudinal adjustment……………………………………………………………………………………………………………………3310
5.6 Removing and installing backrest adjustment drive………………………………………………………………………………………………………………………3314
5.7 Removing and installing inclination adjustment drive……………………………………………………………………………………………………………………3316
5.8 Removing and installing height adjustment drive………………………………………………………………………………………………………………………..3318
5.9 Removing and installing lumbar support (4-way, electric)………………………………………………………………………………………………………………..3319
6 Seats, 2nd row…………………………………………………………………………………………………………………………………………………………..3321
6.1 Tools……………………………………………………………………………………………………………………………………………………………..3321
6.2 Removing and installing seat…………………………………………………………………………………………………………………………………………3322
6.3 Removing and installing front trim……………………………………………………………………………………………………………………………………3324
6.4 Removing and installing side trim…………………………………………………………………………………………………………………………………….3324
6.5 Removing and installing footwell trim…………………………………………………………………………………………………………………………………3324
6.6 Removing and installing operating levers for backrest adjustment and seat longitudinal adjustment……………………………………………………………………………3325
6.7 Removing and installing……………………………………………………………………………………………………………………………………………..3326
6.8 Removing and installing trim of backrest operating lever………………………………………………………………………………………………………………..3326
6.9 Removing and installing backrest cover panel…………………………………………………………………………………………………………………………..3326
6.10 Removing and installing Bowden cable for operating backrest…………………………………………………………………………………………………………….3327
7 Seats, 3rd row…………………………………………………………………………………………………………………………………………………………..3329
7.1 Tools……………………………………………………………………………………………………………………………………………………………..3329
7.2 Removing and installing seat…………………………………………………………………………………………………………………………………………3329
7.3 Removing and installing backrest mechanism trim………………………………………………………………………………………………………………………..3331
7.4 Removing and installing side seat frame trim…………………………………………………………………………………………………………………………..3332
7.5 Removing and installing seat frame stop buffer…………………………………………………………………………………………………………………………3333
7.6 Removing and installing backrest release loop………………………………………………………………………………………………………………………….3334
7.7 Removing and installing backrest……………………………………………………………………………………………………………………………………..3334
7.8 Removing and installing backrest cover panel…………………………………………………………………………………………………………………………..3335
7.9 Removing and installing seat cushions…………………………………………………………………………………………………………………………………3337
74 – Seat – padding, covers…………………………………………………………………………………………………………………………………………………….3339
1 Front seat covers and padding……………………………………………………………………………………………………………………………………………..3339
1.1 Tools……………………………………………………………………………………………………………………………………………………………..3339
1.2 Removing and installing front seat cushion cover and padding…………………………………………………………………………………………………………….3340
1.3 Removing and installing front seat backrest cover and padding……………………………………………………………………………………………………………3343
2 Second row seat covers and padding…………………………………………………………………………………………………………………………………………3347
2.1 Tools……………………………………………………………………………………………………………………………………………………………..3347
2.2 Removing and installing seat cushion cover and padding………………………………………………………………………………………………………………….3347
2.3 Removing and installing cover and padding for squab with integrated child seat…………………………………………………………………………………………….3348
2.4 Removing and installing push button with trim for adjusting mechanism of child seat………………………………………………………………………………………..3353
2.5 Removing and installing spacer for seat frame with integrated child seat………………………………………………………………………………………………….3354
2.6 Removing and installing backrest cover and padding……………………………………………………………………………………………………………………..3355
3 Third row seat covers and padding………………………………………………………………………………………………………………………………………….3358
3.1 Tools……………………………………………………………………………………………………………………………………………………………..3358
3.2 Removing and installing seat cushion cover and padding………………………………………………………………………………………………………………….3358
3.3 Removing and installing backrest cover and padding……………………………………………………………………………………………………………………..3359
Sharan2011-Heating__air_conditioning………………………………………………………………………………………………………………………………………………..3361
00 – Technical data……………………………………………………………………………………………………………………………………………………………3365
1 Notes on safety………………………………………………………………………………………………………………………………………………………….3365
1.1 Safety precautions when working on air conditioning systems……………………………………………………………………………………………………………..3365
1.2 Safety measures for when working on vehicles with a start-stop system…………………………………………………………………………………………………….3365
1.3 Safety precautions when working on cooling system………………………………………………………………………………………………………………………3365
2 General notes……………………………………………………………………………………………………………………………………………………………3367
2.1 Notes concerning odours in air conditioned vehicles…………………………………………………………………………………………………………………….3367
2.2 Notes for vehicles with start-stop system……………………………………………………………………………………………………………………………..3367
3 Repair notes…………………………………………………………………………………………………………………………………………………………….3368
3.1 Working on refrigerant circuit……………………………………………………………………………………………………………………………………….3368
3.2 Refrigerant circuit seals……………………………………………………………………………………………………………………………………………3368
3.3 Check cooling performance……………………………………………………………………………………………………………………………………………3369
4 Technical data…………………………………………………………………………………………………………………………………………………………..3370
4.1 Capacities for refrigerant R134a……………………………………………………………………………………………………………………………………..3370
4.2 Refrigerant oil…………………………………………………………………………………………………………………………………………………….3370
4.3 Oil distribution……………………………………………………………………………………………………………………………………………………3370
80 – Heating………………………………………………………………………………………………………………………………………………………………….3372
1 Heating…………………………………………………………………………………………………………………………………………………………………3372
87 – Air conditioning system……………………………………………………………………………………………………………………………………………………3373
1 Overview of fitting locations – air conditioning system………………………………………………………………………………………………………………………3373
1.1 Overview of fitting locations – components not located in passenger compartment……………………………………………………………………………………………3373
1.1.1 Overview of fitting locations – components located outside the passenger compartment, air conditioning system with electric/manual controls…………………………………3373
1.1.2 Fitting locations overview – components not located in passenger compartment, Climatronic……………………………………………………………………………..3375
1.2 Overview of fitting locations – components located in front section of passenger compartment………………………………………………………………………………..3378
1.2.1 Overview of fitting locations – components located in front section of passenger compartment, air conditioning system with electric/manual controls………………………….3378
1.2.2 Overview – components inside front passenger compartment, Climatronic……………………………………………………………………………………………….3380
1.3 Fittings locations overview – components located in rear section of passenger compartment…………………………………………………………………………………..3381
2 Refrigerant circuit………………………………………………………………………………………………………………………………………………………3382
2.1 System overview – refrigerant circuit…………………………………………………………………………………………………………………………………3382
2.2 Assembly overview – condenser………………………………………………………………………………………………………………………………………..3383
2.3 Removing and installing high-pressure sender -G65-……………………………………………………………………………………………………………………..3384
2.4 Removing and installing expansion valve……………………………………………………………………………………………………………………………….3385
2.4.1 Removing and installing front expansion valve…………………………………………………………………………………………………………………….3385
2.4.2 Removing and installing rear expansion valve……………………………………………………………………………………………………………………..3386
2.5 Removing and installing condenser…………………………………………………………………………………………………………………………………….3387
2.6 Removing and installing desiccant bag or cartridge……………………………………………………………………………………………………………………..3389
2.7 Removing and installing evacuating and charging valves on low and high-pressure side……………………………………………………………………………………….3393
3 Air conditioner compressor………………………………………………………………………………………………………………………………………………..3395
3.1 Assembly overview – drive unit of air conditioner compressor…………………………………………………………………………………………………………….3395
3.2 Assembly overview – belt pulley………………………………………………………………………………………………………………………………………3396
3.2.1 Assembly overview – Denso belt pulley……………………………………………………………………………………………………………………………3396
3.3 Removing air conditioner compressor from and installing on bracket……………………………………………………………………………………………………….3397
3.4 Removing and installing air conditioner compressor……………………………………………………………………………………………………………………..3398
3.5 Checking excess pressure relief valve on air conditioner compressor………………………………………………………………………………………………………3402
3.6 Removing and installing belt pulley…………………………………………………………………………………………………………………………………..3403
3.6.1 Removing and installing belt pulley – Denso………………………………………………………………………………………………………………………3403
4 Control motors…………………………………………………………………………………………………………………………………………………………..3405
4.1 Overview of fitting locations – front control motors……………………………………………………………………………………………………………………3405
4.1.1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls………………………………………………………….3405
4.1.2 Overview of fitting locations – front control motors, Climatronic…………………………………………………………………………………………………..3406
4.2 Removing and installing temperature flap control motor -V68-…………………………………………………………………………………………………………….3407
4.3 Removing and installing rear temperature flap control motor -V137-……………………………………………………………………………………………………….3408
4.4 Removing and installing air recirculation flap control motor -V113-………………………………………………………………………………………………………3409
4.5 Removing and installing defroster flap control motor -V107-……………………………………………………………………………………………………………..3409
4.6 Removing and installing left temperature flap control motor -V158-……………………………………………………………………………………………………….3410
4.7 Removing and installing right temperature flap control motor -V159-………………………………………………………………………………………………………3411
4.8 Removing and installing fresh air/recirculated air, air flow flap control motor -V425-……………………………………………………………………………………..3411
4.9 Removing and installing front air distribution flap control motor -V426-………………………………………………………………………………………………….3412
4.10 Removing and installing rear air distribution flap control motor -V427- with potentiometer for rear air distribution flap control motor -G643-…………………………………..3412
4.11 Removing and installing air distribution flap control motor -V428-………………………………………………………………………………………………………3413
5 Front heater and air conditioning unit……………………………………………………………………………………………………………………………………..3414
5.1 Removing and installing auxiliary air heater element -Z35-………………………………………………………………………………………………………………3414
5.2 Removing and installing heater and air conditioning unit………………………………………………………………………………………………………………..3415
5.3 Dismantling and assembling heater and air conditioning unit……………………………………………………………………………………………………………..3419
5.3.1 Dismantling and assembling heater and air conditioning unit, manually regulated air conditioning system…………………………………………………………………3419
5.3.2 Dismantling and assembling heater and air conditioning unit, Climatronic…………………………………………………………………………………………….3420
5.3.3 Dismantling and assembling evaporator housing…………………………………………………………………………………………………………………….3423
5.3.4 Removing and installing evaporator………………………………………………………………………………………………………………………………3423
5.4 Removing and installing dust and pollen filter…………………………………………………………………………………………………………………………3424
5.5 Removing and installing fresh air blower -V2-………………………………………………………………………………………………………………………….3425
5.6 Removing and installing heat exchanger………………………………………………………………………………………………………………………………..3426
5.7 Removing and installing evaporator temperature sensor -G308-…………………………………………………………………………………………………………….3429
5.8 Removing and installing condensate drain hose………………………………………………………………………………………………………………………….3429
5.9 Checking condensation drainage……………………………………………………………………………………………………………………………………….3430
5.10 Removing and installing fresh air blower series resistor with overheating fuse -N24-………………………………………………………………………………………3431
5.11 Removing and installing glove box cooling…………………………………………………………………………………………………………………………….3431
6 Rear heater and air conditioning unit………………………………………………………………………………………………………………………………………3433
6.1 Assembly overview – heater and air conditioning unit……………………………………………………………………………………………………………………3433
6.2 Removing and installing heater and air conditioning unit………………………………………………………………………………………………………………..3434
6.3 Dismantling and assembling heater and air conditioning unit……………………………………………………………………………………………………………..3437
6.4 Removing and installing rear fresh air blower -V80-…………………………………………………………………………………………………………………….3437
6.5 Removing and installing rear fresh air blower control unit -J391-………………………………………………………………………………………………………..3438
6.6 Removing and installing heat exchanger………………………………………………………………………………………………………………………………..3438
7 Air duct………………………………………………………………………………………………………………………………………………………………..3440
7.1 Removing and installing air ducts…………………………………………………………………………………………………………………………………….3440
7.1.1 Overview of air ducts………………………………………………………………………………………………………………………………………….3440
7.1.2 Removing and installing side vent air ducts………………………………………………………………………………………………………………………3441
7.1.3 Removing and installing centre vent air duct……………………………………………………………………………………………………………………..3441
7.1.4 Removing and installing rear air ducts…………………………………………………………………………………………………………………………..3441
7.1.5 Removing and installing footwell vent air ducts for 2nd row of seats………………………………………………………………………………………………..3442
7.1.6 Removing and installing footwell vent air ducts for 3rd row of seats………………………………………………………………………………………………..3444
7.1.7 Removing and installing air ducting from rear heater and air conditioning unit to moulded headliner…………………………………………………………………….3445
7.2 Removing and installing exhaust ventilation for passenger compartment…………………………………………………………………………………………………….3445
7.3 Checking exhaust ventilation for passenger compartment………………………………………………………………………………………………………………….3446
7.4 Removing and installing fresh air intake………………………………………………………………………………………………………………………………3446
7.5 Removing and installing vents………………………………………………………………………………………………………………………………………..3447
7.5.1 Removing and installing left or right side window vents……………………………………………………………………………………………………………3447
7.5.2 Removing and installing centre vent……………………………………………………………………………………………………………………………..3447
7.5.3 Removing and installing left and right side vents…………………………………………………………………………………………………………………3448
7.5.4 Removing and installing driver side footwell vents………………………………………………………………………………………………………………..3449
7.5.5 Removing and installing front passenger side footwell vents………………………………………………………………………………………………………..3450
7.5.6 Removing and installing long rear vent…………………………………………………………………………………………………………………………..3451
7.5.7 Removing and installing short rear vent………………………………………………………………………………………………………………………….3451
7.5.8 Removing and installing footwell vents for 3rd row of seats………………………………………………………………………………………………………..3452
8 Coolant circuit………………………………………………………………………………………………………………………………………………………….3454
8.1 Checking 2nd heat exchanger switch-off valve -N317-…………………………………………………………………………………………………………………….3454
8.2 Removing and installing 2nd heat exchanger switch-off valve -N317-……………………………………………………………………………………………………….3455
9 Operating and display unit………………………………………………………………………………………………………………………………………………..3458
9.1 Overview of operating and display unit………………………………………………………………………………………………………………………………..3458
9.1.1 Overview of operating and display unit, electrically/manually controlled air conditioning system, up to week 21/2011……………………………………………………..3458
9.1.2 Overview of control and display unit, air conditioning system with electric/manual controls, as of week 22/2011 to week 21/2012……………………………………………3460
9.1.3 Overview of control and display unit, air conditioning system with electric/manual controls, as of week 22/2012………………………………………………………….3461
9.1.4 Overview of operating and display unit, Climatronic up to week 21/2011………………………………………………………………………………………………3462
9.1.5 Overview of operating and display unit, Climatronic from week 22/2011 to week 21/2012…………………………………………………………………………………3465
9.1.6 Overview of operating and display unit, Climatronic from week 22/2012……………………………………………………………………………………………….3466
9.1.7 Overview of operating and display unit, rear……………………………………………………………………………………………………………………..3469
9.2 Removing and installing operating and display unit……………………………………………………………………………………………………………………..3469
9.2.1 Removing and installing operating and display unit, air conditioning system with electric/manual controls……………………………………………………………….3469
9.2.2 Removing and installing operating and display unit, Climatronic…………………………………………………………………………………………………….3470
9.2.3 Removing and installing operating and display unit, rear…………………………………………………………………………………………………………..3471
10 Other controlling and regulating components………………………………………………………………………………………………………………………………..3473
10.1 Removing and installing sunlight penetration photosensor -G107-…………………………………………………………………………………………………………3473
10.2 Working principles of air quality sensor -G238-……………………………………………………………………………………………………………………….3474
10.3 Removing and installing air quality sensor -G238-……………………………………………………………………………………………………………………..3475
10.4 Removing and installing ambient temperature sensor -G17-……………………………………………………………………………………………………………….3475
10.5 Removing and installing left vent temperature sender -G150-…………………………………………………………………………………………………………….3476
10.6 Removing and installing right vent temperature sender -G151-……………………………………………………………………………………………………………3476
10.7 Removing and installing left footwell vent temperature sender -G261-…………………………………………………………………………………………………….3477
10.8 Removing and installing right footwell vent temperature sender -G262-……………………………………………………………………………………………………3477
10.9 Removing and installing rear vent temperature sender -G174-…………………………………………………………………………………………………………….3478
Sharan2011-Maintenance…………………………………………………………………………………………………………………………………………………………….3479
1 Engine list…………………………………………………………………………………………………………………………………………………………………3483
2 Service work………………………………………………………………………………………………………………………………………………………………..3485
2.1 Information reference flexible or fixed service……………………………………………………………………………………………………………………………3485
2.1.1 Service identification…………………………………………………………………………………………………………………………………………….3485
2.1.2 Flexible service………………………………………………………………………………………………………………………………………………….3485
2.1.3 Fixed service…………………………………………………………………………………………………………………………………………………….3486
2.1.4 Service interval display…………………………………………………………………………………………………………………………………………..3486
2.2 Service tables for market group A………………………………………………………………………………………………………………………………………..3487
2.2.1 Service tables for market group A…………………………………………………………………………………………………………………………………..3487
2.3 Service tables for market group B and C…………………………………………………………………………………………………………………………………..3492
2.3.1 Delivery inspection……………………………………………………………………………………………………………………………………………….3493
2.3.2 Scopes of service…………………………………………………………………………………………………………………………………………………3494
2.3.3 Time or mileage dependent additional work up to model year ►2013……………………………………………………………………………………………………….3496
2.3.4 Time or mileage dependent additional work as of model year 2014►……………………………………………………………………………………………………….3497
3 General…………………………………………………………………………………………………………………………………………………………………….3499
3.1 Raising vehicle with lifting platform or trolley jack………………………………………………………………………………………………………………………3499
3.1.1 Safety instructions and work preparation:……………………………………………………………………………………………………………………………3499
3.1.2 Lifting points for lifting platform or trolley jack:………………………………………………………………………………………………………………….3500
3.2 Sticker……………………………………………………………………………………………………………………………………………………………….3500
3.2.1 Attaching “Your next service dates” sticker:…………………………………………………………………………………………………………………………3500
3.2.3 Entries in service schedule………………………………………………………………………………………………………………………………………..3501
3.3 Connecting vehicle diagnostic tester……………………………………………………………………………………………………………………………………..3502
3.4 Vehicle identification number……………………………………………………………………………………………………………………………………………3503
3.4.3 Interpretation of vehicle identification number:……………………………………………………………………………………………………………………..3503
3.5 Vehicle data sticker……………………………………………………………………………………………………………………………………………………3504
3.6 Countries with elevated sulphur content in diesel fuel……………………………………………………………………………………………………………………..3505
3.7 Allocation of countries to market groups………………………………………………………………………………………………………………………………….3505
3.8 Engine code and engine number……………………………………………………………………………………………………………………………………………3507
3.9 Severe operating conditions……………………………………………………………………………………………………………………………………………..3507
3.10 Countries with high levels of dust………………………………………………………………………………………………………………………………………3507
3.11 Type plate……………………………………………………………………………………………………………………………………………………………3508
4 Descriptions of work…………………………………………………………………………………………………………………………………………………………3509
4.1 Swivel joints, axle bearings, coupling rod bearings and anti-roll bar rubber mountings: Visual check for damage…………………………………………………………………..3511
4.2 Driving light assist and cornering light: Check function……………………………………………………………………………………………………………………3512
4.2.1 Checking driving light assist………………………………………………………………………………………………………………………………………3512
4.2.2 Checking cornering light (static cornering light)…………………………………………………………………………………………………………………….3513
4.3 Battery: Checking battery terminal clamps for secure seating………………………………………………………………………………………………………………..3513
4.4 Battery: checking using battery tester with printer VAS 6161………………………………………………………………………………………………………………..3516
4.5 Status of battery: Read – send diagnosis protocol via online………………………………………………………………………………………………………………..3516
4.6 Checking tyres: Condition, wear pattern, tyre pressure and tread depth……………………………………………………………………………………………………….3516
4.6.1 Checking condition of tyre…………………………………………………………………………………………………………………………………………3517
4.6.2 Checking wear pattern……………………………………………………………………………………………………………………………………………..3517
4.6.4 General notes…………………………………………………………………………………………………………………………………………………….3518
4.6.5 Tyre pressure: check, correct if necessary…………………………………………………………………………………………………………………………..3519
4.7 Front passenger front airbag: Check key switch and “On/Off function”…………………………………………………………………………………………………………3525
4.8 Brake system and shock absorbers: Perform visual check for leaks and damage…………………………………………………………………………………………………..3526
4.9 Brake and clutch system: Changing brake fluid……………………………………………………………………………………………………………………………..3526
4.9.1 Instructions for use and safety…………………………………………………………………………………………………………………………………….3527
4.9.2 Procedure, changing brake fluid…………………………………………………………………………………………………………………………………….3527
4.10 Brake fluid level (dependent upon lining/pad wear): Check………………………………………………………………………………………………………………….3531
4.10.1 Procedure, brake fluid level (dependent upon lining/pad wear): Check…………………………………………………………………………………………………..3531
4.11 Thickness of brake pads/linings and condition of brake discs, front and rear: Check…………………………………………………………………………………………..3532
4.11.1 Front disc brake pads: Checking thickness…………………………………………………………………………………………………………………………..3533
4.11.2 Rear disc brake pads: Checking thickness……………………………………………………………………………………………………………………………3533
4.11.3 Condition of brake discs: Check……………………………………………………………………………………………………………………………………3534
4.12 Diesel particulate filter: Check………………………………………………………………………………………………………………………………………..3534
4.13 Window regulators: Check positioning (open and close functions)…………………………………………………………………………………………………………….3535
4.14 Reading fault memory of all systems with vehicle diagnostic tester, correcting possible faults according to repair guidelines……………………………………………………..3535
4.15 Bonnet: lubricating arrester……………………………………………………………………………………………………………………………………………3536
4.16 Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage………………………………………………………………………………………………3536
4.17 Interior and exterior body: Performing visual check for corrosion when doors and flaps are open………………………………………………………………………………..3537
4.18 Poly V-belt: Check condition……………………………………………………………………………………………………………………………………………3537
4.19 Diesel fuel filter: renew………………………………………………………………………………………………………………………………………………3537
4.19.1 Diesel fuel filter: Replace……………………………………………………………………………………………………………………………………….3538
4.20 Cooling system: Check frost protection and coolant level…………………………………………………………………………………………………………………..3541
4.20.1 Checking frost protection, if necessary replenish coolant additive…………………………………………………………………………………………………….3541
4.20.2 Checking coolant level, replenish coolant if necessary……………………………………………………………………………………………………………….3542
4.20.3 Mixture ratio:…………………………………………………………………………………………………………………………………………………..3543
4.21 Air filter: clean housing and renew filter element………………………………………………………………………………………………………………………..3543
4.21.1 Removing and installing air filter element, 1.4 l TSI engines…………………………………………………………………………………………………………3544
4.21.2 Removing and installing air filter element………………………………………………………………………………………………………………………….3545
4.22 Multi-purpose additive for petrol fuels: add……………………………………………………………………………………………………………………………..3546
4.23 Engine oil level: Check………………………………………………………………………………………………………………………………………………..3547
4.24 Engine oil: Drain or extract; renew oil filter and replenish engine oil……………………………………………………………………………………………………..3548
4.24.1 Draining or extracting engine oil and renewing oil filter, 1.4 l TSI engines……………………………………………………………………………………………3549
4.24.2 Draining engine oil and renewing oil filter, 1.4 l TSI engines………………………………………………………………………………………………………..3551
4.24.3 Draining or extracting engine oil and renewing oil filter, 1.8 l TSI engines and 2.0 l TSI engines………………………………………………………………………..3554
4.24.4 Draining engine oil and renewing oil filter, 2.0 l TSI engines………………………………………………………………………………………………………..3556
4.24.5 Draining or extracting engine oil and renewing oil filter, common rail diesel engines……………………………………………………………………………………3559
4.24.6 Draining engine oil and renewing oil filter, common rail diesel engines………………………………………………………………………………………………..3562
4.24.7 Replenishing engine oil…………………………………………………………………………………………………………………………………………..3564
4.25 Engine oil: capacities and specifications………………………………………………………………………………………………………………………………..3564
4.26 Engine cover panel “top”: Removing and installing…………………………………………………………………………………………………………………………3565
4.26.1 Engine and designer cover -top-: Removing and installing, 1.4 l TSI engine……………………………………………………………………………………………..3565
4.26.2 Removing and installing engine cover panel, 2.0 l TSI engines…………………………………………………………………………………………………………3566
4.26.3 Removing and installing engine cover panel, common rail diesel engines…………………………………………………………………………………………………3567
4.27 Removing and installing engine cover panel -bottom- (noise insulation)………………………………………………………………………………………………………3567
4.28 Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage……………………………………………………………………3568
4.29 Panoramic tilting/sliding roof with rear panorama roof: Check function, clean guide rails and grease; clean wind deflector………………………………………………………..3568
4.29.1 Checking function, cleaning and greasing guide rails ………………………………………………………………………………………………………………..3569
4.29.2 Cleaning wind deflector…………………………………………………………………………………………………………………………………………..3571
4.30 Performing road test (driving behaviour, noises, air conditioner etc.)………………………………………………………………………………………………………3571
4.31 Wheel securing bolts: Tightening to specified torque………………………………………………………………………………………………………………………3572
4.32 Reducing agent (AdBlue®): Replenish……………………………………………………………………………………………………………………………………..3575
4.32.1 General…………………………………………………………………………………………………………………………………………………………3576
4.32.2 Health/endangerment and cleaning…………………………………………………………………………………………………………………………………..3578
4.32.3 Disposal instructions…………………………………………………………………………………………………………………………………………….3578
4.32.4 Work preparation for filling reducing agent tank…………………………………………………………………………………………………………………….3578
4.32.5 Filling reducing agent tank……………………………………………………………………………………………………………………………………….3579
4.32.6 Work after filling reducing agent tank……………………………………………………………………………………………………………………………..3579
4.33 Reducing agent (AdBlue®): Change………………………………………………………………………………………………………………………………………..3580
4.34 Reading radio code using vehicle diagnostic tester………………………………………………………………………………………………………………………..3580
4.35 Radio/navigation system: Enter PIN of anti-theft coding and store local radio stations to station buttons……………………………………………………………………….3580
4.36 Tyre pressure monitoring: Perform basic setting…………………………………………………………………………………………………………………………..3581
4.37 Checking tyre repair set……………………………………………………………………………………………………………………………………………….3582
4.38 Headlight adjustment: Checking halogen headlights…………………………………………………………………………………………………………………………3583
4.38.1 Test and adjustment conditions…………………………………………………………………………………………………………………………………….3583
4.38.2 Checking headlight adjustment (ECE)………………………………………………………………………………………………………………………………..3583
4.38.3 Checking headlight adjustment (SAE)………………………………………………………………………………………………………………………………..3584
4.38.4 Adjusting halogen headlights………………………………………………………………………………………………………………………………………3585
4.39 Headlight adjustment: Checking gas discharge headlights without DLA…………………………………………………………………………………………………………3586
4.39.1 Test and adjustment conditions…………………………………………………………………………………………………………………………………….3586
4.39.2 Checking headlight adjustment (ECE)………………………………………………………………………………………………………………………………..3587
4.39.3 Checking headlight adjustment (SAE)………………………………………………………………………………………………………………………………..3588
4.39.4 Gas discharge headlights without “Dynamic Light Assist” dynamic high beam regulation: adjusting…………………………………………………………………………..3589
4.40 Headlight adjustment: Checking gas discharge headlights with DLA……………………………………………………………………………………………………………3591
4.40.1 Checking and adjusting prerequisites:………………………………………………………………………………………………………………………………3591
4.40.2 Checking headlight adjustment (ECE)………………………………………………………………………………………………………………………………..3591
4.40.3 Checking headlight adjustment (SAE)………………………………………………………………………………………………………………………………..3593
4.40.4 Gas discharge headlights with “Dynamic Light Assist” dynamic main beam regulation: adjusting……………………………………………………………………………..3596
4.41 Headlight adjustment: Checking fog lights………………………………………………………………………………………………………………………………..3597
4.41.1 Test and adjustment conditions…………………………………………………………………………………………………………………………………….3597
4.41.2 Checking headlight adjustment……………………………………………………………………………………………………………………………………..3598
4.41.3 Adjusting fog lights and other additional lights…………………………………………………………………………………………………………………….3598
4.42 Sliding sunroof drains: Check not blocked, clean if necessary………………………………………………………………………………………………………………3599
4.43 Window wash/wipe system and headlight washer system: checking function, park position and for damage, if necessary refilling fluid…………………………………………………3599
4.43.1 Checking anti-freeze protection of fluid, topping up fluid……………………………………………………………………………………………………………3599
4.43.2 Window wash/wipe system: checking jet setting and adjusting if necessary……………………………………………………………………………………………….3601
4.43.3 Headlight washer system: Checking spray jet settings…………………………………………………………………………………………………………………3603
4.43.4 Windscreen wiper blades: Check park position………………………………………………………………………………………………………………………..3603
4.43.5 Rear window wiper blade: checking park position……………………………………………………………………………………………………………………..3603
4.44 Wiper blade protection: Remove………………………………………………………………………………………………………………………………………….3603
4.44.1 Removing wiper blade protection, version 1………………………………………………………………………………………………………………………….3604
4.44.2 Removing wiper blade protection, version 2………………………………………………………………………………………………………………………….3605
4.44.3 Renewing wiper blade protection, version 3 “transport wiper blade”…………………………………………………………………………………………………….3606
4.45 Service interval display: Reset…………………………………………………………………………………………………………………………………………3606
4.45.1 Resetting service interval display using vehicle diagnostic tester…………………………………………………………………………………………………….3607
4.45.2 Resetting service interval display without vehicle diagnostic tester…………………………………………………………………………………………………..3607
4.46 Service interval display: Recode………………………………………………………………………………………………………………………………………..3609
4.47 Track rod ends: Check clearance, security and boots……………………………………………………………………………………………………………………….3610
4.48 Auxiliary heater: Set weekday in menu of dash panel insert…………………………………………………………………………………………………………………3611
4.49 Dust and pollen filter: Clean housing and renew filter element……………………………………………………………………………………………………………..3612
4.50 Transportation mode: Switch off…………………………………………………………………………………………………………………………………………3612
4.51 Transportation devices: Remove blocking pieces from front axle springs………………………………………………………………………………………………………3613
4.52 Transport locks: Remove tie-down rings…………………………………………………………………………………………………………………………………..3614
4.53 Clock and date: Set to correct time……………………………………………………………………………………………………………………………………..3615
4.54 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of lines, plugs……………………………………………………………………………..3616
4.55 Camshaft drive toothed belt: Renew (diesel engines)……………………………………………………………………………………………………………………….3616
4.56 Camshaft drive toothed belt: Check………………………………………………………………………………………………………………………………………3616
4.56.1 Check condition of toothed belt……………………………………………………………………………………………………………………………………3617
4.57 Coolant pump toothed belt: check………………………………………………………………………………………………………………………………………..3617
4.58 Spark plugs: Renew…………………………………………………………………………………………………………………………………………………….3619
4.58.1 Renewing spark plugs, 1.4 l TSI engines…………………………………………………………………………………………………………………………….3621
4.58.2 Renewing spark plugs, 1.4 l TSI engines…………………………………………………………………………………………………………………………….3623
4.58.4 Renewing spark plugs, 2.0 l TSI engines…………………………………………………………………………………………………………………………….3628
4.59 6-speed dual clutch gearbox (DSG) 02E: Changing DSG transmission oil and filter………………………………………………………………………………………………3629
4.60 Haldex coupling: Change oil…………………………………………………………………………………………………………………………………………….3630
5 Exhaust emissions test……………………………………………………………………………………………………………………………………………………….3634
5.1 Exhaust emissions test for petrol engines…………………………………………………………………………………………………………………………………3634
5.2 Exhaust emissions test for diesel engines with OBD…………………………………………………………………………………………………………………………3642
6 Glossary……………………………………………………………………………………………………………………………………………………………………3653
Sharan2011-Propshaft_and_rear_final_drive……………………………………………………………………………………………………………………………………………3656
00 – Technical data……………………………………………………………………………………………………………………………………………………………3660
1 Safety instructions………………………………………………………………………………………………………………………………………………………3660
1.1 Safety precautions when using test and measuring equipment during a road test……………………………………………………………………………………………..3660
1.2 Safety precautions when working on vehicles with a Start/Stop system……………………………………………………………………………………………………..3661
2 Identification…………………………………………………………………………………………………………………………………………………………..3662
2.1 Identification of final drive………………………………………………………………………………………………………………………………………..3662
2.1.1 Final drive code 02D/0BS/0AY……………………………………………………………………………………………………………………………………3662
2.1.2 Identification, final drive 0CQ/0CR……………………………………………………………………………………………………………………………..3662
3 Repair instructions………………………………………………………………………………………………………………………………………………………3663
3.1 General repair notes………………………………………………………………………………………………………………………………………………..3663
3.1.1 Oil………………………………………………………………………………………………………………………………………………………….3663
3.1.2 Locking devices……………………………………………………………………………………………………………………………………………….3663
3.1.3 Bearing………………………………………………………………………………………………………………………………………………………3663
3.1.4 Shims………………………………………………………………………………………………………………………………………………………..3664
3.2 Seals and sealing rings……………………………………………………………………………………………………………………………………………..3664
3.3 Nuts and bolts……………………………………………………………………………………………………………………………………………………..3664
4 Technical data…………………………………………………………………………………………………………………………………………………………..3665
4.1 Allocation gearbox – engine………………………………………………………………………………………………………………………………………….3665
4.1.1 Allocation gearbox – engine, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ►………………………………………………………………………………………….3665
4.1.2 Allocation gearbox – engine, Golf 2013 ►, Golf Estate 2014 ►……………………………………………………………………………………………………….3665
4.1.3 Allocation gearbox – engine, Passat 2015 ►, Passat Estate 2015 ►……………………………………………………………………………………………………3665
4.1.4 Allocation gearbox – engine, Sharan 2016 ►……………………………………………………………………………………………………………………….3666
4.2 Capacities…………………………………………………………………………………………………………………………………………………………3666
4.2.1 Capacities, final drive 0BS…………………………………………………………………………………………………………………………………….3666
4.2.2 Capacities, final drive 0AY…………………………………………………………………………………………………………………………………….3667
4.2.3 Capacities, 0CQ final drive…………………………………………………………………………………………………………………………………….3667
4.2.4 Capacities, 0CR final drive…………………………………………………………………………………………………………………………………….3667
5 Electrical components…………………………………………………………………………………………………………………………………………………….3668
5.1 Overview of fitting locations – electrical components…………………………………………………………………………………………………………………..3668
5.1.1 Overview of fitting locations – electrical components, rear final drive “0BS” with Haldex clutch generation IV…………………………………………………………..3668
5.1.2 Fitting location overview – electrical components, rear final drive “0CQ/0CR/0AY” with Haldex coupling generation V………………………………………………………3669
39 – Final drive – rear differential…………………………………………………………………………………………………………………………………………….3670
1 Final drive……………………………………………………………………………………………………………………………………………………………..3670
1.1 Assembly overview – final drive………………………………………………………………………………………………………………………………………3670
1.2 Removing and installing final drive…………………………………………………………………………………………………………………………………..3671
1.2.1 Removing and installing final drive, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ►…………………………………………………………………………………..3671
1.2.2 Removing and installing final drive, Golf 2013 ►………………………………………………………………………………………………………………….3679
1.2.3 Removing and installing final drive, Golf Estate 2014 ►……………………………………………………………………………………………………………3686
1.2.4 Removing and installing final drive, Passat 2015 ►, Passat Variant 2015 ►……………………………………………………………………………………………3694
1.2.5 Removing and installing rear final drive, Sharan 2016 ►……………………………………………………………………………………………………………3701
2 Assembly mountings……………………………………………………………………………………………………………………………………………………….3705
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………..3705
2.1.1 Assembly overview – subframe, rear final drive 0BS, 0CR, 0AY……………………………………………………………………………………………………….3705
2.1.2 Assembly overview – assembly mounting, rear final drive 0CQ………………………………………………………………………………………………………..3706
2.2 Removing and installing bonded rubber mounting…………………………………………………………………………………………………………………………3707
2.2.1 Removing and installing bonded rubber bush, rear final drove 0BS, 0CR, 0AY…………………………………………………………………………………………..3707
2.2.2 Removing and installing bonded rubber mounting, rear final drove 0CQ………………………………………………………………………………………………..3709
3 Gear oil………………………………………………………………………………………………………………………………………………………………..3714
3.1 Checking gear oil level……………………………………………………………………………………………………………………………………………..3714
4 High-performance oil for Haldex coupling……………………………………………………………………………………………………………………………………3716
4.1 Checking oil level in Haldex coupling…………………………………………………………………………………………………………………………………3716
4.2 Draining and filling high performance oil for Haldex coupling……………………………………………………………………………………………………………3717
5 Oil seals……………………………………………………………………………………………………………………………………………………………….3720
5.1 Overview of fitting locations – seals…………………………………………………………………………………………………………………………………3720
5.2 Renewing right oil seal……………………………………………………………………………………………………………………………………………..3721
5.2.1 Renewing right oil seal, rear final drive 0BS…………………………………………………………………………………………………………………….3721
5.2.2 Renewing right oil seal, rear final drive 0CQ/0CR/0AY……………………………………………………………………………………………………………..3723
5.3 Renewing left oil seal………………………………………………………………………………………………………………………………………………3725
5.3.1 Renewing left oil seal, rear final drive 0BS……………………………………………………………………………………………………………………..3725
5.3.2 Renewing left oil seal, rear final drive 0CQ/0CR/0AY………………………………………………………………………………………………………………3728
5.4 Renewing seal for propshaft flange on rear final drive………………………………………………………………………………………………………………….3730
6 Haldex coupling………………………………………………………………………………………………………………………………………………………….3737
6.1 Testing operation…………………………………………………………………………………………………………………………………………………..3737
6.2 Assembly overview – Haldex coupling…………………………………………………………………………………………………………………………………..3737
6.2.1 Assembly overview – Haldex clutch, generation IV………………………………………………………………………………………………………………….3737
6.2.2 Assembly overview – Haldex clutch, generation V…………………………………………………………………………………………………………………..3740
6.3 Removing and installing Haldex coupling pump -V181-…………………………………………………………………………………………………………………….3741
6.3.1 Removing and installing Haldex coupling pump -V181-, generation IV………………………………………………………………………………………………….3741
6.3.2 Removing and installing Haldex coupling pump -V181-, generation V…………………………………………………………………………………………………..3743
6.4 Removing and installing Haldex coupling……………………………………………………………………………………………………………………………….3745
6.4.1 Removing and installing Haldex coupling, generation IV…………………………………………………………………………………………………………….3745
6.4.2 Removing and installing Haldex coupling, generation V……………………………………………………………………………………………………………..3750
6.5 Removing and installing all-wheel drive control unit -J492-……………………………………………………………………………………………………………..3755
6.5.1 Removing and installing all-wheel drive control unit -J492-, generation IV…………………………………………………………………………………………..3755
6.5.2 Removing and installing all-wheel drive control unit -J492-, generation V……………………………………………………………………………………………3758
7 Propshaft……………………………………………………………………………………………………………………………………………………………….3759
7.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..3759
7.1.1 Assembly overview – propshaft, CC 2012 ►, Passat 2011 ►, Passat Variant 2011 ►, Golf 2013 ►, Golf Variant 2014 ►, Passat 2015 ►, Passat Variant 2015 ►……………………….3759
7.1.2 Assembly overview – propshaft, Sharan 2016 ►……………………………………………………………………………………………………………………..3761
7.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….3762
7.2.1 Removing and installing propshaft, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ►…………………………………………………………………………………….3762
7.2.2 Removing and installing propshaft, Golf 2013 ►, Golf Estate 2014 ►………………………………………………………………………………………………….3766
7.2.3 Removing and installing propshaft, Passat 2015 ►, Passat Variant 2015 ►……………………………………………………………………………………………..3770
7.2.4 Removing and installing propshaft, Sharan 2016 ►………………………………………………………………………………………………………………….3775
7.3 Removing and installing front flexible coupling………………………………………………………………………………………………………………………..3779
7.4 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………3780
Sharan2011-Running_gear__axles__steering…………………………………………………………………………………………………………………………………………….3786
00 – Technical data……………………………………………………………………………………………………………………………………………………………3794
1 Checklist for evaluating running gear of accident vehicles……………………………………………………………………………………………………………………3794
2 General information………………………………………………………………………………………………………………………………………………………3796
40 – Front suspension………………………………………………………………………………………………………………………………………………………….3797
1 Evaluating accident vehicles………………………………………………………………………………………………………………………………………………3797
2 Raising wheel suspension to unladen position………………………………………………………………………………………………………………………………..3798
3 Overview – front axle…………………………………………………………………………………………………………………………………………………….3800
4 Assembly overview: subframe……………………………………………………………………………………………………………………………………………….3802
4.1 Assembly overview: front left vehicle level sender -G78-………………………………………………………………………………………………………………..3804
4.2 Removing and installing front left vehicle level sender -G78-……………………………………………………………………………………………………………3805
4.3 Repairing thread in longitudinal member……………………………………………………………………………………………………………………………….3806
4.4 Fixing position of subframe………………………………………………………………………………………………………………………………………….3806
4.5 Lowering subframe…………………………………………………………………………………………………………………………………………………..3808
4.6 Removing and installing subframe without steering box…………………………………………………………………………………………………………………..3812
4.7 Removing and installing subframe with steering box……………………………………………………………………………………………………………………..3816
4.8 Repairing subframe………………………………………………………………………………………………………………………………………………….3821
5 Assembly overview: front wheel suspension, suspension link……………………………………………………………………………………………………………………3830
5.1 Checking swivel joint……………………………………………………………………………………………………………………………………………….3831
5.2 Removing and installing swivel joint………………………………………………………………………………………………………………………………….3832
5.3 Removing and installing suspension link with mounting bracket……………………………………………………………………………………………………………3835
5.4 Removing and installing suspension link with mounting bracket (left side for vehicles with DSG or automatic gearboxes)…………………………………………………………3838
5.5 Renewing bonded rubber bush for suspension link………………………………………………………………………………………………………………………..3844
5.6 Renewing mounting bracket with suspension link bush…………………………………………………………………………………………………………………….3846
6 Assembly overview: wheel bearing…………………………………………………………………………………………………………………………………………..3849
6.1 Removing and installing wheel bearing unit…………………………………………………………………………………………………………………………….3851
6.2 Removing and installing wheel bearing housing………………………………………………………………………………………………………………………….3853
7 Assembly overview: anti-roll bar…………………………………………………………………………………………………………………………………………..3858
7.1 Removing and installing anti-roll bar…………………………………………………………………………………………………………………………………3858
8 Assembly overview: suspension strut………………………………………………………………………………………………………………………………………..3864
8.1 Removing and installing suspension strut………………………………………………………………………………………………………………………………3865
8.2 Repairing suspension strut…………………………………………………………………………………………………………………………………………..3871
9 Removing and installing drive shafts……………………………………………………………………………………………………………………………………….3874
9.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft………………………………………………………………………………………..3874
9.2 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft……………………………………………………………………………………..3875
9.3 Removing and installing drive shaft with constant velocity joint…………………………………………………………………………………………………………3877
9.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint……………………………………………………………………………………….3880
9.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint………………………………………………………………………………………3885
9.6 Removing and installing drive shafts with triple roller joint AAR3300i……………………………………………………………………………………………………3891
10 Repairing drive shaft – overview of drive shafts……………………………………………………………………………………………………………………………3896
10.1 Heat shield for drive shafts………………………………………………………………………………………………………………………………………..3897
11 Assembly overview: drive shaft with VL107 constant velocity joint…………………………………………………………………………………………………………….3898
11.1 Dismantling and assembling drive shaft with VL107 constant velocity joint………………………………………………………………………………………………..3900
11.2 Checking outer constant velocity joint……………………………………………………………………………………………………………………………….3903
11.3 Checking inner constant velocity joint……………………………………………………………………………………………………………………………….3904
12 Assembly overview: drive shaft with VL107 constant velocity slip joint………………………………………………………………………………………………………..3907
12.1 Dismantling and assembling drive shaft with VL107 constant velocity slip joint……………………………………………………………………………………………3909
12.2 Checking outer constant velocity joint……………………………………………………………………………………………………………………………….3912
13 Assembly overview: drive shaft with triple roller joint AAR3300i……………………………………………………………………………………………………………..3914
13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i…………………………………………………………………………………………………3916
42 – Rear suspension…………………………………………………………………………………………………………………………………………………………..3922
1 Evaluating accident vehicles………………………………………………………………………………………………………………………………………………3922
2 Rear axle in unladen position……………………………………………………………………………………………………………………………………………..3923
3 Overview – rear axle……………………………………………………………………………………………………………………………………………………..3925
4 Assembly overview: subframe (front-wheel drive)……………………………………………………………………………………………………………………………..3927
4.1 Fixing position of subframe………………………………………………………………………………………………………………………………………….3927
4.2 Lowering rear axle………………………………………………………………………………………………………………………………………………….3928
4.3 Removing and installing rear axle…………………………………………………………………………………………………………………………………….3930
4.4 Repairing subframe………………………………………………………………………………………………………………………………………………….3933
5 Assembly overview: transverse link, track rod (front-wheel drive)……………………………………………………………………………………………………………..3942
5.1 Assembly overview: rear left vehicle level sender -G76-, front-wheel drive………………………………………………………………………………………………..3944
5.2 Removing and installing rear left vehicle level sender -G76-…………………………………………………………………………………………………………….3944
5.3 Removing and installing upper transverse link………………………………………………………………………………………………………………………….3945
5.4 Removing and installing lower transverse link………………………………………………………………………………………………………………………….3947
5.5 Removing and installing track rod…………………………………………………………………………………………………………………………………….3949
6 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)……………………………………………………………………………………………………..3952
6.1 Removing and installing wheel bearing housing………………………………………………………………………………………………………………………….3953
6.2 Renewing bonded rubber bush for wheel bearing housing…………………………………………………………………………………………………………………..3956
6.3 Removing and installing wheel bearing unit…………………………………………………………………………………………………………………………….3959
6.4 Removing and installing trailing arm with mounting bracket………………………………………………………………………………………………………………3962
6.5 Repairing trailing arm………………………………………………………………………………………………………………………………………………3965
7 Assembly overview: shock absorber, coil spring (front-wheel drive)…………………………………………………………………………………………………………….3968
7.1 Converting to Nivomat……………………………………………………………………………………………………………………………………………….3969
7.2 Removing and installing coil spring…………………………………………………………………………………………………………………………………..3969
7.3 Removing and installing shock absorbers……………………………………………………………………………………………………………………………….3971
7.4 Repairing shock absorber…………………………………………………………………………………………………………………………………………….3973
8 Assembly overview: anti-roll bar (front-wheel drive)…………………………………………………………………………………………………………………………3975
8.1 Removing and installing anti-roll bar…………………………………………………………………………………………………………………………………3975
9 Rear axle in unladen position (four-wheel drive)…………………………………………………………………………………………………………………………….3978
10 Overview of rear axle (four-wheel drive)…………………………………………………………………………………………………………………………………..3980
11 Assembly overview: subframe, final drive (four-wheel drive)………………………………………………………………………………………………………………….3982
11.1 Fixing position of subframe…………………………………………………………………………………………………………………………………………3982
11.2 Lowering rear axle…………………………………………………………………………………………………………………………………………………3983
11.3 Removing and installing rear axle……………………………………………………………………………………………………………………………………3986
11.4 Repairing subframe…………………………………………………………………………………………………………………………………………………3991
12 Assembly overview: transverse link, track rod (four-wheel drive)……………………………………………………………………………………………………………..4000
12.1 Assembly overview: rear left vehicle level sender -G76-………………………………………………………………………………………………………………..4003
12.2 Removing and installing rear left vehicle level sender -G76-……………………………………………………………………………………………………………4003
12.3 Removing and installing upper transverse link…………………………………………………………………………………………………………………………4004
12.4 Removing and installing lower transverse link…………………………………………………………………………………………………………………………4006
12.5 Removing and installing track rod……………………………………………………………………………………………………………………………………4008
13 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)……………………………………………………………………………………………………..4012
13.1 Removing and installing wheel bearing housing…………………………………………………………………………………………………………………………4013
13.2 Renewing bonded rubber bush for wheel bearing housing………………………………………………………………………………………………………………….4016
13.3 Removing and installing wheel bearing unit……………………………………………………………………………………………………………………………4018
13.4 Removing and installing trailing arm with mounting bracket……………………………………………………………………………………………………………..4020
13.5 Repairing trailing arm……………………………………………………………………………………………………………………………………………..4023
14 Assembly overview: shock absorber, coil spring (four-wheel drive)…………………………………………………………………………………………………………….4027
14.1 Converting to Nivomat………………………………………………………………………………………………………………………………………………4028
14.2 Removing and installing coil spring………………………………………………………………………………………………………………………………….4028
14.3 Removing and installing shock absorbers………………………………………………………………………………………………………………………………4030
14.4 Repairing shock absorber……………………………………………………………………………………………………………………………………………4032
15 Assembly overview: anti-roll bar (four-wheel drive)…………………………………………………………………………………………………………………………4034
15.1 Removing and installing anti-roll bar………………………………………………………………………………………………………………………………..4034
16 Assembly overview: drive shaft……………………………………………………………………………………………………………………………………………4037
16.1 Loosening and tightening 12-point flange bolt securing drive shaft………………………………………………………………………………………………………4038
16.2 Removing and installing drive shaft………………………………………………………………………………………………………………………………….4039
16.3 Dismantling and assembling drive shaft……………………………………………………………………………………………………………………………….4042
16.4 Checking inner constant velocity joint……………………………………………………………………………………………………………………………….4045
43 – Self-levelling suspension………………………………………………………………………………………………………………………………………………….4048
1 Evaluating accident vehicles………………………………………………………………………………………………………………………………………………4048
2 Components of adaptive chassis control DCC and fitting locations………………………………………………………………………………………………………………4049
2.1 Shock absorber damping adjustment button -E387-………………………………………………………………………………………………………………………..4050
2.2 Removing and installing front left and right body acceleration senders -G341/G342-…………………………………………………………………………………………4050
2.3 Renewing bracket for front left/right body acceleration sender -G341/G342-………………………………………………………………………………………………..4051
2.4 Assembly overview: front left/right vehicle level sender -G78/G289- for adaptive chassis control DCC…………………………………………………………………………4053
2.5 Removing and installing front left/right vehicle level sender -G78/G289-………………………………………………………………………………………………….4054
2.6 Assembly overview: rear left vehicle level sender -G76- for adaptive chassis control DCC……………………………………………………………………………………4055
2.7 Removing and installing rear left vehicle level sender -G76- for adaptive chassis control DCC, front-wheel drive………………………………………………………………4056
2.8 Assembly overview: rear left vehicle level sender -G76- for adaptive chassis control DCC, four-wheel drive……………………………………………………………………4057
2.9 Removing and installing rear left vehicle level sender -G76- for adaptive chassis control DCC, four-wheel drive……………………………………………………………….4058
2.10 Removing and installing electronically controlled damping control unit -J250-…………………………………………………………………………………………….4059
2.11 Removing and installing retainer for electronically controlled damping control unit -J250-…………………………………………………………………………………4060
2.12 Basic setting of adaptive chassis control DCC…………………………………………………………………………………………………………………………4060
2.13 Cable routing left front axle……………………………………………………………………………………………………………………………………….4061
2.14 Cable routing right front axle………………………………………………………………………………………………………………………………………4062
2.15 Cable routing rear axle…………………………………………………………………………………………………………………………………………….4063
3 Assembly overview: suspension strut for adaptive chassis control DCC…………………………………………………………………………………………………………..4064
3.1 Removing and installing suspension strut for adaptive chassis control DCC…………………………………………………………………………………………………4066
4 Assembly overview: shock absorber for adaptive chassis control DCC…………………………………………………………………………………………………………….4075
4.1 Removing and installing rear body acceleration sender -G343-…………………………………………………………………………………………………………….4076
4.2 Removing and installing shock absorber for adaptive chassis control DCC…………………………………………………………………………………………………..4077
4.3 Repairing shock absorber for adaptive chassis control DCC……………………………………………………………………………………………………………….4079
5 Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive)……………………………………………………………………………………………4082
5.1 Removing and installing rear body acceleration sender -G343- (four-wheel drive)……………………………………………………………………………………………4083
5.2 Removing and installing shock absorber for adaptive chassis control DCC (four-wheel drive)………………………………………………………………………………….4084
5.3 Repairing shock absorber for adaptive chassis control DCC (four-wheel drive)………………………………………………………………………………………………4086
44 – Wheels, tyres, vehicle geometry…………………………………………………………………………………………………………………………………………….4089
1 Evaluating accident vehicles………………………………………………………………………………………………………………………………………………4089
2 Specified torque for fitting wheels………………………………………………………………………………………………………………………………………..4090
3 Fitting wheel and tyre……………………………………………………………………………………………………………………………………………………4091
3.1 General information…………………………………………………………………………………………………………………………………………………4091
3.2 Fittings instructions……………………………………………………………………………………………………………………………………………….4091
4 Removing and fitting tyres (wheels with tyre pressure monitoring)……………………………………………………………………………………………………………..4093
4.1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring)…………………………………………………………………………4093
4.2 Wheel change……………………………………………………………………………………………………………………………………………………….4093
4.3 Pressing tyre off wheel rim………………………………………………………………………………………………………………………………………….4094
4.4 Removing tyre from wheel…………………………………………………………………………………………………………………………………………….4095
4.5 Fitting tyre to wheel rim……………………………………………………………………………………………………………………………………………4095
5 Self-sealing tyres “ContiSeal”…………………………………………………………………………………………………………………………………………….4097
5.1 Explanation for mobility tyres……………………………………………………………………………………………………………………………………….4097
5.2 Handling mobility tyres……………………………………………………………………………………………………………………………………………..4098
6 Tyre monitor display……………………………………………………………………………………………………………………………………………………..4099
6.1 System fault in the ABS system……………………………………………………………………………………………………………………………………….4099
6.2 Perform basic setting……………………………………………………………………………………………………………………………………………….4100
7 Tyre pressure monitor (TPM)……………………………………………………………………………………………………………………………………………….4101
7.1 Button behaviour……………………………………………………………………………………………………………………………………………………4101
7.2 Assembly overview: tyre pressure sensor……………………………………………………………………………………………………………………………….4102
7.3 Removing and installing tyre pressure sensor…………………………………………………………………………………………………………………………..4103
8 Wheel alignment………………………………………………………………………………………………………………………………………………………….4104
8.1 General……………………………………………………………………………………………………………………………………………………………4104
8.2 Test prerequisites………………………………………………………………………………………………………………………………………………….4106
8.3 Test preparations…………………………………………………………………………………………………………………………………………………..4106
8.4 Wheel alignment specifications……………………………………………………………………………………………………………………………………….4107
8.5 Overview – wheel alignment procedure………………………………………………………………………………………………………………………………….4108
8.6 Correcting front axle camber…………………………………………………………………………………………………………………………………………4109
8.7 Adjusting camber on rear axle………………………………………………………………………………………………………………………………………..4111
8.8 Adjusting toe at rear axle…………………………………………………………………………………………………………………………………………..4112
8.9 Adjusting front axle toe…………………………………………………………………………………………………………………………………………….4113
8.10 Basic setting for steering angle sender -G85-…………………………………………………………………………………………………………………………4114
8.11 Vehicle data sticker……………………………………………………………………………………………………………………………………………….4114
9 Wheels, tyres……………………………………………………………………………………………………………………………………………………………4115
9.1 Models with breakdown set……………………………………………………………………………………………………………………………………………4115
9.2 Tyre sealant……………………………………………………………………………………………………………………………………………………….4115
9.3 Removing a tyre…………………………………………………………………………………………………………………………………………………….4115
9.4 Fitting a new tyre………………………………………………………………………………………………………………………………………………….4116
9.5 Tyre sealant disposal……………………………………………………………………………………………………………………………………………….4116
10 Instructions for changing or fitting wheels ……………………………………………………………………………………………………………………………….4117
10.1 Fitting wheels…………………………………………………………………………………………………………………………………………………….4118
11 Protecting wheel centring seat against corrosion……………………………………………………………………………………………………………………………4119
12 Rough running due to wheels/tyres – causes and rectification…………………………………………………………………………………………………………………4120
12.1 Causes of rough running…………………………………………………………………………………………………………………………………………….4120
12.2 Balancing wheels…………………………………………………………………………………………………………………………………………………..4120
12.3 Conducting a road test before balancing wheels………………………………………………………………………………………………………………………..4120
12.4 Balancing wheels on stationary wheel balancing machine…………………………………………………………………………………………………………………4121
12.5 Vibration control system -VAS 6230 A-………………………………………………………………………………………………………………………………..4124
12.6 Finish balancer……………………………………………………………………………………………………………………………………………………4124
12.7 Radial and lateral runout of wheels and tyres…………………………………………………………………………………………………………………………4125
12.8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V.A.G 1435-……………………………………………………………………………………….4125
12.9 Checking radial and lateral runout on wheel rim……………………………………………………………………………………………………………………….4126
12.10 Matching…………………………………………………………………………………………………………………………………………………………4127
12.11 Flat spots caused by storage or handling…………………………………………………………………………………………………………………………….4128
13 Adaptive cruise control………………………………………………………………………………………………………………………………………………….4130
13.1 Calibrating adaptive cruise control………………………………………………………………………………………………………………………………….4130
14 Front camera for driver assistance systems -R242-…………………………………………………………………………………………………………………………..4136
14.1 Adjusting the front camera for driver assistance system R242……………………………………………………………………………………………………………4136
48 – Steering…………………………………………………………………………………………………………………………………………………………………4144
1 Evaluating accident vehicles………………………………………………………………………………………………………………………………………………4144
2 General repair instructions……………………………………………………………………………………………………………………………………………….4145
2.1 Steering box……………………………………………………………………………………………………………………………………………………….4145
2.2 Gaskets and seals…………………………………………………………………………………………………………………………………………………..4145
2.3 Nuts and bolts……………………………………………………………………………………………………………………………………………………..4145
2.4 Electrical components……………………………………………………………………………………………………………………………………………….4146
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments………………………………………………………………………………………………………..4146
3 Assembly overview – airbag and steering wheel……………………………………………………………………………………………………………………………….4147
3.1 Removing and installing airbag and steering wheel………………………………………………………………………………………………………………………4147
4 Assembly overview: steering column, left-hand drive………………………………………………………………………………………………………………………….4150
4.1 Removing and installing steering column, left-hand drive vehicle…………………………………………………………………………………………………………4150
4.2 Handling and transporting steering column……………………………………………………………………………………………………………………………..4159
4.3 Checking steering column for damage…………………………………………………………………………………………………………………………………..4160
5 Assembly overview: steering column, right-hand drive…………………………………………………………………………………………………………………………4161
5.1 Removing and installing steering column, right-hand drive vehicle………………………………………………………………………………………………………..4161
5.2 Handling and transporting steering column……………………………………………………………………………………………………………………………..4169
5.3 Checking steering column for damage…………………………………………………………………………………………………………………………………..4170
6 Electromechanical steering box, LHD vehicle…………………………………………………………………………………………………………………………………4172
6.1 Assembly overview – electromechanical steering box for LHD vehicle……………………………………………………………………………………………………….4172
6.2 Removing and installing steering box, left-hand drive vehicle……………………………………………………………………………………………………………4173
7 Electromechanical steering box, RHD vehicle…………………………………………………………………………………………………………………………………4181
7.1 Assembly overview – electromechanical steering box for RHD vehicle……………………………………………………………………………………………………….4181
7.2 Removing and installing steering box, right-hand drive vehicle…………………………………………………………………………………………………………..4182
8 Repairing electromechanical steering box, LHD vehicle………………………………………………………………………………………………………………………..4189
8.1 Assembly overview: electromechanical steering box, LHD vehicle…………………………………………………………………………………………………………..4189
8.2 Renewing bonded rubber bushes for power-assisted steering box……………………………………………………………………………………………………………4190
8.3 Removing and installing track rod…………………………………………………………………………………………………………………………………….4192
8.4 Removing and installing track rod ball joint…………………………………………………………………………………………………………………………..4195
8.5 Removing and installing boot…………………………………………………………………………………………………………………………………………4197
8.6 Checking play, attachment and bellows of track rod ball joints…………………………………………………………………………………………………………..4200
8.7 Allocation of track rod ball joints…………………………………………………………………………………………………………………………………..4200
9 Repairing electromechanical steering box, RHD vehicle………………………………………………………………………………………………………………………..4201
9.1 Assembly overview: electromechanical steering box, RHD vehicle…………………………………………………………………………………………………………..4201
9.2 Removing and installing track rod…………………………………………………………………………………………………………………………………….4202
9.3 Removing and installing track rod ball joint…………………………………………………………………………………………………………………………..4205
9.4 Removing and installing boot…………………………………………………………………………………………………………………………………………4206
9.5 Checking play, attachment and bellows of track rod ball joints…………………………………………………………………………………………………………..4209
9.6 Allocation of track rod ball joints…………………………………………………………………………………………………………………………………..4209
Sharan2011-Wheels_and_Tyres_Guide…………………………………………………………………………………………………………………………………………………..4210
44 – Wheels, tyres, vehicle geometry…………………………………………………………………………………………………………………………………………….4214
1 General notes on using the “Wheels and Tyres Guide”………………………………………………………………………………………………………………………….4214
1.1 General……………………………………………………………………………………………………………………………………………………………4214
1.2 Explanations regarding world regions………………………………………………………………………………………………………………………………….4215
1.3 Definition of tyre package…………………………………………………………………………………………………………………………………………..4216
1.4 Procedure for determining the required tyre package…………………………………………………………………………………………………………………….4216
2 Notes on the vehicle registration certificate……………………………………………………………………………………………………………………………….4217
2.1 Vehicle registration certificate part 1……………………………………………………………………………………………………………………………….4217
2.2 Version key, D2…………………………………………………………………………………………………………………………………………………….4217
3 Wheel and tyre combinations without tyre package…………………………………………………………………………………………………………………………….4219
3.1 Sharan, Sharan 4Motion – from model year 2011 (Typ 7N)………………………………………………………………………………………………………………….4219
4 Wheel and tyre combinations depending on tyre packages……………………………………………………………………………………………………………………….4221
4.1 Type Approval No. (K): e1*2007/46*0401*10……………………………………………………………………………………………………………………………..4221
4.2 Type Approval No. (K): e1*2007/46*0401*11 to e1*2007/46*0401*12………………………………………………………………………………………………………….4222
4.3 Changing to other wheel and tyre combinations………………………………………………………………………………………………………………………….4224
5 Wheel allocation…………………………………………………………………………………………………………………………………………………………4225
5.1 6 1/2 J x 16……………………………………………………………………………………………………………………………………………………….4225
5.2 7 J x 17…………………………………………………………………………………………………………………………………………………………..4226
5.3 71/2 J x 18………………………………………………………………………………………………………………………………………………………..4228
6 Recommended summer tyres, worldwide except North America, China……………………………………………………………………………………………………………….4229
7 Recommended all-season tyres, worldwide except North America and China…………………………………………………………………………………………………………4230
8 Recommended winter tyres, worldwide except North America and China…………………………………………………………………………………………………………….4231
9 Recommended temporary spare tyres and wheels………………………………………………………………………………………………………………………………..4232
Sharan2011-Wheels_and_Tyres_Guide_-_General_Information……………………………………………………………………………………………………………………………….4233
44 – Wheels, tyres, vehicle geometry…………………………………………………………………………………………………………………………………………….4237
1 Specifications for converting wheel and tyre combinations…………………………………………………………………………………………………………………….4237
1.1 Legislative conditions………………………………………………………………………………………………………………………………………………4237
1.1.1 Permissible wheel and tyre combinations in Germany………………………………………………………………………………………………………………..4237
1.1.2 Vehicles with Tyre Pressure Monitoring System…………………………………………………………………………………………………………………….4238
1.2 Technical conditions………………………………………………………………………………………………………………………………………………..4238
1.3 Load-carrying capacity depending on vehicle speed, winter tyres………………………………………………………………………………………………………….4238
1.4 Vehicle registration documents since 01-10-2005………………………………………………………………………………………………………………………..4240
1.5 COC document (EEC Certificate of Conformity)…………………………………………………………………………………………………………………………..4241
1.6 EU general type approval number, sales type and sales or trade designation………………………………………………………………………………………………..4241
2 Handling problems………………………………………………………………………………………………………………………………………………………..4243
2.1 Rolling noise………………………………………………………………………………………………………………………………………………………4243
2.1.1 General notes on tyre noise…………………………………………………………………………………………………………………………………….4243
2.1.2 Flat spots (from locking wheels)………………………………………………………………………………………………………………………………..4244
2.2 Vehicle pulls to one side……………………………………………………………………………………………………………………………………………4245
2.2.1 General………………………………………………………………………………………………………………………………………………………4245
2.2.2 Conicity……………………………………………………………………………………………………………………………………………………..4245
2.2.3 Remedies when vehicle pulls to one side………………………………………………………………………………………………………………………….4246
2.2.4 Strategic rotation of wheels for non-directional tyres…………………………………………………………………………………………………………….4247
2.2.5 Strategic rotation of wheels having unidirectional tyres…………………………………………………………………………………………………………..4248
2.3 Vibration………………………………………………………………………………………………………………………………………………………….4249
2.3.1 Vibration, causes for vibration…………………………………………………………………………………………………………………………………4249
2.3.2 Vibration, conducting a road test before balancing wheels………………………………………………………………………………………………………….4249
2.3.3 Vibration, vibration control system……………………………………………………………………………………………………………………………..4250
2.4 Eliminating flat spots caused by storage or handling……………………………………………………………………………………………………………………4250
3 Evaluating tyres…………………………………………………………………………………………………………………………………………………………4252
3.1 Flat spots caused by storage or handling………………………………………………………………………………………………………………………………4252
3.2 Undulations………………………………………………………………………………………………………………………………………………………..4252
3.3 Saw-tooth wear……………………………………………………………………………………………………………………………………………………..4253
3.4 Flat spots caused by hard braking…………………………………………………………………………………………………………………………………….4253
3.5 Swellings in the tyre sidewall……………………………………………………………………………………………………………………………………….4253
3.6 Cuts………………………………………………………………………………………………………………………………………………………………4255
3.7 Damage caused by foreign bodies………………………………………………………………………………………………………………………………………4255
3.8 Stripped profile……………………………………………………………………………………………………………………………………………………4255
3.9 Tyre damage due to insufficient tyre pressure………………………………………………………………………………………………………………………….4256
3.10 Checking tyres…………………………………………………………………………………………………………………………………………………….4256
3.11 Damage caused when fitting………………………………………………………………………………………………………………………………………….4257
4 Tyre wear……………………………………………………………………………………………………………………………………………………………….4259
4.1 Factors influencing the service life of tyres………………………………………………………………………………………………………………………….4259
4.2 Saw-tooth wear……………………………………………………………………………………………………………………………………………………..4260
4.3 Wear behaviour of high-speed tyres……………………………………………………………………………………………………………………………………4260
4.4 Measuring tread depth……………………………………………………………………………………………………………………………………………….4261
4.5 One-sided wear……………………………………………………………………………………………………………………………………………………..4261
4.6 Outer shoulder wear…………………………………………………………………………………………………………………………………………………4264
4.7 Diagonal washout……………………………………………………………………………………………………………………………………………………4265
4.8 Wear in middle of tyre………………………………………………………………………………………………………………………………………………4265
4.9 Permissible deviation in tread depth………………………………………………………………………………………………………………………………….4266
5 Overview of components……………………………………………………………………………………………………………………………………………………4267
5.1 Assembly overview – wheel……………………………………………………………………………………………………………………………………………4267
5.1.1 Assembly overview – standard wheel………………………………………………………………………………………………………………………………4267
5.1.2 Assembly overview – wheel, PAX………………………………………………………………………………………………………………………………….4268
6 Fitting tyre…………………………………………………………………………………………………………………………………………………………….4270
6.1 Pressing tyre off wheel rim………………………………………………………………………………………………………………………………………….4270
6.2 Removing tyre sealant……………………………………………………………………………………………………………………………………………….4270
6.3 Removing tyre from wheel…………………………………………………………………………………………………………………………………………….4271
6.3.1 Removing tyres, wheels without and with tyre pressure monitoring……………………………………………………………………………………………………4271
6.3.2 Removing tyres, run-flat tyres, ultra-high-performance tyres……………………………………………………………………………………………………….4272
6.4 Ensuring proper assembly temperature for tyres…………………………………………………………………………………………………………………………4274
6.5 Mounting tyre………………………………………………………………………………………………………………………………………………………4274
6.5.1 Mounting tyre, wheels without and with tyre pressure monitoring…………………………………………………………………………………………………….4274
6.5.2 Mounting tyre, run-flat tyres, ultra-high performance tyres………………………………………………………………………………………………………..4276
6.6 Matching wheel rims and tyres………………………………………………………………………………………………………………………………………..4278
6.7 Balancing wheel…………………………………………………………………………………………………………………………………………………….4279
6.7.1 Balancing wheel, balancing wheel on stationary wheel balancer………………………………………………………………………………………………………4279
6.7.2 Balancing wheel, balancing wheel with finish balancer……………………………………………………………………………………………………………..4282
6.7.3 Balancing wheel, checking radial and lateral run-out of wheels and tyres…………………………………………………………………………………………….4283
6.7.4 Balancing wheel, checking radial and lateral run-out on wheel rim…………………………………………………………………………………………………..4284
7 Fitting wheels…………………………………………………………………………………………………………………………………………………………..4286
7.1 Fitting wheel………………………………………………………………………………………………………………………………………………………4286
7.1.1 Fitting wheel, fitting instructions for Volkswagen………………………………………………………………………………………………………………..4286
7.1.2 Fitting wheel, fitting instructions for Audi……………………………………………………………………………………………………………………..4290
7.1.3 Fitting wheel, position of anti-theft wheel bolts for steel wheels………………………………………………………………………………………………….4297
8 Information on tyres……………………………………………………………………………………………………………………………………………………..4298
8.1 Identification markings on the tyre sidewall…………………………………………………………………………………………………………………………..4298
8.1.1 Identification markings on the tyre sidewall, standard tyres……………………………………………………………………………………………………….4298
8.1.2 Identification markings on the tyre sidewall, tyres with run-flat system (PAX)……………………………………………………………………………………….4300
8.2 Tyre dimension……………………………………………………………………………………………………………………………………………………..4300
8.3 Load rating code/load index (LI)……………………………………………………………………………………………………………………………………..4300
8.4 Speed rating code…………………………………………………………………………………………………………………………………………………..4301
8.5 EU tyre label………………………………………………………………………………………………………………………………………………………4302
8.5.1 EU tyre label, summary…………………………………………………………………………………………………………………………………………4302
8.5.2 EU tyre label, objectives………………………………………………………………………………………………………………………………………4303
8.5.3 EU tyre label, categories………………………………………………………………………………………………………………………………………4304
8.6 Structure of a radial belted tyre…………………………………………………………………………………………………………………………………….4307
8.6.1 Cross section of a radial belted tyre……………………………………………………………………………………………………………………………4307
8.6.2 Run-flat tyres, structure and identification of a SST tyre…………………………………………………………………………………………………………4308
8.6.3 Run-flat tyres, seal inside technology…………………………………………………………………………………………………………………………..4309
8.6.4 Run-flat tyres, structure of a PAX tyre………………………………………………………………………………………………………………………….4311
8.7 Run-flat tyre, SST (Self Supporting Tyre)……………………………………………………………………………………………………………………………..4313
8.7.1 Run-flat tyres – general information…………………………………………………………………………………………………………………………….4313
8.7.2 Run-flat tyres, retrofitting/requirements when using run-flat tyres…………………………………………………………………………………………………4314
8.7.3 Run-flat tyres, repair work…………………………………………………………………………………………………………………………………….4315
8.8 Run-flat tyres, PAX…………………………………………………………………………………………………………………………………………………4315
8.8.1 Run-flat tyres, PAX, inflating tyre……………………………………………………………………………………………………………………………..4315
8.8.2 Run-flat tyres, PAX, wheel alignment…………………………………………………………………………………………………………………………….4316
8.8.3 Repairing run-flat tyres, PAX…………………………………………………………………………………………………………………………………..4316
8.8.4 Run-flat tyres, PAX, checking…………………………………………………………………………………………………………………………………..4316
8.9 Tyre storage……………………………………………………………………………………………………………………………………………………….4317
8.10 Reinforced and Extra Load (XL) tyres…………………………………………………………………………………………………………………………………4318
8.11 Winter tyres………………………………………………………………………………………………………………………………………………………4318
8.12 Winter tyres with speed symbol V…………………………………………………………………………………………………………………………………….4320
8.13 Rolling resistance optimised tyres…………………………………………………………………………………………………………………………………..4321
8.14 Tyre ageing……………………………………………………………………………………………………………………………………………………….4321
8.15 Tyres with flange protection………………………………………………………………………………………………………………………………………..4323
8.16 Tyre sizes for vehicles with four-wheel drive…………………………………………………………………………………………………………………………4323
8.17 Increase in temperature due to insufficient tyre pressure………………………………………………………………………………………………………………4324
9 Information on wheel rims…………………………………………………………………………………………………………………………………………………4325
9.1 Structure of wheel rim………………………………………………………………………………………………………………………………………………4325
9.2 Identification……………………………………………………………………………………………………………………………………………………..4326
9.3 Composite wheels……………………………………………………………………………………………………………………………………………………4326
9.4 Care and maintenance of alloy wheel rims………………………………………………………………………………………………………………………………4326
9.5 Restoring alloy wheels………………………………………………………………………………………………………………………………………………4327
9.6 Removing and installing hub cover for alloy wheels with open threaded connection…………………………………………………………………………………………..4327
9.7 Renewing trim elements………………………………………………………………………………………………………………………………………………4328
9.7.1 Renewing trim elements, bonded trim elements……………………………………………………………………………………………………………………..4328
9.7.2 Renewing trim elements, bolted trim elements……………………………………………………………………………………………………………………..4332
9.8 Removing and installing valve………………………………………………………………………………………………………………………………………..4334
9.8.1 Removing and installing valve, description of the valve……………………………………………………………………………………………………………4334
9.8.2 Removing and installing valve, rubber valve………………………………………………………………………………………………………………………4334
9.8.3 Removing and installing valve, metal valve……………………………………………………………………………………………………………………….4335
9.9 Run-flat tyre system PAX…………………………………………………………………………………………………………………………………………….4336
9.9.1 Run-flat tyre system PAX, support ring…………………………………………………………………………………………………………………………..4336
9.9.3 Run-flat tyre system PAX, checking support ring…………………………………………………………………………………………………………………..4337
10 Tyre Pressure Monitoring System…………………………………………………………………………………………………………………………………………..4339
10.1 Tyre pressure monitor display……………………………………………………………………………………………………………………………………….4339
10.2 Tyre Pressure Monitoring System……………………………………………………………………………………………………………………………………..4339
11 Tyre pressure sensor…………………………………………………………………………………………………………………………………………………….4340
11.1 Assembly overview – tyre pressure sensor……………………………………………………………………………………………………………………………..4340
11.1.1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve…………………………………………………………………………………………..4340
11.1.2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve………………………………………………………………………………………..4341
11.2 Removing and installing tyre pressure sensor………………………………………………………………………………………………………………………….4343
11.2.1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve……………………………………………………………………………………….4343
11.2.2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, customer service version……………………………………………………………..4344
11.2.3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, production version…………………………………………………………………..4345
11.2.4 Removing and installing tyre pressure sensor, metal valve body…………………………………………………………………………………………………….4347
11.2.6 Removing and installing tyre pressure sensor, Siemens tyre pressure monitoring system………………………………………………………………………………..4349
12 Tyre sealant……………………………………………………………………………………………………………………………………………………………4351
12.1 Tyre sealant, use-by date…………………………………………………………………………………………………………………………………………..4351
12.2 Tyre sealant, disposal……………………………………………………………………………………………………………………………………………..4351
13 Wheel bolts…………………………………………………………………………………………………………………………………………………………….4352
13.1 Wheel bolts, versions………………………………………………………………………………………………………………………………………………4352
13.2 Wheel bolts, anti-theft wheel bolt…………………………………………………………………………………………………………………………………..4353
13.3 Wheel bolts, adapter sets for anti-theft wheel bolts…………………………………………………………………………………………………………………..4353
14 Snow chains…………………………………………………………………………………………………………………………………………………………….4355
14.1 Assembly and use of snow chains……………………………………………………………………………………………………………………………………..4355
15 Temporary spare wheels…………………………………………………………………………………………………………………………………………………..4356
15.1 Notes on temporary spare wheels……………………………………………………………………………………………………………………………………..4356
Sharan2011-Wheels_and_Tyres_Guide_-_Standard…………………………………………………………………………………………………………………………………………4357
44 – Wheels, tyres, vehicle geometry…………………………………………………………………………………………………………………………………………….4365
1 General notes on wheels and tyres (passenger cars)…………………………………………………………………………………………………………………………..4365
2 Legislative and technical conditions for converting wheel and tyre combinations…………………………………………………………………………………………………4367
2.1 Legislative conditions for converting wheel and tyre combinations………………………………………………………………………………………………………..4367
2.2 Technical conditions for converting wheel and tyre combinations………………………………………………………………………………………………………….4367
2.3 Additional wheel housing extensions (flaps)……………………………………………………………………………………………………………………………4368
2.4 „Series 80“ tyres…………………………………………………………………………………………………………………………………………………..4368
3 Documents and codes/designations…………………………………………………………………………………………………………………………………………..4369
3.1 New vehicle registration documents since 01.10.2005…………………………………………………………………………………………………………………….4369
3.2 COC document (EEC Certificate of Conformity)…………………………………………………………………………………………………………………………..4370
3.3 EU general type approval number, sales type and sales or trade designation………………………………………………………………………………………………..4370
4 Useful information regarding tyres…………………………………………………………………………………………………………………………………………4372
4.1 Identification markings on the tyre sidewall…………………………………………………………………………………………………………………………..4372
4.2 Explanation of tyre markings…………………………………………………………………………………………………………………………………………4373
4.3 Speed ratings for tyres……………………………………………………………………………………………………………………………………………..4374
4.4 Undulations………………………………………………………………………………………………………………………………………………………..4375
4.5 Tyre storage……………………………………………………………………………………………………………………………………………………….4376
4.6 Tyre ageing………………………………………………………………………………………………………………………………………………………..4376
4.7 Tyre sizes for vehicles with four-wheel drive………………………………………………………………………………………………………………………….4378
4.8 Winter tyres……………………………………………………………………………………………………………………………………………………….4378
4.9 Winter tyres with speed symbol „V“……………………………………………………………………………………………………………………………………4379
4.10 Extra Load (XL) V winter tyres………………………………………………………………………………………………………………………………………4380
4.11 Maximum speeds for V and Extra Load (XL) winter tyres………………………………………………………………………………………………………………….4380
4.12 Reinforced and Extra Load (XL) tyres…………………………………………………………………………………………………………………………………4381
4.13 Snow chains……………………………………………………………………………………………………………………………………………………….4381
5 Tyre wear/ mileage for passenger car tyres………………………………………………………………………………………………………………………………….4383
5.1 General……………………………………………………………………………………………………………………………………………………………4383
5.2 Requirements to be met by tyres………………………………………………………………………………………………………………………………………4383
5.3 Wear behaviour of high-speed tyres……………………………………………………………………………………………………………………………………4384
5.4 Factors influencing the service life of a tyre…………………………………………………………………………………………………………………………4384
5.5 Driving style………………………………………………………………………………………………………………………………………………………4384
5.6 Tyre maintenance……………………………………………………………………………………………………………………………………………………4385
5.7 Evenly worn tyres…………………………………………………………………………………………………………………………………………………..4386
5.8 Measuring tread depth……………………………………………………………………………………………………………………………………………….4387
5.9 One-sided wear……………………………………………………………………………………………………………………………………………………..4387
5.10 Outer shoulder wear………………………………………………………………………………………………………………………………………………..4390
5.11 Wear in middle of tyre……………………………………………………………………………………………………………………………………………..4390
5.12 Diagonal washout…………………………………………………………………………………………………………………………………………………..4392
6 Tyre noise………………………………………………………………………………………………………………………………………………………………4393
6.1 General notes on tyre noise………………………………………………………………………………………………………………………………………….4393
6.2 Saw-tooth wear……………………………………………………………………………………………………………………………………………………..4393
6.3 Flat spots (from locking wheels)……………………………………………………………………………………………………………………………………..4394
7 Vehicle pulls to one side…………………………………………………………………………………………………………………………………………………4396
7.1 General……………………………………………………………………………………………………………………………………………………………4396
7.2 Conicity…………………………………………………………………………………………………………………………………………………………..4396
7.3 Remedies when vehicle pulls to one side……………………………………………………………………………………………………………………………….4397
7.4 Strategic rotation of wheels for non-directional tyres………………………………………………………………………………………………………………….4398
7.5 Strategic rotation of wheels having unidirectional tyres………………………………………………………………………………………………………………..4399
8 Tyre damage……………………………………………………………………………………………………………………………………………………………..4401
8.1 General information…………………………………………………………………………………………………………………………………………………4401
8.2 Construction of a radial belted tyre………………………………………………………………………………………………………………………………….4402
8.3 Impact damage………………………………………………………………………………………………………………………………………………………4402
8.4 Cuts………………………………………………………………………………………………………………………………………………………………4404
8.5 Damage caused by foreign bodies………………………………………………………………………………………………………………………………………4404
8.6 Loss of air from tyre……………………………………………………………………………………………………………………………………………….4404
8.7 Tyre pressure………………………………………………………………………………………………………………………………………………………4404
8.8 Tyre damage due to insufficient tyre pressure………………………………………………………………………………………………………………………….4405
8.9 Rising tyre temperature caused by insufficient inflation pressure………………………………………………………………………………………………………..4406
8.10 Tyre damage due to fitting error (fitting damage)……………………………………………………………………………………………………………………..4407
9 Tyres with run-flat properties…………………………………………………………………………………………………………………………………………….4409
9.1 General……………………………………………………………………………………………………………………………………………………………4409
9.2 Design and identification……………………………………………………………………………………………………………………………………………4410
9.3 Retrofitting/requirements when using run-flat tyres…………………………………………………………………………………………………………………….4410
9.4 Repairs……………………………………………………………………………………………………………………………………………………………4411
10 Rolling resistance optimised tyres………………………………………………………………………………………………………………………………………..4412
11 Facts about disc-type wheels (passenger cars)………………………………………………………………………………………………………………………………4413
11.1 Design of disc-type wheel…………………………………………………………………………………………………………………………………………..4413
11.2 Data on wheel rims…………………………………………………………………………………………………………………………………………………4413
11.3 Wheel rims – pitch circle diameter…………………………………………………………………………………………………………………………………..4414
11.4 Split rim composite wheels………………………………………………………………………………………………………………………………………….4414
11.5 Alloy wheels with exchangeable trim elements………………………………………………………………………………………………………………………….4414
11.6 Alloy wheels with exchangeable trim elements (Zaragoza)………………………………………………………………………………………………………………..4415
11.6.1 Tools……………………………………………………………………………………………………………………………………………………….4415
11.6.2 Materials……………………………………………………………………………………………………………………………………………………4416
11.6.3 Installing trim element……………………………………………………………………………………………………………………………………….4416
11.6.4 Removing trim element…………………………………………………………………………………………………………………………………………4418
11.7 Care and maintenance of alloy wheel rims……………………………………………………………………………………………………………………………..4419
11.8 Restoring alloy wheels……………………………………………………………………………………………………………………………………………..4419
11.9 The valve…………………………………………………………………………………………………………………………………………………………4421
12 Notes on use of temporary spare wheels…………………………………………………………………………………………………………………………………….4422
13 Fox from model year 2006…………………………………………………………………………………………………………………………………………………4423
13.1 Fox, type 5Z model year 2006 to model year 2012……………………………………………………………………………………………………………………….4423
13.2 Wheel allocation for Fox, type 5Z model year 2006 to model year 2012…………………………………………………………………………………………………….4424
13.2.1 5 J x 14…………………………………………………………………………………………………………………………………………………….4425
13.2.2 6 J x 14…………………………………………………………………………………………………………………………………………………….4425
13.2.3 6 J x 15…………………………………………………………………………………………………………………………………………………….4427
14 up! from model year 2012…………………………………………………………………………………………………………………………………………………4430
14.1 Advance information about up! Model year 2012…………………………………………………………………………………………………………………………4430
15 Polo from model year 2010………………………………………………………………………………………………………………………………………………..4431
15.1 Polo, type 6R model year 2010 to model year 2012………………………………………………………………………………………………………………………4431
15.2 Wheel allocation for Polo, type 6R model year 2010 to model year 2012……………………………………………………………………………………………………4433
15.2.1 5 J x 14…………………………………………………………………………………………………………………………………………………….4433
15.2.2 6 J x 15 offset 38……………………………………………………………………………………………………………………………………………4434
15.2.3 6 J x 15 offset 40……………………………………………………………………………………………………………………………………………4434
15.2.4 7 J x 16…………………………………………………………………………………………………………………………………………………….4435
15.2.5 7 J x 17…………………………………………………………………………………………………………………………………………………….4436
16 Polo BlueMotion from model year 2010………………………………………………………………………………………………………………………………………4437
16.1 Polo BlueMotion, type 6R model year 2010 to model year 2012…………………………………………………………………………………………………………….4437
16.2 Wheel allocation for Polo BlueMotion, type 6R model year 2010 to model year 2012………………………………………………………………………………………….4438
16.2.1 51/2 J x 15………………………………………………………………………………………………………………………………………………….4438
16.2.2 6 J x 15 offset 38……………………………………………………………………………………………………………………………………………4439
16.2.3 6 J x 15 offset 40……………………………………………………………………………………………………………………………………………4439
17 CrossPolo from model year 2011……………………………………………………………………………………………………………………………………………4441
17.1 CrossPolo, type 6R model year 2011 to model year 2012………………………………………………………………………………………………………………….4441
17.2 Wheel allocation CrossPolo, type 6R model year 2011 to model year 2012…………………………………………………………………………………………………..4443
17.2.1 5 J x 14…………………………………………………………………………………………………………………………………………………….4443
17.2.2 6 J x 15 offset 38……………………………………………………………………………………………………………………………………………4444
17.2.3 6 J x 15 offset 40……………………………………………………………………………………………………………………………………………4444
17.2.4 7 J x 16…………………………………………………………………………………………………………………………………………………….4445
17.2.5 7 J x 17…………………………………………………………………………………………………………………………………………………….4446
17.2.6 71/2 J x 17………………………………………………………………………………………………………………………………………………….4447
18 Polo GTI from model year 2011…………………………………………………………………………………………………………………………………………….4448
18.1 Polo GTI, type 6R model year 2011 to model year 2012…………………………………………………………………………………………………………………..4448
18.2 Wheel allocation Polo GTI, type 6R model year 2011 to model year 2012……………………………………………………………………………………………………4449
18.2.1 6 J x 15 offset 38……………………………………………………………………………………………………………………………………………4449
18.2.2 6 J x 15 offset 40……………………………………………………………………………………………………………………………………………4449
18.2.3 7 J x 16…………………………………………………………………………………………………………………………………………………….4450
18.2.4 7 J x 17…………………………………………………………………………………………………………………………………………………….4451
19 Golf from model year 2009………………………………………………………………………………………………………………………………………………..4452
19.1 Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012…………………………………………………………………………………………………….4452
19.2 Wheel allocation for Golf, Golf 4Motion, sales type 5K model year 2009 to model year 2012………………………………………………………………………………….4456
19.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4456
19.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4457
19.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4458
19.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4459
19.2.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4464
19.2.6 7 J x 17…………………………………………………………………………………………………………………………………………………….4465
19.2.7 71/2 J x 17………………………………………………………………………………………………………………………………………………….4468
19.2.8 71/2 J x 18………………………………………………………………………………………………………………………………………………….4470
20 Golf BlueMotion from model year 2009………………………………………………………………………………………………………………………………………4474
20.1 Golf BlueMotion, sales type 5K model year 2009 to model year 2012……………………………………………………………………………………………………….4474
20.2 Wheel allocation for Golf BlueMotion, sales type 5K model year 2009 to model year 2012…………………………………………………………………………………….4476
20.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4476
20.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4477
20.2.3 61/2 J x 16………………………………………………………………………………………………………………………………………………….4478
21 Golf GTD from model year 2010…………………………………………………………………………………………………………………………………………….4484
21.1 Golf GTD, sales type 5K, model year 2010 to model year 2012…………………………………………………………………………………………………………….4484
21.2 Wheel allocation for Golf GTD, type 5K model year 2010 to model year 2012………………………………………………………………………………………………..4486
21.2.1 6 J x 16…………………………………………………………………………………………………………………………………………………….4486
21.2.2 61/2 J x 16………………………………………………………………………………………………………………………………………………….4486
21.2.3 6 J x 17…………………………………………………………………………………………………………………………………………………….4491
21.2.4 7 J x 17…………………………………………………………………………………………………………………………………………………….4492
21.2.5 71/2 J x 17………………………………………………………………………………………………………………………………………………….4495
21.2.6 71/2 J x 18………………………………………………………………………………………………………………………………………………….4497
22 Golf GTI from model year 2010…………………………………………………………………………………………………………………………………………….4501
22.1 Golf GTI, sales type 5K, model year 2010 to model year 2012…………………………………………………………………………………………………………….4501
22.2 Wheel allocation for Golf GTI, type 5K model year 2010 to model year 2012………………………………………………………………………………………………..4503
22.2.1 6 J x 16…………………………………………………………………………………………………………………………………………………….4503
22.2.2 61/2 J x 16………………………………………………………………………………………………………………………………………………….4504
22.2.3 6 J x 17…………………………………………………………………………………………………………………………………………………….4509
22.2.4 7 J x 17…………………………………………………………………………………………………………………………………………………….4509
22.2.5 71/2 J x 17………………………………………………………………………………………………………………………………………………….4513
22.2.6 71/2 J x 18………………………………………………………………………………………………………………………………………………….4514
22.2.7 71/2 J x 19………………………………………………………………………………………………………………………………………………….4517
23 Golf R from model year 2010………………………………………………………………………………………………………………………………………………4519
23.1 Golf R, sales type 5K model year 2010………………………………………………………………………………………………………………………………..4519
23.2 Golf R, sales type 5K model year 2011 to model year 2012……………………………………………………………………………………………………………….4520
23.3 Wheel allocation for Golf R, type 5K model year 2010 to model year 2012………………………………………………………………………………………………….4521
23.3.1 6 J x 17…………………………………………………………………………………………………………………………………………………….4522
23.3.2 7 J x 17…………………………………………………………………………………………………………………………………………………….4522
23.3.3 71/2 J x 17………………………………………………………………………………………………………………………………………………….4522
23.3.4 71/2 J x 18………………………………………………………………………………………………………………………………………………….4524
23.3.5 8 J x 19…………………………………………………………………………………………………………………………………………………….4527
24 CrossGolf from model year 2011……………………………………………………………………………………………………………………………………………4529
24.1 CrossGolf, sales type 521 model year 2011 to model year 2012……………………………………………………………………………………………………………4529
24.2 Wheel allocation CrossGolf, sales type 521 model year 2011 to model year 2012…………………………………………………………………………………………….4532
24.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4532
24.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4533
24.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4534
24.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4535
24.2.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4540
24.2.6 7 J x 17 offset 47……………………………………………………………………………………………………………………………………………4541
24.2.7 7 J x 17 offset 54……………………………………………………………………………………………………………………………………………4541
24.2.8 71/2 J x 17………………………………………………………………………………………………………………………………………………….4545
25 Golf Cabriolet from model year 2012……………………………………………………………………………………………………………………………………….4546
25.1 Golf Cabriolet, sales type 517 from model year 2012……………………………………………………………………………………………………………………4546
25.2 Wheel allocation Golf Cabriolet, sales type 517 from model year 2012…………………………………………………………………………………………………….4548
25.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4548
25.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4549
25.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4550
25.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4551
25.2.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4556
25.2.6 7 J x 17…………………………………………………………………………………………………………………………………………………….4557
25.2.7 71/2 J x 17………………………………………………………………………………………………………………………………………………….4560
25.2.8 71/2 J x 18………………………………………………………………………………………………………………………………………………….4562
26 Golf Plus from model year 2009……………………………………………………………………………………………………………………………………………4566
26.1 Golf Plus, sales type 521 model year 2009 to model year 2011……………………………………………………………………………………………………………4566
26.2 Golf Plus, sales type 521 model year 2012…………………………………………………………………………………………………………………………….4571
26.3 Wheel allocation for Golf Plus, sales type 521 model year 2009 to model year 2012…………………………………………………………………………………………4575
26.3.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4575
26.3.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4576
26.3.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4577
26.3.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4577
26.3.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4582
26.3.6 7 J x 17…………………………………………………………………………………………………………………………………………………….4583
26.3.7 71/2 J x 17………………………………………………………………………………………………………………………………………………….4586
26.3.8 71/2 J x 18………………………………………………………………………………………………………………………………………………….4588
27 Golf Plus BlueMotion from model year 2010………………………………………………………………………………………………………………………………….4592
27.1 Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012…………………………………………………………………………………………………4592
27.2 Wheel allocation for Golf Plus BlueMotion, sales type 521, model year 2010 to model year 2012………………………………………………………………………………4594
27.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4594
27.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4595
27.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4596
27.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4597
28 Golf Variant from model year 2010…………………………………………………………………………………………………………………………………………4603
28.1 Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012……………………………………………………………………………………..4603
28.2 Wheel allocation for Golf Variant, Golf Variant 4Motion, sales type AJ5 model year 2010 to model year 2012…………………………………………………………………..4609
28.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4609
28.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4610
28.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4611
28.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4612
28.2.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4617
28.2.6 7 J x 17…………………………………………………………………………………………………………………………………………………….4618
28.2.7 71/2 J x 17………………………………………………………………………………………………………………………………………………….4621
28.2.8 71/2 J x 18………………………………………………………………………………………………………………………………………………….4623
29 Golf Variant BlueMotion from model year 2010……………………………………………………………………………………………………………………………….4627
29.1 Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012………………………………………………………………………………………………4627
29.2 Wheel allocation for Golf Variant BlueMotion, sales type AJ5, model year 2010 to model year 2012……………………………………………………………………………4628
29.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4628
29.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4629
29.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4630
29.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4631
30 Jetta from model year 2011……………………………………………………………………………………………………………………………………………….4637
30.1 Jetta, sales type 162 model year 2011 to model year 2012……………………………………………………………………………………………………………….4637
30.2 Wheel allocation Jetta, sales type 162 model year 2011…………………………………………………………………………………………………………………4640
30.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4640
30.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4641
30.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4642
30.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4643
30.2.5 7 J x 17…………………………………………………………………………………………………………………………………………………….4648
30.2.6 71/2 J x 17………………………………………………………………………………………………………………………………………………….4652
30.2.7 71/2 J x 18………………………………………………………………………………………………………………………………………………….4653
31 Jetta from model year 2011 (NAR)………………………………………………………………………………………………………………………………………….4657
31.1 Jetta, sales type 162 from model year 2011 (NAR)………………………………………………………………………………………………………………………4657
31.2 Wheel allocation for Jetta, sales type 162 from model year 2011 (NAR)……………………………………………………………………………………………………4659
31.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4659
31.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4659
31.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4661
31.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4661
31.2.5 7 J x 17…………………………………………………………………………………………………………………………………………………….4666
31.2.6 71/2 J x 17………………………………………………………………………………………………………………………………………………….4670
31.2.7 71/2 J x 18………………………………………………………………………………………………………………………………………………….4671
32 Beetle from model year 2012………………………………………………………………………………………………………………………………………………4675
32.1 Beetle, sales type 5C1, from model year 2012………………………………………………………………………………………………………………………….4675
32.2 Beetle, sales type 5C1, from model year 2012………………………………………………………………………………………………………………………….4676
32.2.1 61/2 J x 16………………………………………………………………………………………………………………………………………………….4677
32.2.2 7 J x 17…………………………………………………………………………………………………………………………………………………….4677
32.2.3 8 J x 18…………………………………………………………………………………………………………………………………………………….4679
32.2.4 8 J x 19…………………………………………………………………………………………………………………………………………………….4680
33 Scirocco from model year 2009…………………………………………………………………………………………………………………………………………….4681
33.1 Scirocco, sales type 137, model year 2009 to model year 2011……………………………………………………………………………………………………………4681
33.2 Scirocco, sales type 137 model year 2012……………………………………………………………………………………………………………………………..4684
33.3 Wheel allocation for Scirocco, sales type 137 model year 2009 to model year 2012………………………………………………………………………………………….4686
33.3.1 61/2 J x 16………………………………………………………………………………………………………………………………………………….4686
33.3.2 61/2 J x 17………………………………………………………………………………………………………………………………………………….4686
33.3.3 7 J x 17…………………………………………………………………………………………………………………………………………………….4687
33.3.4 8 J x 17…………………………………………………………………………………………………………………………………………………….4687
33.3.5 8 J x 18…………………………………………………………………………………………………………………………………………………….4689
33.3.6 8 J x 19…………………………………………………………………………………………………………………………………………………….4690
34 Scirocco R from model year 2010…………………………………………………………………………………………………………………………………………..4692
34.1 Scirocco R, sales type 137, model year 2010 to model year 2011………………………………………………………………………………………………………….4692
34.2 Scirocco R, sales type 137 model year 2012……………………………………………………………………………………………………………………………4693
34.3 Wheel allocation for Scirocco R, sales type 137, model year 2010 to model year 2012……………………………………………………………………………………….4694
34.3.1 61/2 J x 17………………………………………………………………………………………………………………………………………………….4695
34.3.2 7 J x 17…………………………………………………………………………………………………………………………………………………….4695
34.3.3 8 J x 17…………………………………………………………………………………………………………………………………………………….4695
34.3.4 8 J x 18…………………………………………………………………………………………………………………………………………………….4697
34.3.5 8 J x 19…………………………………………………………………………………………………………………………………………………….4699
35 Touran from model year 2003………………………………………………………………………………………………………………………………………………4700
35.1 Touran, type 1T model year 2003 to model year 2006…………………………………………………………………………………………………………………….4700
35.2 Touran, type 1T model year 2007 to model year 2010…………………………………………………………………………………………………………………….4703
35.3 Touran, type 1T and type 1t model year 2011 to model year 2012………………………………………………………………………………………………………….4708
35.4 Wheel allocation Touran, type 1T and type 1t model year 2003 to model year 2012…………………………………………………………………………………………..4713
35.4.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4713
35.4.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4714
35.4.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4715
35.4.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4715
35.4.5 6 J x 17…………………………………………………………………………………………………………………………………………………….4721
35.4.6 7 J x 17…………………………………………………………………………………………………………………………………………………….4721
35.4.7 71/2 J x 18………………………………………………………………………………………………………………………………………………….4722
36 CrossTouran from model year 2008………………………………………………………………………………………………………………………………………….4723
36.1 CrossTouran, type 1T model year 2008 to model year 2009………………………………………………………………………………………………………………..4723
36.2 CrossTouran, type 1T and type 1t model year 2010 to model year 2012……………………………………………………………………………………………………..4726
36.3 Wheel allocation CrossTouran, type 1T and type 1t model year 2008 to model year 2012………………………………………………………………………………………4730
36.3.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4730
36.3.2 6 J x 16…………………………………………………………………………………………………………………………………………………….4731
36.3.3 61/2 J x 17………………………………………………………………………………………………………………………………………………….4731
36.3.4 8 J x 17…………………………………………………………………………………………………………………………………………………….4732
37 Touran BlueMotion from model year 2009…………………………………………………………………………………………………………………………………….4733
37.1 Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012………………………………………………………………………………………………..4733
37.2 Wheel allocation Touran BlueMotion, type 1T and type 1t model year 2009 to model year 2012…………………………………………………………………………………4735
37.2.1 6 J x 15…………………………………………………………………………………………………………………………………………………….4735
37.2.2 61/2 J x 15………………………………………………………………………………………………………………………………………………….4736
37.2.3 6 J x 16…………………………………………………………………………………………………………………………………………………….4737
37.2.4 61/2 J x 16………………………………………………………………………………………………………………………………………………….4737
38 Tiguan from model year 2008………………………………………………………………………………………………………………………………………………4743
38.1 Tiguan, type 5N model year 2008 to model year 2011…………………………………………………………………………………………………………………….4743
38.2 Tiguan, type 5N, model year 2012…………………………………………………………………………………………………………………………………….4744
38.3 Wheel allocation for Tiguan, type 5N model year 2008 to model year 2012………………………………………………………………………………………………….4746
38.3.1 6 1/2 J x 16…………………………………………………………………………………………………………………………………………………4746
38.3.2 61/2 J x 17………………………………………………………………………………………………………………………………………………….4748
38.3.3 7 J x 17…………………………………………………………………………………………………………………………………………………….4748
38.3.4 7 J x 18…………………………………………………………………………………………………………………………………………………….4749
38.3.5 9 J x 19…………………………………………………………………………………………………………………………………………………….4750
39 Eos from model year 2006…………………………………………………………………………………………………………………………………………………4751
39.1 Eos, type 1F from model year 2006……………………………………………………………………………………………………………………………………4751
39.2 Eos, type 1F model year 2007 to model year 2012……………………………………………………………………………………………………………………….4752
39.3 Wheel allocation for Eos, type 1F model year 2006 to model year 2012…………………………………………………………………………………………………….4755
39.3.1 61/2 J x 16………………………………………………………………………………………………………………………………………………….4755
39.3.2 7 J x 16…………………………………………………………………………………………………………………………………………………….4756
39.3.3 6 J x 17…………………………………………………………………………………………………………………………………………………….4758
39.3.4 71/2 J x 17………………………………………………………………………………………………………………………………………………….4759
39.3.5 8 J x 18…………………………………………………………………………………………………………………………………………………….4762
40 Passat saloon from model year 2011………………………………………………………………………………………………………………………………………..4765
40.1 Passat saloon, sales type 362 model year 2011 to model year 2012………………………………………………………………………………………………………..4765
40.2 Wheel allocation Passat saloon, sales type 362 model year 2011 to model year 2012…………………………………………………………………………………………4770
40.2.1 61/2 J x 16………………………………………………………………………………………………………………………………………………….4771
40.2.2 7 J x 16…………………………………………………………………………………………………………………………………………………….4771
40.2.3 6 J x 17…………………………………………………………………………………………………………………………………………………….4772
40.2.4 61/2 J x 17………………………………………………………………………………………………………………………………………………….4773
40.2.5 71/2 J x 17………………………………………………………………………………………………………………………………………………….4773
40.2.6 8 J x 18…………………………………………………………………………………………………………………………………………………….4774
41 Passat Variant from model year 2011……………………………………………………………………………………………………………………………………….4776
41.1 Passat estate, sales type 365 model year 2011 to model year 2012………………………………………………………………………………………………………..4776
41.2 Wheel allocation Passat estate, sales type 365 model year 2011 to model year 2012…………………………………………………………………………………………4781
41.2.1 61/2 J x 16………………………………………………………………………………………………………………………………………………….4781
41.2.2 7 J x 16…………………………………………………………………………………………………………………………………………………….4782
41.2.3 6 J x 17…………………………………………………………………………………………………………………………………………………….4783
41.2.4 61/2 J x 17………………………………………………………………………………………………………………………………………………….4783
41.2.5 71/2 J x 17………………………………………………………………………………………………………………………………………………….4784
41.2.6 8 J x 18…………………………………………………………………………………………………………………………………………………….4785
42 Passat CC from model year 2009, CC from model year 2010……………………………………………………………………………………………………………………..4787
42.1 Passat CC, sales type 357 model year 2009…………………………………………………………………………………………………………………………….4787
42.2 Passat CC, CC, sales type 357 model year 2010 to model year 2012………………………………………………………………………………………………………..4789
42.3 Wheel allocation Passat CC, CC, sales type 357 model year 2009 to model year 2012…………………………………………………………………………………………4790
42.3.1 61/2 J x 17………………………………………………………………………………………………………………………………………………….4790
42.3.2 8 J x 17…………………………………………………………………………………………………………………………………………………….4791
42.3.3 8 J x 18…………………………………………………………………………………………………………………………………………………….4792
42.3.4 8 J x 19…………………………………………………………………………………………………………………………………………………….4794
43 Phaeton from model year 2003……………………………………………………………………………………………………………………………………………..4795
43.1 Phaeton, type 3D, model year 2003 to model year 2009 – short and long wheelbase…………………………………………………………………………………………..4795
43.2 Phaeton, type 3D and type 3d, model year 2010 to model year 2012 – short and long wheelbase………………………………………………………………………………..4798
43.3 Wheel allocation for Phaeton, type 3D and type 3d, model year 2003 to model year 2012 – short and long wheelbase……………………………………………………………..4800
43.3.1 71/2 J x 16………………………………………………………………………………………………………………………………………………….4800
43.3.2 71/2 J x 17………………………………………………………………………………………………………………………………………………….4800
43.3.3 71/2 J x 18………………………………………………………………………………………………………………………………………………….4802
43.3.4 81/2 J x 18………………………………………………………………………………………………………………………………………………….4802
43.3.5 81/2 J x 19 offset 38…………………………………………………………………………………………………………………………………………4804
43.3.6 81/2 J x 19 offset 45…………………………………………………………………………………………………………………………………………4805
43.3.7 9 J x 19 offset 35……………………………………………………………………………………………………………………………………………4805
43.3.8 9 J x 19 offset 40……………………………………………………………………………………………………………………………………………4806
43.3.9 9 J x 20…………………………………………………………………………………………………………………………………………………….4806
44 Sharan from model year 2011………………………………………………………………………………………………………………………………………………4808
44.1 Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012………………………………………………………………………………………………………4808
44.2 Wheel allocation Sharan, Sharan 4Motion, type 7N model year 2011 to model year 2012……………………………………………………………………………………….4810
44.2.1 6 1/2 J x 16…………………………………………………………………………………………………………………………………………………4810
44.2.2 7 J x 17…………………………………………………………………………………………………………………………………………………….4811
44.2.3 71/2 J x 18………………………………………………………………………………………………………………………………………………….4811
45 Touareg from model year 2010……………………………………………………………………………………………………………………………………………..4813
45.1 Touareg, type 7P and type 7p, model year 2010 to model year 2012………………………………………………………………………………………………………..4813
45.2 Wheel allocation for Touareg, type 7P and type 7p, model year 2010 to model year 2012……………………………………………………………………………………..4815
45.2.1 71/2 J x 17………………………………………………………………………………………………………………………………………………….4815
45.2.2 8 J x 18…………………………………………………………………………………………………………………………………………………….4816
45.2.3 81/2 J x 19………………………………………………………………………………………………………………………………………………….4817
45.2.4 9 J x 20…………………………………………………………………………………………………………………………………………………….4817
45.2.5 91/2 J x 21………………………………………………………………………………………………………………………………………………….4818
46 Touareg hybrid from model year 2011……………………………………………………………………………………………………………………………………….4820
46.1 Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012………………………………………………………………………………………………..4820
46.2 Wheel allocation Touareg hybrid, type 7PH and type 7pH, model year 2011 to model year 2012…………………………………………………………………………………4821
46.2.1 8 J x 18…………………………………………………………………………………………………………………………………………………….4821
46.2.2 81/2 J x 19………………………………………………………………………………………………………………………………………………….4822
47 Breakdown set for VW Vehicles…………………………………………………………………………………………………………………………………………….4824
48 Temporary spare tyres and wheels for VW vehicles……………………………………………………………………………………………………………………………4825
49 Recommended summer tyres…………………………………………………………………………………………………………………………………………………4826
49.1 Summer tyres for Fox from model year 2006…………………………………………………………………………………………………………………………….4826
49.2 Summer tyres for Polo from model year 2010……………………………………………………………………………………………………………………………4826
49.3 Summer tyres for Polo BlueMotion from model year 2010………………………………………………………………………………………………………………….4827
49.4 Summer tyres for CrossPolo from model year 2011……………………………………………………………………………………………………………………….4828
49.5 Summer tyres for Polo GTI from model year 2011………………………………………………………………………………………………………………………..4828
49.6 Summer tyres for Golf from model year 2009……………………………………………………………………………………………………………………………4829
49.7 Summer tyres for Golf BlueMotion from model year 2009………………………………………………………………………………………………………………….4830
49.8 Summer tyres for Golf GTD from model year 2009………………………………………………………………………………………………………………………..4831
49.9 Summer tyres for Golf GTI from model year 2009………………………………………………………………………………………………………………………..4831
49.10 Summer tyres for Golf R from model year 2010…………………………………………………………………………………………………………………………4832
49.11 Summer tyres for CrossGolf from model year 2011………………………………………………………………………………………………………………………4833
49.12 Summer tyres Golf Cabriolet from model year 2012……………………………………………………………………………………………………………………..4834
49.13 Summer tyres for Golf Plus from model year 2009………………………………………………………………………………………………………………………4835
49.14 Summer tyres for Golf Plus BlueMotion from model year 2010…………………………………………………………………………………………………………….4836
49.15 Summer tyres for Golf Variant from model year 2010……………………………………………………………………………………………………………………4837
49.16 Summer tyres for Golf Variant BlueMotion from model year 2010………………………………………………………………………………………………………….4838
49.17 Summer tyres for Jetta from model year 2011………………………………………………………………………………………………………………………….4839
49.18 Summer tyres for Beetle from model year 2012…………………………………………………………………………………………………………………………4841
49.19 Summer tyres for Scirocco from model year 2009……………………………………………………………………………………………………………………….4841
49.20 Summer tyres for Scirocco R from model year 2010……………………………………………………………………………………………………………………..4841
49.21 Summer tyres for Touran from model year 2003…………………………………………………………………………………………………………………………4842
49.22 Summer tyres for Touran BlueMotion from model year 2009……………………………………………………………………………………………………………….4842
49.23 Summer tyres for CrossTouran from model year 2008…………………………………………………………………………………………………………………….4843
49.24 Summer tyres for Tiguan from model year 2008…………………………………………………………………………………………………………………………4843
49.25 Summer tyres for Eos from model year 2006……………………………………………………………………………………………………………………………4844
49.26 Summer tyres for Passat saloon from model year 2011…………………………………………………………………………………………………………………..4844
49.27 Summer tyres for Passat Variant from model year 2011………………………………………………………………………………………………………………….4845
49.28 Summer tyres Passat CC from model year 2009, CC from model year 2010……………………………………………………………………………………………………4846
49.29 Summer tyres for Sharan from model year 2011…………………………………………………………………………………………………………………………4846
49.30 Summer tyres for Phaeton from model year 2003………………………………………………………………………………………………………………………..4846
49.31 Summer tyres for Touareg from model year 2010………………………………………………………………………………………………………………………..4847
49.32 Summer tyres for Touareg hybrid from model year 2011………………………………………………………………………………………………………………….4847
50 Recommended all-season tyres……………………………………………………………………………………………………………………………………………..4848
50.1 All-season tyres for Polo from model year 2010………………………………………………………………………………………………………………………..4848
50.2 All-season tyres for Polo BlueMotion from model year 2010………………………………………………………………………………………………………………4848
50.3 All-season tyres for CrossPolo from model year 2011……………………………………………………………………………………………………………………4848
50.4 All-season tyres for Polo GTI from model year 2011…………………………………………………………………………………………………………………….4849
50.5 All-season tyres for Golf from model year 2009………………………………………………………………………………………………………………………..4849
50.6 All-season tyres for CrossGolf from model year 2011……………………………………………………………………………………………………………………4849
50.7 All-weather tyres Golf Cabriolet from model year 2012………………………………………………………………………………………………………………….4850
50.8 All-season tyres for Golf Plus from model year 2009……………………………………………………………………………………………………………………4850
50.9 All-season tyres for Golf Variant from model year 2010…………………………………………………………………………………………………………………4851
50.10 All-season tyres for Jetta from model year 2011………………………………………………………………………………………………………………………4851
50.11 All-season tyres for Jetta from model year 2011 (NAR)…………………………………………………………………………………………………………………4851
50.12 All-season tyres for Touran from model year 2003……………………………………………………………………………………………………………………..4852
50.13 All-season tyres for Beetle from model year 2012……………………………………………………………………………………………………………………..4852
50.14 All-season tyres for Tiguan from model year 2008……………………………………………………………………………………………………………………..4852
50.15 All-season tyres for Eos from model year 2006………………………………………………………………………………………………………………………..4852
50.16 All-season tyres for Passat saloon from model year 2011……………………………………………………………………………………………………………….4853
50.17 All-season tyres for Passat Variant from model year 2011………………………………………………………………………………………………………………4853
50.18 All-season tyres Passat CC from model year 2009, CC from model year 2010………………………………………………………………………………………………..4853
50.19 All-season tyres for Sharan from model year 2011……………………………………………………………………………………………………………………..4854
50.20 All-season tyres for Phaeton from model year 2003…………………………………………………………………………………………………………………….4854
50.21 All-season tyres for Touareg from model year 2010…………………………………………………………………………………………………………………….4854
50.22 All-season tyres Touareg hybrid from model year 2010………………………………………………………………………………………………………………….4854
51 Recommended winter tyres…………………………………………………………………………………………………………………………………………………4856
51.1 Winter tyres for Fox from model year 2006…………………………………………………………………………………………………………………………….4856
51.2 Winter tyres for Polo from model year 2010……………………………………………………………………………………………………………………………4856
51.3 Winter tyres for Polo BlueMotion from model year 2010………………………………………………………………………………………………………………….4857
51.4 Winter tyres for CrossPolo from model year 2011……………………………………………………………………………………………………………………….4857
51.5 Winter tyres for Polo GTI from model year 2011………………………………………………………………………………………………………………………..4857
51.6 Winter tyres for Golf from model year 2009……………………………………………………………………………………………………………………………4857
51.7 Winter tyres for Golf BlueMotion from model year 2009………………………………………………………………………………………………………………….4858
51.8 Winter tyres for Golf GTD from model year 2009………………………………………………………………………………………………………………………..4858
51.9 Winter tyres for Golf GTI from model year 2009………………………………………………………………………………………………………………………..4858
51.10 Winter tyres for Golf R from model year 2010…………………………………………………………………………………………………………………………4858
51.11 Winter tyres for CrossGolf from model year 20011……………………………………………………………………………………………………………………..4859
51.12 Winter tyres Golf Cabriolet from model year 2012……………………………………………………………………………………………………………………..4859
51.13 Winter tyres for Golf Plus from model year 2009………………………………………………………………………………………………………………………4859
51.14 Winter tyres for Golf Plus BlueMotion from model year 2010…………………………………………………………………………………………………………….4860
51.15 Winter tyres for Golf Variant from model year 2010……………………………………………………………………………………………………………………4860
51.16 Winter tyres for Golf Variant BlueMotion from model year 2010………………………………………………………………………………………………………….4860
51.17 Winter tyres for Jetta from model year 2011………………………………………………………………………………………………………………………….4861
51.18 Winter tyres for Beetle from model year 2012…………………………………………………………………………………………………………………………4861
51.19 Winter tyres for Scirocco from model year 2009……………………………………………………………………………………………………………………….4861
51.20 Winter tyres for Scirocco R from model year 2010……………………………………………………………………………………………………………………..4861
51.21 Winter tyres for Touran from model year 2003…………………………………………………………………………………………………………………………4862
51.22 Winter tyres for Touran BlueMotion from model year 2009……………………………………………………………………………………………………………….4862
51.23 Winter tyres for CrossTouran from model year 2008…………………………………………………………………………………………………………………….4862
51.24 Winter tyres for Tiguan from model year 2008…………………………………………………………………………………………………………………………4863
51.25 Winter tyres for Eos from model year 2006……………………………………………………………………………………………………………………………4863
51.26 Winter tyres for Passat saloon from model year 2011…………………………………………………………………………………………………………………..4863
51.27 Winter tyres for Passat Variant from model year 2011………………………………………………………………………………………………………………….4863
51.28 Winter tyres Passat CC from model year 2009, CC from model year 2010……………………………………………………………………………………………………4864
51.29 Winter tyres for Sharan from model year 2011…………………………………………………………………………………………………………………………4864
51.30 Winter tyres for Phaeton from model year 2003………………………………………………………………………………………………………………………..4864
51.31 Winter tyres for Touareg from model year 2010………………………………………………………………………………………………………………………..4864
51.32 Winter tyres Touareg hybrid from model year 2010……………………………………………………………………………………………………………………..4865
Sharan2016-4-cylinder_common_rail_engine_(2_0 l__4V__turbocharger)……………………………………………………………………………………………………………………..4866
00 – Technical data……………………………………………………………………………………………………………………………………………………………4874
1 Safety instructions………………………………………………………………………………………………………………………………………………………4874
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………..4874
1.2 Safety precautions when working on vehicles with a start/stop system……………………………………………………………………………………………………..4874
1.3 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………4875
1.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………4875
1.5 Safety precautions when working on the SCR system………………………………………………………………………………………………………………………4875
1.6 Safety precautions when working on exhaust system………………………………………………………………………………………………………………………4876
2 Identification…………………………………………………………………………………………………………………………………………………………..4877
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………..4877
3 Repair instructions………………………………………………………………………………………………………………………………………………………4879
3.1 Rules for cleanliness……………………………………………………………………………………………………………………………………………….4879
3.2 Adapting learnt value for SCR system………………………………………………………………………………………………………………………………….4879
3.3 Foreign objects in engine……………………………………………………………………………………………………………………………………………4879
3.4 Contact corrosion…………………………………………………………………………………………………………………………………………………..4880
3.5 Routing and securing lines…………………………………………………………………………………………………………………………………………..4880
3.6 Installing coolers, condensers and radiators…………………………………………………………………………………………………………………………..4880
10 – Removing and installing engine……………………………………………………………………………………………………………………………………………..4881
1 Removing and installing engine…………………………………………………………………………………………………………………………………………….4881
1.1 Removing engine…………………………………………………………………………………………………………………………………………………….4881
1.2 Separating engine and gearbox………………………………………………………………………………………………………………………………………..4891
1.2.1 Separating engine and gearbox, vehicles with manual gearbox………………………………………………………………………………………………………..4891
1.2.2 Separating engine and gearbox, vehicles with dual clutch gearbox……………………………………………………………………………………………………4893
1.3 Securing engine on engine and gearbox support………………………………………………………………………………………………………………………….4896
1.4 Installing engine…………………………………………………………………………………………………………………………………………………..4897
2 Assembly mountings……………………………………………………………………………………………………………………………………………………….4902
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………..4902
2.1.1 Assembly overview – assembly mounting, CC………………………………………………………………………………………………………………………..4902
2.1.2 Assembly overview – assembly mountings, Sharan and Tiguan………………………………………………………………………………………………………….4905
2.2 Supporting engine in installation position…………………………………………………………………………………………………………………………….4907
2.2.1 Supporting engine in installation position, CC……………………………………………………………………………………………………………………4907
2.2.2 Supporting engine in installation position, Sharan………………………………………………………………………………………………………………..4909
2.2.3 Supporting engine in installation position, Tiguan………………………………………………………………………………………………………………..4913
2.3 Removing and installing engine mountings………………………………………………………………………………………………………………………………4915
2.3.1 Removing and installing engine mountings, Sharan and Tiguan………………………………………………………………………………………………………..4915
2.3.2 Removing and installing engine mountings, CC……………………………………………………………………………………………………………………..4915
2.4 Removing and installing gearbox mounting………………………………………………………………………………………………………………………………4916
2.5 Removing and installing pendulum support………………………………………………………………………………………………………………………………4918
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)………………………………………………………………………………………………….4919
2.7 Adjusting assembly mountings…………………………………………………………………………………………………………………………………………4919
3 Engine cover panel……………………………………………………………………………………………………………………………………………………….4922
3.1 Removing and installing engine cover panel…………………………………………………………………………………………………………………………….4922
13 – Crankshaft group………………………………………………………………………………………………………………………………………………………….4923
1 Cylinder block (pulley end)……………………………………………………………………………………………………………………………………………….4923
1.1 Assembly overview – cylinder block (pulley end)………………………………………………………………………………………………………………………..4923
1.2 Assembly overview – Sealing flange, belt pulley end…………………………………………………………………………………………………………………….4925
1.3 Removing and installing poly V-belt…………………………………………………………………………………………………………………………………..4925
1.4 Removing and installing tensioning device for poly V-belt……………………………………………………………………………………………………………….4927
1.5 Removing and installing vibration damper………………………………………………………………………………………………………………………………4927
1.6 Removing and installing engine support………………………………………………………………………………………………………………………………..4927
1.7 Removing and installing ancillary bracket……………………………………………………………………………………………………………………………..4928
1.8 Removing and installing sealing flange on pulley end……………………………………………………………………………………………………………………4930
2 Cylinder block, gearbox end……………………………………………………………………………………………………………………………………………….4933
2.1 Assembly overview – cylinder block, gearbox end………………………………………………………………………………………………………………………..4933
2.2 Removing and installing flywheel……………………………………………………………………………………………………………………………………..4934
2.3 Removing and installing sealing flange on gearbox side………………………………………………………………………………………………………………….4935
3 Crankshaft………………………………………………………………………………………………………………………………………………………………4943
3.1 Assembly overview – crankshaft……………………………………………………………………………………………………………………………………….4943
3.2 Crankshaft dimensions……………………………………………………………………………………………………………………………………………….4944
3.3 Measuring axial clearance of crankshaft……………………………………………………………………………………………………………………………….4944
3.4 Renewing needle bearing in crankshaft…………………………………………………………………………………………………………………………………4945
4 Pistons and conrods………………………………………………………………………………………………………………………………………………………4948
4.1 Assembly overview – pistons and conrods……………………………………………………………………………………………………………………………….4948
4.2 Removing and installing pistons………………………………………………………………………………………………………………………………………4950
4.3 Measuring piston projection at TDC……………………………………………………………………………………………………………………………………4952
4.4 Checking piston and cylinder bore…………………………………………………………………………………………………………………………………….4953
4.5 Checking radial clearance of conrods………………………………………………………………………………………………………………………………….4954
15 – Cylinder head, valve gear………………………………………………………………………………………………………………………………………………….4956
1 Cylinder head……………………………………………………………………………………………………………………………………………………………4956
1.1 Assembly overview – cylinder head cover……………………………………………………………………………………………………………………………….4956
1.2 Assembly overview – cylinder head…………………………………………………………………………………………………………………………………….4958
1.3 Removing and installing cylinder head cover……………………………………………………………………………………………………………………………4960
1.4 Removing and installing cylinder head…………………………………………………………………………………………………………………………………4961
1.5 Removing and installing injector seals………………………………………………………………………………………………………………………………..4969
1.6 Checking compression………………………………………………………………………………………………………………………………………………..4971
1.7 Removing and installing camshaft housing………………………………………………………………………………………………………………………………4972
2 Toothed belt drive……………………………………………………………………………………………………………………………………………………….4977
2.1 Exploded view – toothed belt cover……………………………………………………………………………………………………………………………………4977
2.2 Assembly overview – toothed belt……………………………………………………………………………………………………………………………………..4978
2.3 Removing and installing toothed belt guard…………………………………………………………………………………………………………………………….4979
2.3.1 Removing and installing upper toothed belt guard, vehicles without SCR system………………………………………………………………………………………..4979
2.3.2 Removing and installing upper toothed belt guard, vehicles with SCR system…………………………………………………………………………………………..4981
2.3.3 Removing and installing lower toothed belt guard………………………………………………………………………………………………………………….4983
2.4 Detaching toothed belt from camshaft………………………………………………………………………………………………………………………………….4984
2.5 Removing and installing toothed belt………………………………………………………………………………………………………………………………….4988
3 Valve gear………………………………………………………………………………………………………………………………………………………………4999
3.1 Assembly overview – valve gear……………………………………………………………………………………………………………………………………….4999
3.2 Measuring axial play of camshaft……………………………………………………………………………………………………………………………………..5002
3.3 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………..5003
3.4 Removing and installing inlet camshaft control valve 1 -N205-……………………………………………………………………………………………………………5005
3.5 Removing and installing camshaft adjuster……………………………………………………………………………………………………………………………..5005
3.5.1 Removing and installing control valve for the camshaft adjuster…………………………………………………………………………………………………….5008
3.6 Checking hydraulic compensation elements………………………………………………………………………………………………………………………………5010
3.7 Removing and installing valve stem seals………………………………………………………………………………………………………………………………5011
3.7.1 Removing and installing valve stem oil seals (cylinder head installed)………………………………………………………………………………………………5011
3.7.2 Removing and installing valve stem oil seals (cylinder head removed)………………………………………………………………………………………………..5014
4 Inlet and exhaust valves………………………………………………………………………………………………………………………………………………….5019
4.1 Checking valve guides……………………………………………………………………………………………………………………………………………….5019
4.2 Checking valves…………………………………………………………………………………………………………………………………………………….5020
4.3 Valve dimensions……………………………………………………………………………………………………………………………………………………5020
17 – Lubrication………………………………………………………………………………………………………………………………………………………………5021
1 Sump, oil pump…………………………………………………………………………………………………………………………………………………………..5021
1.1 Assembly overview – sump / oil pump…………………………………………………………………………………………………………………………………..5021
1.2 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………5024
1.3 Removing and installing sump…………………………………………………………………………………………………………………………………………5024
1.4 Removing and installing oil pump……………………………………………………………………………………………………………………………………..5028
1.5 Engine oil…………………………………………………………………………………………………………………………………………………………5028
2 Engine oil cooler………………………………………………………………………………………………………………………………………………………..5029
3 Oil filter, oil pressure switch……………………………………………………………………………………………………………………………………………5030
3.1 Assembly overview – oil filter housing, oil pressure switch……………………………………………………………………………………………………………..5030
3.2 Removing and installing oil filter housing…………………………………………………………………………………………………………………………….5031
3.3 Removing and installing oil pressure switch -F1-……………………………………………………………………………………………………………………….5033
3.4 Removing and installing oil pressure switch for reduced oil pressure -F378-……………………………………………………………………………………………….5035
3.5 Removing and installing oil pressure regulating valve -N428-…………………………………………………………………………………………………………….5035
3.6 Checking oil pressure……………………………………………………………………………………………………………………………………………….5036
19 – Cooling………………………………………………………………………………………………………………………………………………………………….5037
1 Cooling system, coolant…………………………………………………………………………………………………………………………………………………..5037
1.1 Coolant hose schematic diagram……………………………………………………………………………………………………………………………………….5037
1.1.1 Assembly overview – coolant hoses, vehicles without SCR system……………………………………………………………………………………………………..5037
1.1.2 Assembly overview – coolant hoses, vehicles with SCR system………………………………………………………………………………………………………..5040
1.2 Draining and filling coolant…………………………………………………………………………………………………………………………………………5042
1.2.1 Draining and filling coolant, Sharan…………………………………………………………………………………………………………………………….5042
1.2.2 Draining and filling coolant, Tiguan and CC………………………………………………………………………………………………………………………5047
1.3 Checking cooling system for leaks…………………………………………………………………………………………………………………………………….5052
2 Coolant pump, regulation of cooling system………………………………………………………………………………………………………………………………….5055
2.1 Assembly overview – coolant pump, thermostat…………………………………………………………………………………………………………………………..5055
2.2 Assembly overview – coolant temperature sender…………………………………………………………………………………………………………………………5057
2.3 Assembly overview – electric coolant pump……………………………………………………………………………………………………………………………..5058
2.3.1 Charge air cooling pump -V188- version 1, auxiliary pump for heating -V488-, version 1………………………………………………………………………………..5058
2.3.2 Charge air cooling pump -V188-, version 2………………………………………………………………………………………………………………………..5059
2.3.3 Assembly overview – auxiliary pump for heating -V488-, version 2……………………………………………………………………………………………………5060
2.3.4 Assembly overview – charge air cooling pump -V188-, version 3………………………………………………………………………………………………………5061
2.3.5 Assembly overview – auxiliary pump for heating -V488-, version 3……………………………………………………………………………………………………5062
2.4 Removing and installing coolant pump………………………………………………………………………………………………………………………………….5063
2.5 Removing and installing thermostat……………………………………………………………………………………………………………………………………5063
2.6 Removing and installing coolant valve for cylinder head -N489-…………………………………………………………………………………………………………..5064
2.7 Checking thermostat…………………………………………………………………………………………………………………………………………………5064
2.8 Removing and installing coolant temperature sender -G62-………………………………………………………………………………………………………………..5065
2.9 Removing and installing electric coolant pump………………………………………………………………………………………………………………………….5066
2.9.1 Removing and installing charge air cooling pump -V188-, versions 1 and 2…………………………………………………………………………………………….5066
2.9.2 Removing and installing auxiliary pump for heating -V488-, version 1………………………………………………………………………………………………..5068
2.9.3 Removing and installing charge air cooling pump -V188-, version 3…………………………………………………………………………………………………..5069
2.9.4 Removing and installing auxiliary pump for heating -V488-, version 2………………………………………………………………………………………………..5072
2.9.5 Removing and installing auxiliary pump for heating -V488-, version 3………………………………………………………………………………………………..5075
3 Coolant pipes……………………………………………………………………………………………………………………………………………………………5079
3.1 Assembly overview – coolant pipes…………………………………………………………………………………………………………………………………….5079
3.2 Removing and installing coolant pipes…………………………………………………………………………………………………………………………………5080
3.2.1 Removing and installing coolant pipes (top front)…………………………………………………………………………………………………………………5080
3.2.2 Removing and installing lower front coolant pipe………………………………………………………………………………………………………………….5081
3.2.3 Removing and installing coolant pipe (front left)…………………………………………………………………………………………………………………5083
3.2.4 Removing and installing left coolant pipes……………………………………………………………………………………………………………………….5084
3.2.5 Removing and installing rear coolant pipe………………………………………………………………………………………………………………………..5085
3.2.6 Removing and installing rear right coolant pipe…………………………………………………………………………………………………………………..5087
4 Radiator, radiator fan……………………………………………………………………………………………………………………………………………………5090
4.1 Assembly overview – radiator and radiator fan………………………………………………………………………………………………………………………….5090
4.1.1 Assembly overview – radiator/radiator fan, Tiguan and CC…………………………………………………………………………………………………………..5090
4.1.2 Assembly overview – radiator and radiator fan, Sharan……………………………………………………………………………………………………………..5092
4.2 Assembly overview – radiator cowl and radiator fan……………………………………………………………………………………………………………………..5094
4.2.1 Assembly overview – radiator cowl, Sharan………………………………………………………………………………………………………………………..5094
4.3 Removing and installing radiator……………………………………………………………………………………………………………………………………..5095
4.3.1 Removing and installing radiator, Sharan…………………………………………………………………………………………………………………………5095
4.3.2 Removing and installing radiator, Tiguan and CC…………………………………………………………………………………………………………………..5099
4.4 Removing and installing water radiator for charge air cooling circuit…………………………………………………………………………………………………….5100
4.4.1 Removing and installing water radiator for charge air cooling circuit, Tiguan and CC………………………………………………………………………………….5100
4.4.2 Removing and installing water radiator for charge air cooling circuit, Sharan………………………………………………………………………………………..5103
4.5 Removing and installing radiator cowling………………………………………………………………………………………………………………………………5104
4.5.1 Removing and installing radiator cowl with radiator fan, Sharan…………………………………………………………………………………………………….5104
4.5.2 Removing and installing radiator cowl with radiator fan, Tiguan…………………………………………………………………………………………………….5105
4.5.3 Removing and installing radiator cowl with radiator fan, CC………………………………………………………………………………………………………..5106
4.6 Removing and installing radiator fan………………………………………………………………………………………………………………………………….5107
4.6.1 Removing and installing radiator fan, Sharan……………………………………………………………………………………………………………………..5107
4.6.2 Removing and installing radiator fan, Tiguan and CC……………………………………………………………………………………………………………….5108
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………..5109
1 Turbocharger…………………………………………………………………………………………………………………………………………………………….5109
1.1 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………..5109
1.2 Removing and installing turbocharger………………………………………………………………………………………………………………………………….5111
1.3 Renewing vacuum unit for turbocharger…………………………………………………………………………………………………………………………………5116
1.4 Removing and installing connecting piece………………………………………………………………………………………………………………………………5120
2 Charge air system………………………………………………………………………………………………………………………………………………………..5122
2.1 Assembly overview – charge air system…………………………………………………………………………………………………………………………………5122
2.2 Removing and installing charge pressure sender -G31-……………………………………………………………………………………………………………………5124
2.3 Checking charge air system for leaks………………………………………………………………………………………………………………………………….5124
23 – Mixture preparation – injection…………………………………………………………………………………………………………………………………………….5127
1 Injection system…………………………………………………………………………………………………………………………………………………………5127
1.1 Overview of fittings – injection system……………………………………………………………………………………………………………………………….5127
1.1.1 Overview of fitting locations – engine compartment………………………………………………………………………………………………………………..5127
1.1.2 Overview of fitting locations – front view of engine………………………………………………………………………………………………………………5130
1.1.3 Overview of fitting locations – rear view of engine, vehicles without SCR system……………………………………………………………………………………..5131
1.1.4 Overview of fitting locations – rear view of engine, vehicles with SCR system………………………………………………………………………………………..5132
1.2 Schematic overview – fuel system……………………………………………………………………………………………………………………………………..5134
1.2.1 Schematic overview – fuel system, version 1………………………………………………………………………………………………………………………5134
1.2.2 Schematic overview – fuel system, version 2………………………………………………………………………………………………………………………5135
1.3 Filling, bleeding fuel system………………………………………………………………………………………………………………………………………..5136
1.4 Checking fuel system for leaks……………………………………………………………………………………………………………………………………….5136
2 Vacuum system……………………………………………………………………………………………………………………………………………………………5138
2.1 Schematic diagram – vacuum system…………………………………………………………………………………………………………………………………….5138
2.2 Testing vacuum system……………………………………………………………………………………………………………………………………………….5138
3 Injectors and high-pressure accumulator (rail)………………………………………………………………………………………………………………………………5140
3.1 Assembly overview – injectors………………………………………………………………………………………………………………………………………..5140
3.2 Assembly overview – high-pressure accumulator (fuel rail)……………………………………………………………………………………………………………….5142
3.3 Testing injectors…………………………………………………………………………………………………………………………………………………..5142
3.4 Adapting correction values for injectors………………………………………………………………………………………………………………………………5143
3.5 Checking return flow rate of injectors with engine running………………………………………………………………………………………………………………5143
3.6 Checking return flow rate of injectors at starter speed…………………………………………………………………………………………………………………5146
3.7 Testing jammed-open injectors………………………………………………………………………………………………………………………………………..5148
3.8 Removing and installing injectors…………………………………………………………………………………………………………………………………….5149
3.9 Removing and installing high-pressure lines……………………………………………………………………………………………………………………………5153
3.9.1 Removing high-pressure line between high-pressure reservoir (rail) and high-pressure pump……………………………………………………………………………..5153
3.9.2 Installing high-pressure line…………………………………………………………………………………………………………………………………..5153
3.10 Removing and installing high-pressure accumulator (rail)……………………………………………………………………………………………………………….5155
4 Air filter………………………………………………………………………………………………………………………………………………………………5157
4.1 Assembly overview – air filter housing………………………………………………………………………………………………………………………………..5157
4.1.1 Assembly overview – air filter housing, CC……………………………………………………………………………………………………………………….5157
4.1.2 Assembly overview – air filter housing, Sharan and Tiguan………………………………………………………………………………………………………….5158
4.2 Removing and installing air filter housing…………………………………………………………………………………………………………………………….5159
4.2.1 Removing and installing air filter housing, CC……………………………………………………………………………………………………………………5159
4.2.2 Removing and installing air filter housing, Sharan and Tiguan………………………………………………………………………………………………………5162
4.2.3 Installing screw-type clips on air ducts…………………………………………………………………………………………………………………………5163
5 Intake manifold………………………………………………………………………………………………………………………………………………………….5165
5.1 Assembly overview – intake manifold…………………………………………………………………………………………………………………………………..5165
5.2 Removing and installing throttle valve module -J338-……………………………………………………………………………………………………………………5167
5.3 Removing and installing intake manifold……………………………………………………………………………………………………………………………….5169
6 Senders and sensors………………………………………………………………………………………………………………………………………………………5174
6.1 Removing and installing charge air temperature sender before charge air cooler -G810-/charge air temperature sender after charge air cooler -G811-………………………………..5174
6.2 Removing and installing fuel temperature sender -G81-…………………………………………………………………………………………………………………..5174
6.3 Removing and installing fuel pressure regulating valve -N276-……………………………………………………………………………………………………………5176
6.3.1 Versions of fuel pressure regulating valve -N276-…………………………………………………………………………………………………………………5176
6.3.2 Removing and installing fuel pressure regulating valve, version 1…………………………………………………………………………………………………..5176
6.3.3 Removing and installing fuel pressure regulating valve -N276-, version 2…………………………………………………………………………………………….5177
6.4 Checking fuel pressure regulating valve -N276-…………………………………………………………………………………………………………………………5179
6.5 Removing and installing fuel pressure sender -G247-…………………………………………………………………………………………………………………….5180
6.6 Removing and installing air mass meter -G70-…………………………………………………………………………………………………………………………..5181
6.7 Removing and installing pressure differential sender -G505-……………………………………………………………………………………………………………..5183
6.8 Removing and installing exhaust gas pressure sensor 1 -G450-…………………………………………………………………………………………………………….5184
7 Engine control unit………………………………………………………………………………………………………………………………………………………5186
7.1 Removing and installing engine control unit -J623-……………………………………………………………………………………………………………………..5186
7.1.1 Removing and installing engine control unit -J623-, Sharan and Tiguan……………………………………………………………………………………………….5186
7.1.2 Removing and installing engine control unit -J623-, CC…………………………………………………………………………………………………………….5187
7.2 Removing and installing engine control unit -J623- with protective housing………………………………………………………………………………………………..5189
7.2.1 Removing and installing engine control unit -J623- with protective housing, Sharan and Tiguan………………………………………………………………………….5189
7.2.2 Removing and installing engine control unit -J623- with protective housing, CC……………………………………………………………………………………….5193
8 High-pressure pump……………………………………………………………………………………………………………………………………………………….5198
8.1 Assembly overview – high-pressure pump………………………………………………………………………………………………………………………………..5198
8.2 Removing and installing high-pressure pump…………………………………………………………………………………………………………………………….5199
9 Lambda probe…………………………………………………………………………………………………………………………………………………………….5202
9.1 Assembly overview – Lambda probe……………………………………………………………………………………………………………………………………..5202
9.1.1 Assembly overview – Lambda probe; vehicles without SCR system………………………………………………………………………………………………………5202
9.1.2 Assembly overview – Lambda probe; vehicles with SCR system…………………………………………………………………………………………………………5203
9.1.3 Assembly overview – lambda probe, vehicles with emission control module, version 2……………………………………………………………………………………5204
9.2 Assembly overview – NOx sender -G295- with control unit for NOx sender -J583-……………………………………………………………………………………………..5205
9.3 Removing and installing Lambda probe………………………………………………………………………………………………………………………………….5205
9.3.1 Removing and installing Lambda probe 1 before catalytic converter -GX10-…………………………………………………………………………………………….5205
9.3.2 Removing and installing Lambda probe 1 after catalytic converter -GX7-………………………………………………………………………………………………5206
9.4 Removing and installing NOx sender -G295- with control unit for NOx sender -J583-………………………………………………………………………………………….5207
26 – Exhaust system……………………………………………………………………………………………………………………………………………………………5212
1 Exhaust pipes, silencers………………………………………………………………………………………………………………………………………………….5212
1.1 Assembly overview – silencers………………………………………………………………………………………………………………………………………..5212
1.1.1 Assembly overview – front exhaust pipe, Sharan and Tiguan………………………………………………………………………………………………………….5212
1.1.2 Assembly overview – front exhaust pipe, CC……………………………………………………………………………………………………………………….5214
1.1.3 Assembly overview – silencers, Tiguan……………………………………………………………………………………………………………………………5215
1.1.4 Assembly overview – silencer, Sharan…………………………………………………………………………………………………………………………….5217
1.1.5 Assembly overview – silencer, CC………………………………………………………………………………………………………………………………..5218
1.2 Removing and installing front exhaust pipe…………………………………………………………………………………………………………………………….5219
1.3 Removing and installing exhaust flap control unit -J883-………………………………………………………………………………………………………………..5220
1.4 Removing and installing silencer……………………………………………………………………………………………………………………………………..5221
1.4.1 Removing and installing silencer, Tiguan…………………………………………………………………………………………………………………………5221
1.4.2 Removing and installing silencer, Sharan…………………………………………………………………………………………………………………………5222
1.4.3 Removing and installing silencer, CC…………………………………………………………………………………………………………………………….5223
1.5 Aligning exhaust system free of tension……………………………………………………………………………………………………………………………….5224
1.5.1 Aligning exhaust system free of tension, Sharan…………………………………………………………………………………………………………………..5224
1.5.2 Aligning exhaust system free of tension, Tiguan…………………………………………………………………………………………………………………..5225
1.5.3 Align exhaust system such that it is not under stress, CC………………………………………………………………………………………………………….5225
1.6 Separating exhaust pipes, silencers…………………………………………………………………………………………………………………………………..5226
1.6.1 Separating exhaust pipes/silencers, Tiguan……………………………………………………………………………………………………………………….5226
1.6.2 Separating exhaust pipes/silencers, CC…………………………………………………………………………………………………………………………..5227
1.7 Installation position of clamp……………………………………………………………………………………………………………………………………….5228
1.7.1 Installation position of clamp, Sharan…………………………………………………………………………………………………………………………..5228
1.7.2 Installation position of clamp, Tiguan…………………………………………………………………………………………………………………………..5229
1.7.3 Installation position of clamp, CC………………………………………………………………………………………………………………………………5230
1.8 Aligning tailpipes………………………………………………………………………………………………………………………………………………….5231
1.9 Checking exhaust system for leaks…………………………………………………………………………………………………………………………………….5231
2 Emission control…………………………………………………………………………………………………………………………………………………………5232
2.1 Assembly overview – emission control………………………………………………………………………………………………………………………………….5232
2.1.1 Versions of emission control module……………………………………………………………………………………………………………………………..5232
2.1.2 Assembly overview – emission control, version 1…………………………………………………………………………………………………………………..5232
2.1.3 Assembly overview – emission control, version 2…………………………………………………………………………………………………………………..5235
2.2 Removing and installing emission control module………………………………………………………………………………………………………………………..5237
2.2.1 Removing and installing emission control module, version 1…………………………………………………………………………………………………………5237
2.2.2 Removing and installing emission control module, version 2…………………………………………………………………………………………………………5244
2.3 Removing and installing catalytic converter……………………………………………………………………………………………………………………………5250
3 SCR system (selective catalytic reduction)………………………………………………………………………………………………………………………………….5251
3.1 Assembly overview – tank for reducing agent……………………………………………………………………………………………………………………………5251
3.1.1 Assembly overview – tank for reducing agent, Tiguan……………………………………………………………………………………………………………….5251
3.1.2 Assembly overview – tank for reducing agent, Sharan……………………………………………………………………………………………………………….5253
3.2 Assembly overview – reducing agent supply line…………………………………………………………………………………………………………………………5254
3.2.1 Assembly overview – reducing agent supply line, Tiguan…………………………………………………………………………………………………………….5254
3.2.2 Assembly overview – reducing agent supply line, Sharan…………………………………………………………………………………………………………….5255
3.3 Assembly overview – delivery module for reducing agent………………………………………………………………………………………………………………….5256
3.4 Removing and installing tank for reducing agent………………………………………………………………………………………………………………………..5256
3.4.1 Removing and installing tank for reducing agent, Tiguan……………………………………………………………………………………………………………5256
3.4.2 Removing and installing tank for reducing agent, Sharan……………………………………………………………………………………………………………5258
3.5 Removing and installing reducing agent supply line……………………………………………………………………………………………………………………..5262
3.5.1 Removing and installing front section of reducing agent supply line…………………………………………………………………………………………………5262
3.5.2 Removing and installing rear section of reducing agent supply line, Sharan…………………………………………………………………………………………..5264
3.5.3 Removing and installing rear section of reducing agent supply line, Tiguan…………………………………………………………………………………………..5265
3.6 Removing and installing delivery module for reducing agent………………………………………………………………………………………………………………5266
3.7 Removing and installing injector for reducing agent -N474-………………………………………………………………………………………………………………5268
3.8 Removing and installing control unit for reducing-agent heater -J891-…………………………………………………………………………………………………….5269
3.8.1 Removing and installing control unit for reducing-agent heater -J891-, Tiguan………………………………………………………………………………………..5269
3.8.2 Removing and installing control unit for reducing-agent heater -J891-, Sharan………………………………………………………………………………………..5271
3.9 Assembly overview – injector for reducing agent -N474-………………………………………………………………………………………………………………….5272
3.10 Emptying tank for reducing agent…………………………………………………………………………………………………………………………………….5273
3.10.1 Emptying tank for reducing agent, Tiguan………………………………………………………………………………………………………………………..5273
3.10.2 Emptying tank for reducing agent, Sharan………………………………………………………………………………………………………………………..5276
3.11 Disconnecting reducing agent supply line……………………………………………………………………………………………………………………………..5279
4 Exhaust gas temperature regulation…………………………………………………………………………………………………………………………………………5281
4.1 Assembly overview – exhaust gas temperature regulation………………………………………………………………………………………………………………….5281
4.1.1 Assembly overview – exhaust gas temperature regulation, vehicles without SCR system…………………………………………………………………………………..5281
4.1.2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system……………………………………………………………………………………..5283
4.1.3 Assembly overview – exhaust gas temperature regulation, vehicles with emission control module, version 2………………………………………………………………..5284
4.2 Removing and installing exhaust gas temperature sender………………………………………………………………………………………………………………….5285
4.2.1 Removing and installing exhaust gas temperature sender 1 -G235-…………………………………………………………………………………………………….5285
4.2.2 Removing and installing exhaust gas temperature sender 2 -G448-, Sharan and Tiguan……………………………………………………………………………………5287
4.2.3 Removing and installing exhaust gas temperature sender 2 -G448-, CC…………………………………………………………………………………………………5290
4.2.4 Removing and installing exhaust gas temperature sender 3 -G495-, Sharan and Tiguan……………………………………………………………………………………5291
4.2.5 Removing and installing exhaust gas temperature sender 3 -G495-, CC…………………………………………………………………………………………………5293
4.2.6 Removing and installing exhaust gas temperature sender 4 -G648-, Sharan and Tiguan……………………………………………………………………………………5295
4.2.7 Removing and installing exhaust gas temperature sender 4 -G648-, CC…………………………………………………………………………………………………5297
5 Exhaust gas recirculation…………………………………………………………………………………………………………………………………………………5300
5.1 Assembly overview – exhaust gas recirculation system……………………………………………………………………………………………………………………5300
5.2 Assembly overview – exhaust gas recirculation control motor -V338-……………………………………………………………………………………………………….5302
5.3 Removing and installing exhaust gas recirculation cooler………………………………………………………………………………………………………………..5302
5.4 Checking exhaust gas recirculation cooler for leaks…………………………………………………………………………………………………………………….5305
5.5 Removing and installing exhaust gas recirculation control motor -V338-……………………………………………………………………………………………………5308
5.6 Removing and installing exhaust gas recirculation control motor 2 -V339-………………………………………………………………………………………………….5309
28 – Glow plug system………………………………………………………………………………………………………………………………………………………….5310
1 Glow plug system…………………………………………………………………………………………………………………………………………………………5310
1.1 Assembly overview – glow plug system………………………………………………………………………………………………………………………………….5310
1.2 Removing and installing glow plug…………………………………………………………………………………………………………………………………….5311
1.3 Removing and installing automatic glow period control unit -J179-………………………………………………………………………………………………………..5313
1.4 Removing and installing Hall sender -G40-……………………………………………………………………………………………………………………………..5313
1.5 Removing and installing engine speed sender -G28-………………………………………………………………………………………………………………………5314
Sharan2016-4-cylinder_injection_engine_(1_4_l_direct_injection_engine__turbocharger)……………………………………………………………………………………………………..5316
00 – Technical data……………………………………………………………………………………………………………………………………………………………5322
1 Safety instructions………………………………………………………………………………………………………………………………………………………5322
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………..5322
1.2 Safety precautions when working on vehicles with a Start/Stop system……………………………………………………………………………………………………..5322
1.3 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………5323
1.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………5323
1.5 Safety precautions when working on ignition system……………………………………………………………………………………………………………………..5323
2 Identification…………………………………………………………………………………………………………………………………………………………..5324
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………..5324
3 Repair instructions………………………………………………………………………………………………………………………………………………………5325
3.1 Rules for cleanliness……………………………………………………………………………………………………………………………………………….5325
3.2 Foreign objects in engine……………………………………………………………………………………………………………………………………………5325
3.3 Contact corrosion…………………………………………………………………………………………………………………………………………………..5325
3.4 Routing and securing lines…………………………………………………………………………………………………………………………………………..5325
3.5 Installing coolers, condensers and radiators…………………………………………………………………………………………………………………………..5326
3.6 Testing vacuum system……………………………………………………………………………………………………………………………………………….5326
10 – Removing and installing engine……………………………………………………………………………………………………………………………………………..5327
1 Removing and installing engine…………………………………………………………………………………………………………………………………………….5327
1.1 Removing engine…………………………………………………………………………………………………………………………………………………….5327
1.1.1 Removing engine, Golf Cabriolet…………………………………………………………………………………………………………………………………5327
1.1.2 Removing engine, Sharan, CC and Tiguan…………………………………………………………………………………………………………………………..5336
1.2 Separating engine and gearbox………………………………………………………………………………………………………………………………………..5346
1.3 Securing engine on engine and gearbox support………………………………………………………………………………………………………………………….5347
1.4 Installing engine…………………………………………………………………………………………………………………………………………………..5349
2 Assembly mountings……………………………………………………………………………………………………………………………………………………….5353
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………..5353
2.1.1 Assembly overview – assembly mountings, Golf Cabriolet and CC………………………………………………………………………………………………………5353
2.1.2 Assembly overview – assembly mountings, Sharan and Tiguan………………………………………………………………………………………………………….5356
2.2 Removing and installing engine mountings………………………………………………………………………………………………………………………………5358
2.2.1 Removing and installing engine mountings, Golf Cabriolet and CC…………………………………………………………………………………………………….5358
2.2.2 Removing and installing engine mountings, Sharan and Tiguan………………………………………………………………………………………………………..5359
2.3 Removing and installing gearbox mounting………………………………………………………………………………………………………………………………5360
2.4 Removing and installing pendulum support………………………………………………………………………………………………………………………………5361
2.5 Supporting engine in installation position…………………………………………………………………………………………………………………………….5362
2.5.1 Supporting engine in installation position, Golf Cabriolet…………………………………………………………………………………………………………5362
2.5.2 Supporting engine in installation position, Tiguan………………………………………………………………………………………………………………..5365
2.5.3 Supporting engine in installation position, Sharan………………………………………………………………………………………………………………..5369
2.5.4 Supporting engine in installation position, CC……………………………………………………………………………………………………………………5371
2.6 Checking adjustment of assembly mountings……………………………………………………………………………………………………………………………..5372
2.7 Adjusting assembly mountings…………………………………………………………………………………………………………………………………………5372
13 – Crankshaft group………………………………………………………………………………………………………………………………………………………….5375
1 Cylinder block (pulley end)……………………………………………………………………………………………………………………………………………….5375
1.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………………5375
1.1.1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor……………………………………………………………………………………5375
1.1.2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor………………………………………………………………………………………5377
1.2 Assembly overview – sealing flange, belt pulley end…………………………………………………………………………………………………………………….5379
1.3 Removing and installing poly V-belt…………………………………………………………………………………………………………………………………..5380
1.3.1 Removing and installing poly V-belt, vehicles without air conditioner compressor……………………………………………………………………………………..5380
1.3.2 Removing and installing poly V-belt, vehicles with air conditioner compressor………………………………………………………………………………………..5381
1.4 Removing and installing tensioner for poly V-belt………………………………………………………………………………………………………………………5383
1.4.1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor…………………………………………………………………………5383
1.4.2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor……………………………………………………………………………5383
1.5 Removing and installing vibration damper………………………………………………………………………………………………………………………………5384
1.6 Removing and installing engine support………………………………………………………………………………………………………………………………..5385
1.7 Renewing crankshaft oil seal – belt pulley end…………………………………………………………………………………………………………………………5387
1.8 Removing and installing sealing flange on pulley end……………………………………………………………………………………………………………………5389
2 Cylinder block, gearbox end……………………………………………………………………………………………………………………………………………….5392
2.1 Assembly overview – cylinder block, gearbox end………………………………………………………………………………………………………………………..5392
2.2 Removing and installing flywheel……………………………………………………………………………………………………………………………………..5393
2.3 Removing and installing sealing flange on gearbox side………………………………………………………………………………………………………………….5394
3 Crankshaft………………………………………………………………………………………………………………………………………………………………5404
3.1 Renewing needle bearing in crankshaft…………………………………………………………………………………………………………………………………5404
3.2 Crankshaft dimensions……………………………………………………………………………………………………………………………………………….5406
3.3 Measuring axial clearance of crankshaft……………………………………………………………………………………………………………………………….5406
4 Pistons and conrods………………………………………………………………………………………………………………………………………………………5408
4.1 Assembly overview – pistons and conrods……………………………………………………………………………………………………………………………….5408
4.2 Removing and installing pistons………………………………………………………………………………………………………………………………………5410
4.3 Removing and installing oil spray jets………………………………………………………………………………………………………………………………..5411
4.4 Checking piston and cylinder bore…………………………………………………………………………………………………………………………………….5412
4.5 Checking radial clearance of conrods………………………………………………………………………………………………………………………………….5413
4.6 Separating new conrod……………………………………………………………………………………………………………………………………………….5413
15 – Cylinder head, valve gear………………………………………………………………………………………………………………………………………………….5415
1 Cylinder head……………………………………………………………………………………………………………………………………………………………5415
1.1 Assembly overview – cylinder head…………………………………………………………………………………………………………………………………….5415
1.2 Assembly overview – camshaft housing………………………………………………………………………………………………………………………………….5417
1.2.1 Assembly overview – camshaft housing, vehicles with adjustable exhaust camshaft………………………………………………………………………………………5417
1.2.2 Assembly overview – camshaft housing, vehicles without adjustable exhaust camshaft……………………………………………………………………………………5419
1.3 Removing and installing cylinder head…………………………………………………………………………………………………………………………………5420
1.4 Removing and installing camshaft housing………………………………………………………………………………………………………………………………5424
1.5 Checking compression………………………………………………………………………………………………………………………………………………..5428
2 Toothed belt drive……………………………………………………………………………………………………………………………………………………….5431
2.1 Assembly overview – toothed belt guard………………………………………………………………………………………………………………………………..5431
2.2 Assembly overview – toothed belt……………………………………………………………………………………………………………………………………..5432
2.2.1 Assembly overview – toothed belt, vehicles without adjustable exhaust camshaft……………………………………………………………………………………….5432
2.2.2 Assembly overview – toothed belt, vehicles with adjustable exhaust camshaft………………………………………………………………………………………….5434
2.3 Removing and installing toothed belt………………………………………………………………………………………………………………………………….5436
2.3.1 Removing and installing toothed belt, vehicles without adjustable exhaust camshaft……………………………………………………………………………………5436
2.3.2 Removing and installing toothed belt, vehicles with adjustable exhaust camshaft………………………………………………………………………………………5448
2.4 Checking valve timing……………………………………………………………………………………………………………………………………………….5461
2.4.1 Checking valve timing, vehicles without adjustable exhaust camshaft…………………………………………………………………………………………………5461
2.4.2 Checking valve timing, vehicles with adjustable exhaust camshaft……………………………………………………………………………………………………5467
2.5 Removing toothed belt from camshaft…………………………………………………………………………………………………………………………………..5472
2.5.1 Removing toothed belt from camshafts, vehicles without adjustable exhaust camshaft……………………………………………………………………………………5472
2.5.2 Removing toothed belt from camshafts, vehicles with adjustable exhaust camshaft………………………………………………………………………………………5483
3 Valve gear………………………………………………………………………………………………………………………………………………………………5495
3.1 Assembly overview – valve gear……………………………………………………………………………………………………………………………………….5495
3.2 Measuring axial play of camshaft……………………………………………………………………………………………………………………………………..5496
3.3 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………..5497
3.3.1 Removing and installing inlet camshaft oil seal, pulley end, vehicles without adjustable exhaust camshaft……………………………………………………………….5497
3.3.2 Removing and installing inlet camshaft oil seal, pulley end, vehicles with adjustable exhaust camshaft………………………………………………………………….5499
3.3.3 Removing and installing exhaust camshaft oil seal, pulley end, vehicles without adjustable exhaust camshaft……………………………………………………………..5501
3.3.4 Removing and installing exhaust camshaft oil seal, pulley end, vehicles with adjustable exhaust camshaft………………………………………………………………..5503
3.3.5 Removing and installing exhaust camshaft oil seal, gearbox end……………………………………………………………………………………………………..5505
3.4 Removing and installing camshaft adjuster……………………………………………………………………………………………………………………………..5507
3.5 Removing and installing inlet camshaft control valve 1 -N205-……………………………………………………………………………………………………………5508
3.6 Removing and installing exhaust camshaft control valve 1 -N318-………………………………………………………………………………………………………….5508
3.7 Removing and installing valve stem seals………………………………………………………………………………………………………………………………5509
3.7.1 Removing and installing valve stem seals, cylinder head installed…………………………………………………………………………………………………..5509
3.7.2 Removing and installing valve stem seals, cylinder head removed…………………………………………………………………………………………………….5513
4 Inlet and exhaust valves………………………………………………………………………………………………………………………………………………….5517
4.1 Checking valve guides……………………………………………………………………………………………………………………………………………….5517
4.2 Checking valves…………………………………………………………………………………………………………………………………………………….5517
4.3 Valve dimensions……………………………………………………………………………………………………………………………………………………5518
17 – Lubrication………………………………………………………………………………………………………………………………………………………………5519
1 Sump, oil pump…………………………………………………………………………………………………………………………………………………………..5519
1.1 Assembly overview – sump and oil pump…………………………………………………………………………………………………………………………………5519
1.2 Engine oil…………………………………………………………………………………………………………………………………………………………5522
1.3 Removing and installing bottom section of sump…………………………………………………………………………………………………………………………5522
1.4 Removing and installing upper part of sump…………………………………………………………………………………………………………………………….5525
1.5 Removing and installing oil pump……………………………………………………………………………………………………………………………………..5527
1.6 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………5528
2 Engine oil cooler………………………………………………………………………………………………………………………………………………………..5530
2.1 Assembly overview – engine oil cooler…………………………………………………………………………………………………………………………………5530
2.2 Removing and installing engine oil cooler……………………………………………………………………………………………………………………………..5530
3 Crankcase breather……………………………………………………………………………………………………………………………………………………….5532
3.1 Assembly overview – crankcase breather system………………………………………………………………………………………………………………………….5532
3.2 Removing and installing oil separator…………………………………………………………………………………………………………………………………5533
4 Oil filter, oil pressure switch……………………………………………………………………………………………………………………………………………5535
4.1 Assembly overview – oil filter/oil pressure switch……………………………………………………………………………………………………………………..5535
4.2 Removing and installing oil pressure switch -F1-……………………………………………………………………………………………………………………….5536
4.3 Removing and installing oil pressure switch for reduced oil pressure -F378-……………………………………………………………………………………………….5537
4.4 Checking oil pressure……………………………………………………………………………………………………………………………………………….5538
4.5 Removing and installing oil pressure regulating valve -N428-…………………………………………………………………………………………………………….5540
19 – Cooling………………………………………………………………………………………………………………………………………………………………….5542
1 Cooling system, coolant…………………………………………………………………………………………………………………………………………………..5542
1.1 Coolant hose schematic diagram……………………………………………………………………………………………………………………………………….5542
1.2 Checking cooling system for leaks…………………………………………………………………………………………………………………………………….5543
1.3 Draining and filling coolant…………………………………………………………………………………………………………………………………………5544
2 Coolant pump, regulation of cooling system………………………………………………………………………………………………………………………………….5550
2.1 Assembly overview – coolant pump, thermostat…………………………………………………………………………………………………………………………..5550
2.2 Assembly overview – electric coolant pump……………………………………………………………………………………………………………………………..5552
2.3 Assembly overview – coolant temperature sender…………………………………………………………………………………………………………………………5554
2.4 Removing and installing electric coolant pump………………………………………………………………………………………………………………………….5554
2.4.1 Removing and installing charge air cooling pump -V188-…………………………………………………………………………………………………………….5554
2.5 Removing and installing coolant pump………………………………………………………………………………………………………………………………….5556
2.6 Removing and installing thermostat……………………………………………………………………………………………………………………………………5561
2.6.1 Removing and installing thermostat for large cooling circuit……………………………………………………………………………………………………….5561
2.6.2 Removing and installing thermostat for small cooling circuit……………………………………………………………………………………………………….5562
2.7 Removing and installing toothed belt pulley for coolant pump…………………………………………………………………………………………………………….5563
2.8 Removing and installing coolant temperature sender -G62-………………………………………………………………………………………………………………..5564
2.9 Removing and installing coolant temperature sender at radiator outlet -G83-……………………………………………………………………………………………….5566
3 Coolant pipes……………………………………………………………………………………………………………………………………………………………5567
3.1 Assembly overview – coolant pipes…………………………………………………………………………………………………………………………………….5567
3.2 Removing and installing coolant pipes…………………………………………………………………………………………………………………………………5567
4 Radiator and radiator fan…………………………………………………………………………………………………………………………………………………5571
4.1 Assembly overview – radiator and radiator fan………………………………………………………………………………………………………………………….5571
4.1.1 Assembly overview – radiator and radiator fan, Golf Cabriolet, CC and Tiguan…………………………………………………………………………………………5571
4.1.2 Assembly overview – radiator and radiator fan, Sharan……………………………………………………………………………………………………………..5574
4.2 Assembly overview – radiator cowl and radiator fan……………………………………………………………………………………………………………………..5576
4.2.1 Assembly overview – radiator cowl and radiator fan, Golf Cabriolet, CC and Tiguan…………………………………………………………………………………….5576
4.2.2 Assembly overview – radiator cowl and radiator fan, Sharan…………………………………………………………………………………………………………5577
4.3 Removing and installing radiator……………………………………………………………………………………………………………………………………..5577
4.3.1 Removing and installing radiator, Golf Cabriolet, CC and Tiguan…………………………………………………………………………………………………….5577
4.3.2 Removing and installing radiator, Sharan…………………………………………………………………………………………………………………………5578
4.4 Removing and installing water radiator for charge air cooling circuit…………………………………………………………………………………………………….5580
4.4.1 Removing and installing water radiator for charge air cooling circuit, Golf Cabriolet, CC and Tiguan……………………………………………………………………5580
4.4.2 Removing and installing water radiator for charge air cooling circuit, Sharan………………………………………………………………………………………..5583
4.5 Removing and installing radiator cowl…………………………………………………………………………………………………………………………………5584
4.5.1 Removing and installing radiator cowl with radiator fan, Golf Cabriolet, CC and Tiguan………………………………………………………………………………..5584
4.5.2 Removing and installing radiator cowl with radiator fan, Sharan…………………………………………………………………………………………………….5585
4.6 Removing and installing radiator fan -V7- and radiator fan 2 -V177-………………………………………………………………………………………………………5586
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………..5588
1 Turbocharger…………………………………………………………………………………………………………………………………………………………….5588
1.1 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………..5588
1.2 Removing and installing turbocharger………………………………………………………………………………………………………………………………….5590
1.3 Removing and installing charge pressure positioner -V465-……………………………………………………………………………………………………………….5593
2 Charge air system………………………………………………………………………………………………………………………………………………………..5595
2.1 Assembly overview – charge air system…………………………………………………………………………………………………………………………………5595
2.2 Removing and installing charge air cooler……………………………………………………………………………………………………………………………..5597
2.3 Removing and installing charge pressure sender -GX26-…………………………………………………………………………………………………………………..5599
2.4 Checking charge air system for leaks………………………………………………………………………………………………………………………………….5600
2.5 Removing and installing air intake pipe……………………………………………………………………………………………………………………………….5602
24 – Mixture preparation – injection…………………………………………………………………………………………………………………………………………….5604
1 Injection system…………………………………………………………………………………………………………………………………………………………5604
1.1 Overview of fitting locations – injection system……………………………………………………………………………………………………………………….5604
1.2 Releasing high pressure in fuel system………………………………………………………………………………………………………………………………..5607
2 Injectors……………………………………………………………………………………………………………………………………………………………….5609
2.1 Assembly overview – fuel rail with injectors…………………………………………………………………………………………………………………………..5609
2.2 Removing and installing fuel rail…………………………………………………………………………………………………………………………………….5610
2.3 Removing and installing injectors…………………………………………………………………………………………………………………………………….5610
2.4 Cleaning injectors………………………………………………………………………………………………………………………………………………….5614
3 Air filter………………………………………………………………………………………………………………………………………………………………5616
3.1 Assembly overview – air filter housing………………………………………………………………………………………………………………………………..5616
3.2 Removing and installing air filter housing…………………………………………………………………………………………………………………………….5617
4 Intake manifold………………………………………………………………………………………………………………………………………………………….5618
4.1 Assembly overview – intake manifold…………………………………………………………………………………………………………………………………..5618
4.2 Removing and installing intake manifold……………………………………………………………………………………………………………………………….5620
4.3 Removing and installing throttle valve module -GX3-…………………………………………………………………………………………………………………….5622
4.4 Cleaning throttle valve module -GX3-………………………………………………………………………………………………………………………………….5623
5 Senders and sensors………………………………………………………………………………………………………………………………………………………5625
5.1 Removing and installing intake manifold sender -GX9-……………………………………………………………………………………………………………………5625
5.2 Removing and installing fuel pressure sender -G247-…………………………………………………………………………………………………………………….5625
5.3 Checking fuel pressure sender -G247-………………………………………………………………………………………………………………………………….5626
6 Engine control unit………………………………………………………………………………………………………………………………………………………5629
6.1 Removing and installing engine control unit -J623-……………………………………………………………………………………………………………………..5629
6.1.1 Removing and installing engine control unit -J623-, Sharan and Tiguan……………………………………………………………………………………………….5629
6.1.2 Removing and installing engine control unit -J623-, Golf Cabriolet and CC……………………………………………………………………………………………5631
6.2 Removing and installing engine control unit -J623- with protective housing………………………………………………………………………………………………..5633
6.2.1 Removing and installing engine control unit -J623- with protective housing, Sharan and Tiguan………………………………………………………………………….5633
6.2.2 Removing and installing engine control unit -J623- with protective housing, Golf Cabriolet and CC………………………………………………………………………5636
7 High-pressure pump……………………………………………………………………………………………………………………………………………………….5641
7.1 Assembly overview – high-pressure pump………………………………………………………………………………………………………………………………..5641
7.2 Removing and installing high-pressure pump…………………………………………………………………………………………………………………………….5642
7.3 Removing and installing high-pressure pipe…………………………………………………………………………………………………………………………….5643
8 Lambda probe…………………………………………………………………………………………………………………………………………………………….5645
8.1 Assembly overview – Lambda probe……………………………………………………………………………………………………………………………………..5645
8.2 Removing and installing Lambda probe 1 before catalytic converter -GX10-………………………………………………………………………………………………….5646
8.3 Removing and installing Lambda probe 1 after catalytic converter -GX7-……………………………………………………………………………………………………5647
26 – Exhaust system……………………………………………………………………………………………………………………………………………………………5648
1 Exhaust pipes, silencers………………………………………………………………………………………………………………………………………………….5648
1.1 Assembly overview – silencers………………………………………………………………………………………………………………………………………..5648
1.1.1 Assembly overview – silencer, Golf Cabriolet……………………………………………………………………………………………………………………..5648
1.1.2 Assembly overview – silencer, CC………………………………………………………………………………………………………………………………..5650
1.1.3 Assembly overview – silencer, Sharan…………………………………………………………………………………………………………………………….5652
1.1.4 Assembly overview – silencers, Tiguan……………………………………………………………………………………………………………………………5653
1.2 Separating exhaust pipes, silencers…………………………………………………………………………………………………………………………………..5654
1.2.1 Separating exhaust pipes/silencers, CC…………………………………………………………………………………………………………………………..5654
1.2.2 Separating exhaust pipes/silencers, Tiguan……………………………………………………………………………………………………………………….5655
1.3 Removing and installing silencer……………………………………………………………………………………………………………………………………..5657
1.3.1 Removing and installing silencer, Golf Cabriolet………………………………………………………………………………………………………………….5657
1.3.2 Removing and installing silencer, CC…………………………………………………………………………………………………………………………….5657
1.3.3 Removing and installing silencer, Tiguan…………………………………………………………………………………………………………………………5660
1.3.4 Removing and installing silencer, Sharan…………………………………………………………………………………………………………………………5660
1.4 Installation position of clamp……………………………………………………………………………………………………………………………………….5661
1.4.1 Installation position of clamp, Golf Cabriolet……………………………………………………………………………………………………………………5661
1.4.2 Installation position of clamp, CC………………………………………………………………………………………………………………………………5662
1.4.3 Installation position of clamp, Sharan…………………………………………………………………………………………………………………………..5662
1.4.4 Installation position of clamp, Tiguan…………………………………………………………………………………………………………………………..5663
1.5 Aligning exhaust system free of stress………………………………………………………………………………………………………………………………..5664
1.5.1 Aligning exhaust system free of stress, Golf Cabriolet…………………………………………………………………………………………………………….5664
1.5.2 Align exhaust system such that it is not under stress, CC………………………………………………………………………………………………………….5665
1.5.3 Aligning exhaust system free of stress, Tiguan……………………………………………………………………………………………………………………5665
1.5.4 Aligning exhaust system free of stress, Sharan……………………………………………………………………………………………………………………5667
1.6 Checking exhaust system for leaks…………………………………………………………………………………………………………………………………….5668
2 Emission control…………………………………………………………………………………………………………………………………………………………5669
2.1 Assembly overview – emission control………………………………………………………………………………………………………………………………….5669
2.2 Removing and installing catalytic converter……………………………………………………………………………………………………………………………5670
28 – Ignition system…………………………………………………………………………………………………………………………………………………………..5673
1 Ignition system………………………………………………………………………………………………………………………………………………………….5673
1.1 Assembly overview – ignition system…………………………………………………………………………………………………………………………………..5673
1.2 Test data, spark plugs………………………………………………………………………………………………………………………………………………5674
1.3 Removing and installing ignition coils with output stage………………………………………………………………………………………………………………..5674
1.4 Removing and installing knock sensor 1 -G61-…………………………………………………………………………………………………………………………..5676
1.5 Removing and installing Hall sender -G40-……………………………………………………………………………………………………………………………..5677
1.6 Removing and installing Hall sender 3 -G300-…………………………………………………………………………………………………………………………..5677
1.7 Removing and installing engine speed sender -G28-………………………………………………………………………………………………………………………5678
Sharan2016-6-speed_dual_clutch_gearbox_02E…………………………………………………………………………………………………………………………………………..5680
00 – Technical data……………………………………………………………………………………………………………………………………………………………5684
1 Safety instructions………………………………………………………………………………………………………………………………………………………5684
1.1 General safety provisions……………………………………………………………………………………………………………………………………………5684
1.2 Safety precautions when working on vehicles with a Start/Stop system……………………………………………………………………………………………………..5685
1.3 Safety measures when tow-starting and towing…………………………………………………………………………………………………………………………..5685
1.4 Safety precautions when using testers and measuring instruments during a road test…………………………………………………………………………………………5685
2 Identification…………………………………………………………………………………………………………………………………………………………..5687
2.1 Gearbox identification………………………………………………………………………………………………………………………………………………5687
2.1.1 Identification on gearbox………………………………………………………………………………………………………………………………………5687
2.1.2 Reading gearbox code letters……………………………………………………………………………………………………………………………………5687
3 Repair instructions………………………………………………………………………………………………………………………………………………………5690
3.1 General repair notes………………………………………………………………………………………………………………………………………………..5690
3.1.1 General notes…………………………………………………………………………………………………………………………………………………5690
3.2 Seals and sealing rings……………………………………………………………………………………………………………………………………………..5691
3.3 Nuts and bolts……………………………………………………………………………………………………………………………………………………..5691
4 Technical data…………………………………………………………………………………………………………………………………………………………..5692
4.1 Allocation of gearbox to engine………………………………………………………………………………………………………………………………………5692
4.1.1 Scirocco 2015 ►……………………………………………………………………………………………………………………………………………….5692
4.1.2 Sharan 2016 ►…………………………………………………………………………………………………………………………………………………5692
4.2 Capacities…………………………………………………………………………………………………………………………………………………………5692
4.2.1 Capacities – dual clutch gearbox………………………………………………………………………………………………………………………………..5692
5 Electrical components…………………………………………………………………………………………………………………………………………………….5693
5.1 Overview of fitting locations – electrical components…………………………………………………………………………………………………………………..5693
30 – Clutch…………………………………………………………………………………………………………………………………………………………………..5694
1 Clutch………………………………………………………………………………………………………………………………………………………………….5694
1.1 Assembly overview – dual clutch………………………………………………………………………………………………………………………………………5694
1.2 Removing and installing clutch end cover………………………………………………………………………………………………………………………………5696
1.3 Removing dual clutch………………………………………………………………………………………………………………………………………………..5700
1.4 Installing dual clutch………………………………………………………………………………………………………………………………………………5701
34 – Controls, housing…………………………………………………………………………………………………………………………………………………………5708
1 Mechatronic unit…………………………………………………………………………………………………………………………………………………………5708
1.1 Assembly overview – mechatronic unit………………………………………………………………………………………………………………………………….5708
1.2 Removing and installing sump…………………………………………………………………………………………………………………………………………5710
1.3 Removing and installing mechatronic unit for dual clutch gearbox -J743-…………………………………………………………………………………………………..5713
1.3.1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed…………………………………………………………………………….5713
1.3.2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed………………………………………………………………………………5723
1.3.3 Removing and installing gearbox input speed sender -G182- and clutch temperature sender -G509-…………………………………………………………………………5731
2 Selector mechanism……………………………………………………………………………………………………………………………………………………….5733
2.1 Assembly overview – selector mechanism………………………………………………………………………………………………………………………………..5733
2.1.1 Assembly overview – selector mechanism, manufacturer ZF……………………………………………………………………………………………………………5733
2.1.2 Assembly overview – selector mechanism, manufacturer ECS…………………………………………………………………………………………………………..5735
2.2 Emergency release from position P…………………………………………………………………………………………………………………………………….5736
2.2.1 Emergency release from P position, manufacturer ZF………………………………………………………………………………………………………………..5736
2.2.2 Emergency release from P position, manufacturer ECS……………………………………………………………………………………………………………….5737
2.3 Removing and installing selector lever handle………………………………………………………………………………………………………………………….5738
2.4 Moving push button to installation position in the handle……………………………………………………………………………………………………………….5741
2.5 Removing and installing selector mechanism…………………………………………………………………………………………………………………………….5743
2.5.1 Removing and installing selector mechanism with selector lever cable………………………………………………………………………………………………..5743
2.5.2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF………………………………………………………………………………5744
2.5.3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS……………………………………………………………………………..5747
2.6 Removing and installing selector lever cable…………………………………………………………………………………………………………………………..5749
2.6.1 Removing and installing selector lever cable, manufacturer ZF………………………………………………………………………………………………………5749
2.6.2 Removing and installing selector lever cable, manufacturer ECS……………………………………………………………………………………………………..5751
2.7 Checking selector mechanism………………………………………………………………………………………………………………………………………….5753
2.8 Checking and adjusting selector lever cable……………………………………………………………………………………………………………………………5754
2.9 Renewing oil seal for selector shaft………………………………………………………………………………………………………………………………….5756
3 Removing and installing gearbox……………………………………………………………………………………………………………………………………………5759
3.1 Removing gearbox……………………………………………………………………………………………………………………………………………………5759
3.1.1 Removing gearbox, Scirocco 2015 ►, vehicles with diesel engine……………………………………………………………………………………………………..5759
3.1.2 Removing gearbox, Scirocco 2015 ►, vehicles with petrol engine……………………………………………………………………………………………………..5766
3.1.3 Removing gearbox, Sharan 2016 ► with 2.0 l diesel engine…………………………………………………………………………………………………………..5772
3.1.4 Removing gearbox, Sharan 2016 ► with 2.0 l petrol engine…………………………………………………………………………………………………………..5781
3.1.5 Removing gearbox, Sharan 2016 ► with 1.4 l petrol engine…………………………………………………………………………………………………………..5790
3.2 Installing gearbox………………………………………………………………………………………………………………………………………………….5797
3.3 Specified torques for gearbox………………………………………………………………………………………………………………………………………..5800
4 Assembly mountings……………………………………………………………………………………………………………………………………………………….5801
4.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………..5801
5 Transporting gearbox……………………………………………………………………………………………………………………………………………………..5803
6 Dismantling and assembling gearbox…………………………………………………………………………………………………………………………………………5804
6.1 Assembly overview – gearbox………………………………………………………………………………………………………………………………………….5804
7 Attachment to engine and gearbox support……………………………………………………………………………………………………………………………………5807
8 Gear oil circuit…………………………………………………………………………………………………………………………………………………………5808
8.1 Removing and installing gear oil cooler……………………………………………………………………………………………………………………………….5808
8.2 Removing and installing cover for gear oil pump………………………………………………………………………………………………………………………..5810
8.3 Removing and installing gearbox oil pump………………………………………………………………………………………………………………………………5812
8.4 Removing and installing gearbox oil filter…………………………………………………………………………………………………………………………….5813
9 Gear oil………………………………………………………………………………………………………………………………………………………………..5816
9.1 Checking gear oil level……………………………………………………………………………………………………………………………………………..5816
9.2 Draining and filling gearbox oil……………………………………………………………………………………………………………………………………..5819
35 – Gears, shafts…………………………………………………………………………………………………………………………………………………………….5823
1 Currently, no repairs can be made to gears and shafts………………………………………………………………………………………………………………………..5823
39 – Final drive – differential…………………………………………………………………………………………………………………………………………………5824
1 Oil seals……………………………………………………………………………………………………………………………………………………………….5824
1.1 Overview of fitting locations – seals…………………………………………………………………………………………………………………………………5824
1.2 Renewing left oil seal………………………………………………………………………………………………………………………………………………5824
1.3 Renewing right oil seal……………………………………………………………………………………………………………………………………………..5827
Sharan2016-6-speed_manual_gearbox_0A6……………………………………………………………………………………………………………………………………………….5833
00 – Technical data……………………………………………………………………………………………………………………………………………………………5839
1 Safety measures for vehicles with Start/Stop system………………………………………………………………………………………………………………………….5839
2 Identification…………………………………………………………………………………………………………………………………………………………..5840
2.1 Identification of manual gearbox……………………………………………………………………………………………………………………………………..5840
3 Identification code, assembly allocation, ratios, capacities………………………………………………………………………………………………………………….5841
3.1 Identification code, assembly allocation, ratios, capacities, Sharan front-wheel drive……………………………………………………………………………………..5841
3.2 Identification code, assembly allocation, ratios, capacities, Sharan all-wheel drive……………………………………………………………………………………….5841
3.3 Identification code, assembly allocation, ratios, capacities, Tiguan front-wheel drive……………………………………………………………………………………..5842
3.4 Identification code, assembly allocation, ratios, capacities, Tiguan all-wheel drive……………………………………………………………………………………….5843
3.5 Calculating overall gear ratio “i”……………………………………………………………………………………………………………………………………5847
4 Overview – power transmission……………………………………………………………………………………………………………………………………………..5848
4.1 Overview – power transmission, front-wheel drive……………………………………………………………………………………………………………………….5848
4.2 Overview – all-wheel drive power train………………………………………………………………………………………………………………………………..5850
5 Four-wheel drive – notes on performance test………………………………………………………………………………………………………………………………..5852
6 General repair notes……………………………………………………………………………………………………………………………………………………..5853
7 Electrical components…………………………………………………………………………………………………………………………………………………….5857
7.1 Overview of fitting locations – electrical components…………………………………………………………………………………………………………………..5857
7.1.1 Overview of fitting locations – electrical components, manual gearbox……………………………………………………………………………………………….5857
7.1.2 Overview of fitting locations – electrical components, clutch mechanism……………………………………………………………………………………………..5858
30 – Clutch…………………………………………………………………………………………………………………………………………………………………..5859
1 Clutch mechanism…………………………………………………………………………………………………………………………………………………………5859
1.1 Overview – clutch mechanism………………………………………………………………………………………………………………………………………….5859
1.2 Assembly overview – pedal cluster…………………………………………………………………………………………………………………………………….5861
1.3 Assembly overview – clutch hydraulics…………………………………………………………………………………………………………………………………5863
1.3.1 Assembly overview – clutch hydraulics (left-hand drive)……………………………………………………………………………………………………………5863
1.3.2 Assembly overview – clutch hydraulics (right-hand drive)…………………………………………………………………………………………………………..5865
1.4 Assembly overview – clutch release mechanism…………………………………………………………………………………………………………………………..5867
1.5 Removing and installing clutch pedal………………………………………………………………………………………………………………………………….5868
1.5.1 Removing……………………………………………………………………………………………………………………………………………………..5868
1.5.2 Installing……………………………………………………………………………………………………………………………………………………5871
1.5.3 Specified torques……………………………………………………………………………………………………………………………………………..5873
1.6 Removing and installing over-centre spring…………………………………………………………………………………………………………………………….5873
1.6.1 Removing……………………………………………………………………………………………………………………………………………………..5873
1.6.2 Installing……………………………………………………………………………………………………………………………………………………5876
1.6.3 Specified torques……………………………………………………………………………………………………………………………………………..5878
1.7 Removing and installing mounting bracket………………………………………………………………………………………………………………………………5878
1.7.1 Removing……………………………………………………………………………………………………………………………………………………..5879
1.7.2 Installing……………………………………………………………………………………………………………………………………………………5883
1.7.3 Specified torques……………………………………………………………………………………………………………………………………………..5884
1.8 Removing and installing clutch master cylinder…………………………………………………………………………………………………………………………5884
1.8.1 Removing……………………………………………………………………………………………………………………………………………………..5885
1.8.2 Installing……………………………………………………………………………………………………………………………………………………5885
1.9 Removing and installing clutch slave cylinder together with release bearing……………………………………………………………………………………………….5886
1.9.1 Removing……………………………………………………………………………………………………………………………………………………..5887
1.9.2 Installing……………………………………………………………………………………………………………………………………………………5887
1.10 Removing and installing line for clutch mechanism……………………………………………………………………………………………………………………..5888
1.10.1 Removing…………………………………………………………………………………………………………………………………………………….5888
1.10.2 Installing…………………………………………………………………………………………………………………………………………………..5889
1.11 Removing line and bleeder from and installing on slave cylinder…………………………………………………………………………………………………………5890
1.12 Bleeding clutch mechanism…………………………………………………………………………………………………………………………………………..5891
1.13 Removing and installing clutch position sender -G476-………………………………………………………………………………………………………………….5892
1.13.1 Removing and installing clutch position sender -G476-, LHD vehicles………………………………………………………………………………………………..5892
1.13.2 Removing and installing clutch position sender -G476-, RHD vehicles………………………………………………………………………………………………..5896
2 Clutch………………………………………………………………………………………………………………………………………………………………….5899
2.1 Assembly overview – “Sachs” clutch……………………………………………………………………………………………………………………………………5899
2.2 Removing and installing “Sachs” clutch………………………………………………………………………………………………………………………………..5901
2.2.1 Removing……………………………………………………………………………………………………………………………………………………..5901
2.2.2 Installing……………………………………………………………………………………………………………………………………………………5902
2.3 Assembly overview – “LuK” clutch……………………………………………………………………………………………………………………………………..5903
2.4 Removing and installing “LuK” clutch………………………………………………………………………………………………………………………………….5905
2.4.1 Removing……………………………………………………………………………………………………………………………………………………..5905
2.4.2 Installing……………………………………………………………………………………………………………………………………………………5906
34 – Controls, housing…………………………………………………………………………………………………………………………………………………………5909
1 Selector mechanism……………………………………………………………………………………………………………………………………………………….5909
1.1 Installation position – selector mechanism…………………………………………………………………………………………………………………………….5909
1.2 Overview – selector mechanism………………………………………………………………………………………………………………………………………..5911
1.3 Assembly overview – gear lever knob and cover………………………………………………………………………………………………………………………….5912
1.4 Assembly overview – Selector lever and selector housing…………………………………………………………………………………………………………………5914
1.5 Assembly overview – Selector cables…………………………………………………………………………………………………………………………………..5916
1.6 Removing and installing gear knob…………………………………………………………………………………………………………………………………….5920
1.7 Removing and installing selector mechanism…………………………………………………………………………………………………………………………….5921
1.7.1 Removing……………………………………………………………………………………………………………………………………………………..5921
1.7.2 Installing……………………………………………………………………………………………………………………………………………………5924
1.7.3 Specified torques……………………………………………………………………………………………………………………………………………..5926
1.8 Dismantling and assembling selector mechanism………………………………………………………………………………………………………………………….5927
1.9 Adjusting selector mechanism…………………………………………………………………………………………………………………………………………5931
1.10 Functional check…………………………………………………………………………………………………………………………………………………..5933
2 Distinguishing between different types of turbo diesel engines, Sharan…………………………………………………………………………………………………………5934
3 Removing and installing gearbox, Sharan front-wheel drive, engine lifting eyes »next to each other« on engine………………………………………………………………………5935
3.1 Removing gearbox……………………………………………………………………………………………………………………………………………………5939
3.2 Installing gearbox………………………………………………………………………………………………………………………………………………….5947
3.3 Specified torques…………………………………………………………………………………………………………………………………………………..5954
4 Removing and installing gearbox, Sharan front-wheel drive, engine lifting eyes »diagonally« on engine……………………………………………………………………………..5955
4.1 Removing gearbox……………………………………………………………………………………………………………………………………………………5957
4.2 Installing gearbox………………………………………………………………………………………………………………………………………………….5968
4.3 Specified torques for gearbox………………………………………………………………………………………………………………………………………..5977
5 Removing and installing gearbox, Sharan all-wheel drive, engine lifting eyes »next to each other« on engine………………………………………………………………………..5978
5.1 Removing gearbox……………………………………………………………………………………………………………………………………………………5981
5.2 Installing gearbox………………………………………………………………………………………………………………………………………………….5990
5.3 Specified torques…………………………………………………………………………………………………………………………………………………..5997
6 Removing and installing gearbox, Sharan all-wheel drive, engine lifting eyes »diagonally« on engine……………………………………………………………………………….5998
6.1 Removing gearbox……………………………………………………………………………………………………………………………………………………6000
6.2 Installing gearbox………………………………………………………………………………………………………………………………………………….6011
6.3 Specified torques for gearbox………………………………………………………………………………………………………………………………………..6019
7 Removing and installing gearbox – Tiguan front-wheel drive……………………………………………………………………………………………………………………6020
7.1 Removing gearbox……………………………………………………………………………………………………………………………………………………6022
7.2 Installing gearbox………………………………………………………………………………………………………………………………………………….6029
7.3 Specified torques…………………………………………………………………………………………………………………………………………………..6036
8 Removing and installing gearbox, Tiguan all-wheel drive………………………………………………………………………………………………………………………6037
8.1 Removing gearbox, Tiguan all-wheel drive with 1.4 l petrol engine………………………………………………………………………………………………………..6037
8.2 Installing gearbox, Tiguan all-wheel drive with 1.4 l petrol engine………………………………………………………………………………………………………6044
8.3 Removing gearbox, Tiguan all-wheel drive with 2.0 l petrol engine………………………………………………………………………………………………………..6051
8.4 Installing gearbox, Tiguan all-wheel drive with 2.0 l petrol engine………………………………………………………………………………………………………6060
8.5 Tiguan four-wheel drive with turbo diesel engine – removing gearbox………………………………………………………………………………………………………6068
8.6 Tiguan four-wheel drive with turbo diesel engine – installing gearbox…………………………………………………………………………………………………….6078
9 Assembly mountings……………………………………………………………………………………………………………………………………………………….6088
9.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………..6088
10 Transporting gearbox…………………………………………………………………………………………………………………………………………………….6089
11 Gearbox oil…………………………………………………………………………………………………………………………………………………………….6090
11.1 Check oil level in manual gearbox and top up………………………………………………………………………………………………………………………….6090
12 Removing and installing bevel box…………………………………………………………………………………………………………………………………………6091
12.1 Removing bevel box, Tiguan with 1.4 l petrol engine……………………………………………………………………………………………………………………6091
12.2 Installing bevel box, Tiguan with 1.4 l petrol engine………………………………………………………………………………………………………………….6095
12.3 Removing bevel box, Tiguan with 2.0 l petrol engine……………………………………………………………………………………………………………………6098
12.4 Installing bevel box, Tiguan with 2.0 l petrol engine………………………………………………………………………………………………………………….6102
12.5 Removing bevel box – vehicles with turbo diesel engine, up to 05.10……………………………………………………………………………………………………..6106
12.6 Installing bevel box – vehicles with turbo diesel engine, up to 05.10……………………………………………………………………………………………………6110
12.7 Removing bevel box, all vehicles with turbo diesel engine, as of 06.10 (common rail, generation II)…………………………………………………………………………6114
12.8 Installing bevel box, all vehicles with turbo diesel engine, as of 06.10 (common rail, generation II)……………………………………………………………………….6119
12.9 Removing bevel box, vehicles with turbo diesel engine, up to 05.15………………………………………………………………………………………………………6123
12.10 Installing bevel box, vehicles with turbo diesel engine, as of 05.15……………………………………………………………………………………………………6129
13 Gear oil in bevel box……………………………………………………………………………………………………………………………………………………6134
13.1 Check gear oil level……………………………………………………………………………………………………………………………………………….6134
13.2 Top up gear oil……………………………………………………………………………………………………………………………………………………6134
13.3 Torque setting…………………………………………………………………………………………………………………………………………………….6137
14 Dismantling and assembling gearbox………………………………………………………………………………………………………………………………………..6138
14.1 Overview – gearbox, front-wheel drive………………………………………………………………………………………………………………………………..6138
14.2 Overview – gearbox, four-wheel drive…………………………………………………………………………………………………………………………………6139
14.3 Overview – dismantling and assembling gearbox…………………………………………………………………………………………………………………………6140
14.4 Assembly overview – removing and installing gearbox housing and selector unit…………………………………………………………………………………………….6141
14.5 Assembly overview – removing and installing input shaft, output shafts, differential, bevel box and selector rods…………………………………………………………….6143
14.6 Securing gearbox to assembly stand…………………………………………………………………………………………………………………………………..6145
14.7 Dismantling and assembling procedure…………………………………………………………………………………………………………………………………6146
14.7.1 Removing…………………………………………………………………………………………………………………………………………………….6149
14.7.2 Installing…………………………………………………………………………………………………………………………………………………..6153
15 Gearbox housing…………………………………………………………………………………………………………………………………………………………6161
15.1 Assembly overview – gearbox housing………………………………………………………………………………………………………………………………….6161
15.2 Repairing gearbox housing…………………………………………………………………………………………………………………………………………..6163
16 Clutch housing………………………………………………………………………………………………………………………………………………………….6165
16.1 Assembly overview – clutch housing…………………………………………………………………………………………………………………………………..6165
16.2 Repairing clutch housing……………………………………………………………………………………………………………………………………………6167
17 Selector unit…………………………………………………………………………………………………………………………………………………………..6169
17.1 Assembly overview – selector unit……………………………………………………………………………………………………………………………………6169
17.2 Renewing locking elbow……………………………………………………………………………………………………………………………………………..6170
17.3 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………6171
17.3.1 Removing…………………………………………………………………………………………………………………………………………………….6171
17.3.2 Installing…………………………………………………………………………………………………………………………………………………..6171
18 Selector forks………………………………………………………………………………………………………………………………………………………….6173
18.1 Assembly overview – selector forks…………………………………………………………………………………………………………………………………..6173
35 – Gears, shafts…………………………………………………………………………………………………………………………………………………………….6174
1 Input shaft……………………………………………………………………………………………………………………………………………………………..6174
1.1 Assembly overview – input shaft………………………………………………………………………………………………………………………………………6174
1.2 Dismantling and assembling input shaft………………………………………………………………………………………………………………………………..6176
1.3 Renewing input shaft seal……………………………………………………………………………………………………………………………………………6181
1.3.1 Procedure…………………………………………………………………………………………………………………………………………………….6182
2 Output shaft…………………………………………………………………………………………………………………………………………………………….6184
2.1 Assembly overview – output shaft for 1st and 2nd gear…………………………………………………………………………………………………………………..6184
2.2 Dismantling and assembling output shaft for 1st and 2nd gear…………………………………………………………………………………………………………….6187
2.3 Assembly overview – output shaft for 3rd and 4th gear…………………………………………………………………………………………………………………..6196
2.4 Dismantling and assembling output shaft for 3rd and 4th gear…………………………………………………………………………………………………………….6199
2.5 Assembly overview – output shaft for reverse gear………………………………………………………………………………………………………………………6207
2.6 Dismantling and assembling reverse gear output shaft……………………………………………………………………………………………………………………6210
2.6.1 Removing stop ring and spring from and installing on reverse gear synchromeshed gear………………………………………………………………………………….6216
39 – Final drive – front differential……………………………………………………………………………………………………………………………………………6219
1 Oil seals……………………………………………………………………………………………………………………………………………………………….6219
1.1 Front-wheel drive and all-wheel drive – renewing left stub shaft oil seal with gearbox installed…………………………………………………………………………….6219
1.1.1 Removing……………………………………………………………………………………………………………………………………………………..6221
1.1.2 Installing……………………………………………………………………………………………………………………………………………………6222
1.2 Front-wheel drive – renewing right stub shaft oil seal with gearbox installed……………………………………………………………………………………………..6223
1.2.1 Installing……………………………………………………………………………………………………………………………………………………6225
1.3 Four-wheel drive – renewing right stub shaft oil seal with bevel box installed…………………………………………………………………………………………….6226
1.3.1 Removing……………………………………………………………………………………………………………………………………………………..6226
1.3.2 Installing……………………………………………………………………………………………………………………………………………………6227
1.4 Four-wheel drive – renewing seal between gearbox and bevel box with gearbox installed………………………………………………………………………………………6228
1.5 Assembly overview – seals in bevel box and stub shaft bearing in bevel box………………………………………………………………………………………………..6229
1.6 Renewing seal between gearbox and bevel box with bevel box removed……………………………………………………………………………………………………….6231
1.7 Renewing stub shaft oil seals with bevel box removed……………………………………………………………………………………………………………………6233
1.8 Renewing bevel box output flange oil seal (bevel box removed)……………………………………………………………………………………………………………6236
1.9 Renewing needle bearing (polygon bearing) on stub shaft of bevel box……………………………………………………………………………………………………..6241
2 Differential…………………………………………………………………………………………………………………………………………………………….6246
2.1 Assembly overview – differential……………………………………………………………………………………………………………………………………..6246
2.2 Dismantling and assembling differential……………………………………………………………………………………………………………………………….6248
2.3 Adjusting differential………………………………………………………………………………………………………………………………………………6252
Sharan2016-6-speed_manual_gearbox_0BB……………………………………………………………………………………………………………………………………………….6256
00 – Technical data……………………………………………………………………………………………………………………………………………………………6260
1 Safety precautions……………………………………………………………………………………………………………………………………………………….6260
1.1 Safety measures for vehicles with Start/Stop system…………………………………………………………………………………………………………………….6260
2 Identification…………………………………………………………………………………………………………………………………………………………..6261
2.1 Gearbox identification………………………………………………………………………………………………………………………………………………6261
3 Identification code, assembly allocation, ratios, capacities………………………………………………………………………………………………………………….6262
3.1 Identification code, assembly allocation, ratios, capacities, Sharan……………………………………………………………………………………………………..6262
3.2 Identification code, assembly allocation, ratios, capacities, Tiguan……………………………………………………………………………………………………..6263
3.3 Calculating overall gear ratio “i”……………………………………………………………………………………………………………………………………6264
4 Overview – power transmission……………………………………………………………………………………………………………………………………………..6265
5 General repair notes……………………………………………………………………………………………………………………………………………………..6267
6 Electrical components…………………………………………………………………………………………………………………………………………………….6270
6.1 Overview of fitting locations – electrical components…………………………………………………………………………………………………………………..6270
6.1.1 Overview of fitting locations – electrical components, manual gearbox……………………………………………………………………………………………….6270
6.1.2 Overview of fitting locations – electrical components, clutch mechanism……………………………………………………………………………………………..6271
30 – Clutch…………………………………………………………………………………………………………………………………………………………………..6272
1 Clutch operation…………………………………………………………………………………………………………………………………………………………6272
1.1 Overview – clutch actuation………………………………………………………………………………………………………………………………………….6272
1.2 Assembly overview – pedal cluster…………………………………………………………………………………………………………………………………….6274
1.3 Assembly overview – clutch hydraulics…………………………………………………………………………………………………………………………………6276
1.3.1 Assembly overview – clutch hydraulics (left-hand drive)……………………………………………………………………………………………………………6276
1.3.2 Assembly overview – clutch hydraulics (right-hand drive)…………………………………………………………………………………………………………..6278
1.4 Removing and installing mounting bracket………………………………………………………………………………………………………………………………6279
1.5 Removing and installing over-centre spring…………………………………………………………………………………………………………………………….6286
1.6 Removing and installing clutch pedal………………………………………………………………………………………………………………………………….6290
1.7 Removing and installing master cylinder……………………………………………………………………………………………………………………………….6295
1.8 Removing and installing clutch position sender -G476-…………………………………………………………………………………………………………………..6297
1.8.1 Removing and installing clutch position sender -G476-, LHD vehicles…………………………………………………………………………………………………6297
1.8.2 Removing and installing clutch position sender -G476-, RHD vehicles…………………………………………………………………………………………………6301
1.9 Removing line and bleeder from and installing on slave cylinder………………………………………………………………………………………………………….6303
1.10 Removing and installing line for clutch mechanism……………………………………………………………………………………………………………………..6303
1.11 Bleeding clutch system……………………………………………………………………………………………………………………………………………..6305
2 Clutch release mechanism………………………………………………………………………………………………………………………………………………….6307
2.1 Assembly overview – clutch release mechanism…………………………………………………………………………………………………………………………..6307
2.2 Removing and installing slave cylinder with release bearing……………………………………………………………………………………………………………..6308
3 Clutch………………………………………………………………………………………………………………………………………………………………….6310
3.1 Differentiating makes of clutch (vehicles with turbo diesel engine)………………………………………………………………………………………………………6310
3.2 Assembly overview – “Sachs” clutch……………………………………………………………………………………………………………………………………6312
3.3 Removing and installing “Sachs” clutch………………………………………………………………………………………………………………………………..6313
3.4 Assembly overview – “LuK” clutch……………………………………………………………………………………………………………………………………..6315
3.5 Removing and installing “LuK” clutch………………………………………………………………………………………………………………………………….6316
34 – Controls, housing…………………………………………………………………………………………………………………………………………………………6320
1 Selector mechanism……………………………………………………………………………………………………………………………………………………….6320
1.1 Installation position of selector mechanism……………………………………………………………………………………………………………………………6320
1.2 Overview – selector mechanism………………………………………………………………………………………………………………………………………..6321
1.3 Assembly overview – gear lever knob and cover………………………………………………………………………………………………………………………….6322
1.4 Removing and installing gear knob…………………………………………………………………………………………………………………………………….6322
1.5 Assembly overview – Selector lever and selector housing…………………………………………………………………………………………………………………6324
1.6 Dismantling and assembling selector mechanism………………………………………………………………………………………………………………………….6326
1.7 Assembly overview – Selector cables…………………………………………………………………………………………………………………………………..6330
1.7.1 Removing and installing relay lever and cable end-piece……………………………………………………………………………………………………………6334
1.8 Removing and installing selector mechanism…………………………………………………………………………………………………………………………….6336
1.9 Adjusting selector mechanism…………………………………………………………………………………………………………………………………………6339
1.10 Functional check…………………………………………………………………………………………………………………………………………………..6342
2 Removing and installing gearbox……………………………………………………………………………………………………………………………………………6343
2.1 Distinguishing between different types of petrol engines………………………………………………………………………………………………………………..6343
2.2 Distinguishing between different types of turbo diesel engines…………………………………………………………………………………………………………..6343
2.3 Removing and installing gearbox, Sharan and Tiguan with petrol engine, engine lifting eyes »at rear« of engine………………………………………………………………..6344
2.3.1 Removing gearbox………………………………………………………………………………………………………………………………………………6347
2.3.2 Installing gearbox…………………………………………………………………………………………………………………………………………….6356
2.4 Removing and installing gearbox, Sharan and Tiguan with petrol engine, engine lifting eyes »at front« of engine……………………………………………………………….6364
2.4.1 Removing gearbox………………………………………………………………………………………………………………………………………………6368
2.4.2 Installing gearbox…………………………………………………………………………………………………………………………………………….6383
2.5 Removing and installing gearbox, Sharan and Tiguan with turbo diesel engine, engine lifting eyes »next to each other« on engine…………………………………………………6391
2.5.1 Removing gearbox………………………………………………………………………………………………………………………………………………6395
2.5.2 Installing gearbox…………………………………………………………………………………………………………………………………………….6405
2.5.3 Specified torques……………………………………………………………………………………………………………………………………………..6413
2.6 Removing and installing gearbox, Sharan and Tiguan with turbo diesel engine, engine lifting eyes »diagonally« on engine………………………………………………………..6414
2.6.1 Removing gearbox………………………………………………………………………………………………………………………………………………6418
2.6.2 Installing gearbox…………………………………………………………………………………………………………………………………………….6432
2.6.3 Specified torques for gearbox…………………………………………………………………………………………………………………………………..6440
3 Transporting gearbox……………………………………………………………………………………………………………………………………………………..6441
4 Assembly overview – assembly mountings……………………………………………………………………………………………………………………………………..6442
5 Gearbox oil……………………………………………………………………………………………………………………………………………………………..6444
5.1 Checking gear oil level……………………………………………………………………………………………………………………………………………..6444
5.2 Filling with gear oil……………………………………………………………………………………………………………………………………………….6444
6 Dismantling and assembling gearbox…………………………………………………………………………………………………………………………………………6446
6.1 Overview – gearbox………………………………………………………………………………………………………………………………………………….6446
6.2 Overview – dismantling and assembling gearbox………………………………………………………………………………………………………………………….6447
6.3 Assembly overview – removing and installing gear housing and selector unit………………………………………………………………………………………………..6448
6.4 Assembly overview – removing and installing input shaft, output shafts, differential and selector rods……………………………………………………………………….6450
6.4.1 Installation position of shafts and selector rods in gearbox……………………………………………………………………………………………………….6451
6.5 Installing to engine and gearbox support………………………………………………………………………………………………………………………………6452
6.6 Dismantling and assembling procedure………………………………………………………………………………………………………………………………….6453
6.6.1 Removing……………………………………………………………………………………………………………………………………………………..6456
6.6.2 Installing……………………………………………………………………………………………………………………………………………………6461
7 Gearbox housing and clutch housing…………………………………………………………………………………………………………………………………………6468
7.1 Assembly overview – gearbox housing…………………………………………………………………………………………………………………………………..6468
7.2 Repairing gearbox housing……………………………………………………………………………………………………………………………………………6470
7.3 Assembly overview – clutch housing……………………………………………………………………………………………………………………………………6477
7.4 Repairing clutch housing…………………………………………………………………………………………………………………………………………….6479
8 Selector unit……………………………………………………………………………………………………………………………………………………………6482
8.1 Assembly overview – selector unit…………………………………………………………………………………………………………………………………….6482
8.2 Renewing oil seal for selector shaft………………………………………………………………………………………………………………………………….6483
8.2.1 Torque setting………………………………………………………………………………………………………………………………………………..6484
9 Selector forks…………………………………………………………………………………………………………………………………………………………..6485
9.1 Assembly overview – selector forks……………………………………………………………………………………………………………………………………6485
9.2 Repairing reverse gear selector fork………………………………………………………………………………………………………………………………….6486
35 – Gears, shafts…………………………………………………………………………………………………………………………………………………………….6488
1 Input shaft……………………………………………………………………………………………………………………………………………………………..6488
1.1 Assembly overview – input shaft………………………………………………………………………………………………………………………………………6488
1.2 Dismantling and assembling input shaft………………………………………………………………………………………………………………………………..6489
1.3 Renewing input shaft seal……………………………………………………………………………………………………………………………………………6492
2 Output shaft…………………………………………………………………………………………………………………………………………………………….6495
2.1 Assembly overview – output shaft for 1st to 4th gears…………………………………………………………………………………………………………………..6495
2.2 Dismantling and assembling output shaft for 1st through 4th gears………………………………………………………………………………………………………..6498
2.2.1 Dismantling output shaft for 1st to 4th gears…………………………………………………………………………………………………………………….6505
2.3 Adjusting output shaft for 1st through 4th gears……………………………………………………………………………………………………………………….6519
2.4 Assembly overview – output shaft for 5th, 6th and reverse gears………………………………………………………………………………………………………….6523
2.5 Dismantling and assembling output shaft for 5th, 6th and reverse gears……………………………………………………………………………………………………6526
2.6 Adjusting output shaft for 5th, 6th and reverse gears…………………………………………………………………………………………………………………..6535
39 – Final drive – differential…………………………………………………………………………………………………………………………………………………6541
1 Oil seals……………………………………………………………………………………………………………………………………………………………….6541
1.1 Renewing left flange shaft oil seal with gearbox installed………………………………………………………………………………………………………………6541
1.2 Renewing right flange shaft oil seal with gearbox installed……………………………………………………………………………………………………………..6542
2 Adjustment overview………………………………………………………………………………………………………………………………………………………6545
3 Differential…………………………………………………………………………………………………………………………………………………………….6546
3.1 Assembly overview – differential……………………………………………………………………………………………………………………………………..6546
3.2 Dismantling and assembling differential……………………………………………………………………………………………………………………………….6548
3.3 Adjusting differential………………………………………………………………………………………………………………………………………………6552
Sharan2016-Air_conditioning_system_with_refrigerant_R134a……………………………………………………………………………………………………………………………..6557
00 – Technical data……………………………………………………………………………………………………………………………………………………………6563
1 General notes on air conditioning systems…………………………………………………………………………………………………………………………………..6563
1.1 Introduction……………………………………………………………………………………………………………………………………………………….6563
1.2 Additional information………………………………………………………………………………………………………………………………………………6563
1.3 Basics of air conditioning…………………………………………………………………………………………………………………………………………..6564
1.3.1 Physical basics:………………………………………………………………………………………………………………………………………………6564
1.3.2 Heat always flows from warmer to colder material………………………………………………………………………………………………………………….6564
1.3.3 Pressure and boiling point……………………………………………………………………………………………………………………………………..6564
1.4 Vapour pressure table for refrigerant R134a……………………………………………………………………………………………………………………………6565
1.5 Refrigerant R134a…………………………………………………………………………………………………………………………………………………..6566
1.5.1 Physical data of refrigerant R134a………………………………………………………………………………………………………………………………6566
1.5.2 Critical point………………………………………………………………………………………………………………………………………………..6566
1.5.3 Environmental aspects of refrigerant R134a……………………………………………………………………………………………………………………….6567
1.6 Characteristics of refrigerant R134a………………………………………………………………………………………………………………………………….6567
1.6.1 Trade names and designations……………………………………………………………………………………………………………………………………6567
1.6.2 Colour……………………………………………………………………………………………………………………………………………………….6567
1.6.3 Vapour pressure……………………………………………………………………………………………………………………………………………….6567
1.6.4 Physical properties of R134a……………………………………………………………………………………………………………………………………6568
1.6.5 Effects on metal………………………………………………………………………………………………………………………………………………6568
1.6.6 Critical temperature and critical pressure……………………………………………………………………………………………………………………….6568
1.6.7 Water content…………………………………………………………………………………………………………………………………………………6568
1.6.8 Combustibility………………………………………………………………………………………………………………………………………………..6568
1.6.9 Charge factor…………………………………………………………………………………………………………………………………………………6568
1.6.10 Detecting leaks………………………………………………………………………………………………………………………………………………6569
1.7 Refrigerant machine oil……………………………………………………………………………………………………………………………………………..6569
1.7.1 Properties of refrigerant oils………………………………………………………………………………………………………………………………….6570
1.8 Comfort……………………………………………………………………………………………………………………………………………………………6571
1.8.1 Environmental aspects………………………………………………………………………………………………………………………………………….6571
1.9 How air conditioning works…………………………………………………………………………………………………………………………………………..6571
1.10 General safety…………………………………………………………………………………………………………………………………………………….6572
1.10.1 Product characteristics……………………………………………………………………………………………………………………………………….6572
1.10.2 Handling refrigerants…………………………………………………………………………………………………………………………………………6572
1.10.3 Wear protective glasses……………………………………………………………………………………………………………………………………….6572
1.10.4 Wear protective gloves and apron……………………………………………………………………………………………………………………………….6573
1.10.5 Do not allow liquid refrigerant to come in contact with the skin…………………………………………………………………………………………………..6573
1.10.6 Do not breath in refrigerant vapour…………………………………………………………………………………………………………………………….6573
1.10.7 Absolutely NO SMOKING…………………………………………………………………………………………………………………………………………6573
1.10.8 Welding and soldering on refrigeration systems…………………………………………………………………………………………………………………..6573
1.10.9 Pungent smell………………………………………………………………………………………………………………………………………………..6573
1.10.10 First aid…………………………………………………………………………………………………………………………………………………..6573
1.10.11 Handling pressure tanks………………………………………………………………………………………………………………………………………6573
1.10.12 Do not heat above 50°C……………………………………………………………………………………………………………………………………….6574
1.10.13 Do not apply uncontrolled heat………………………………………………………………………………………………………………………………..6574
1.10.14 Seal empty containers………………………………………………………………………………………………………………………………………..6574
1.10.15 Safety instructions for using extraction and charging equipment…………………………………………………………………………………………………..6574
1.11 Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a……………………………………………………………………6575
1.12 Basics for working on refrigerant circuit…………………………………………………………………………………………………………………………….6576
1.12.1 O-ring………………………………………………………………………………………………………………………………………………………6577
1.12.2 Before operating the air conditioning system after recharging with refrigerant………………………………………………………………………………………6578
2 General information on refrigerant circuit………………………………………………………………………………………………………………………………….6579
2.1 Refrigerant circuit components……………………………………………………………………………………………………………………………………….6579
2.1.1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides……………………………………………………….6579
2.1.2 Air conditioning system compressor with magnetic clutch:…………………………………………………………………………………………………………..6580
2.1.3 Air conditioner compressor without magnetic clutch………………………………………………………………………………………………………………..6581
2.1.4 Air conditioner compressor without magnetic clutch, with elastic drive coupling………………………………………………………………………………………6582
2.1.5 Electrical air conditioner compressor for high-voltage system………………………………………………………………………………………………………6582
2.1.6 Condenser…………………………………………………………………………………………………………………………………………………….6583
2.1.7 Evaporator……………………………………………………………………………………………………………………………………………………6584
2.1.8 Reservoir…………………………………………………………………………………………………………………………………………………….6584
2.1.9 Restrictor……………………………………………………………………………………………………………………………………………………6585
2.1.10 Receiver…………………………………………………………………………………………………………………………………………………….6585
2.1.11 Expansion valve………………………………………………………………………………………………………………………………………………6586
2.1.12 O-ring………………………………………………………………………………………………………………………………………………………6586
2.1.13 Pipes and hoses in refrigerant circuit………………………………………………………………………………………………………………………….6586
2.1.14 High-pressure safety valve…………………………………………………………………………………………………………………………………….6587
2.2 Design of refrigerant circuit………………………………………………………………………………………………………………………………………..6587
2.3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit…………………………………………………………..6587
2.4 Switch and sender in refrigerant circuit and related connections…………………………………………………………………………………………………………6589
2.4.1 High-pressure switch for air conditioning system -F23-…………………………………………………………………………………………………………….6589
2.4.2 High-pressure switch for magnetic clutch -F118-…………………………………………………………………………………………………………………..6590
2.4.3 Low-pressure switch for air conditioning system -F73-……………………………………………………………………………………………………………..6590
2.4.4 Connections to valves for switches in the refrigerant circuit………………………………………………………………………………………………………6590
2.4.5 Air conditioning system pressure switch -F129-……………………………………………………………………………………………………………………6591
2.4.6 High-pressure sender -G65-……………………………………………………………………………………………………………………………………..6591
2.4.7 Refrigerant pressure and temperature sender -G395-………………………………………………………………………………………………………………..6591
2.4.8 Air conditioner compressor regulating valve -N280-………………………………………………………………………………………………………………..6592
2.5 Electrical components not installed in refrigerant circuit………………………………………………………………………………………………………………6592
2.5.2 Radiator fan control unit -J293-………………………………………………………………………………………………………………………………..6592
2.5.3 Radiator fan control unit -J293-………………………………………………………………………………………………………………………………..6593
2.6 Pressures and temperatures in the refrigerant circuit…………………………………………………………………………………………………………………..6594
2.7 Refrigerant circuit with expansion valve………………………………………………………………………………………………………………………………6594
2.8 Refrigerant circuit with restrictor and reservoir………………………………………………………………………………………………………………………6596
2.9 Test and measurement work that can be performed using a pressure gauge……………………………………………………………………………………………………6598
2.9.1 Pressure gauges enable the following test and measurement work……………………………………………………………………………………………………..6598
2.10 Air conditioner service and recycling equipment……………………………………………………………………………………………………………………….6599
2.10.1 Classification of extraction systems in groups…………………………………………………………………………………………………………………..6599
2.10.2 Charging devices that do not require a permit……………………………………………………………………………………………………………………6599
2.11 Notes to repairs on refrigerant circuit………………………………………………………………………………………………………………………………6600
3 Statutory texts and instructions…………………………………………………………………………………………………………………………………………..6601
3.1 Statutes and regulations…………………………………………………………………………………………………………………………………………….6601
3.2 Recycling and refuse law…………………………………………………………………………………………………………………………………………….6606
3.2.1 Disposal of refrigerant and refrigerant machine oil……………………………………………………………………………………………………………….6606
3.3 Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them (retrofitting)………………………………………………………………………….6607
3.4 Maintaining records on refrigerant……………………………………………………………………………………………………………………………………6607
4 Refrigerant circuit………………………………………………………………………………………………………………………………………………………6608
4.1 Important repair notes on air conditioning…………………………………………………………………………………………………………………………….6608
4.2 Retrofitting refrigerant circuit from R12 refrigerant to R134a refrigerant………………………………………………………………………………………………..6608
5 Working with the air conditioner service station…………………………………………………………………………………………………………………………….6609
5.1 Important notes for working with the air conditioner service station……………………………………………………………………………………………………..6610
5.2 Connecting air conditioner service station for measuring and checking…………………………………………………………………………………………………….6610
5.3 Draining refrigerant circuit using air conditioner service station……………………………………………………………………………………………………….6611
5.4 Evacuating refrigerant circuit using air conditioner service station……………………………………………………………………………………………………..6612
5.5 Charging refrigerant circuit using air conditioner service station……………………………………………………………………………………………………….6613
5.6 Bringing air conditioning system into service after charging…………………………………………………………………………………………………………….6614
5.7 Charging container in air conditioner service station with refrigerant……………………………………………………………………………………………………6615
5.8 Draining air conditioner service station………………………………………………………………………………………………………………………………6615
6 Detecting leaks in refrigerant circuit……………………………………………………………………………………………………………………………………..6617
6.1 Leak detection in refrigerant circuit using compressed air or nitrogen……………………………………………………………………………………………………6618
6.2 Searching for leaks in refrigerant circuits using leak detector -V.A.G 1796-………………………………………………………………………………………………6620
6.3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model………………………………………………6621
7 Clearing refrigerant circuit of contaminants………………………………………………………………………………………………………………………………..6627
7.1 Blowing through refrigerant circuit with compressed air and nitrogen……………………………………………………………………………………………………..6627
7.1.1 Blowing out refrigerant circuit…………………………………………………………………………………………………………………………………6629
7.2 Purging (cleaning) refrigerant circuit with refrigerant R134a……………………………………………………………………………………………………………6629
7.2.1 Principle circuit diagrams for various purging circuits……………………………………………………………………………………………………………6639
7.2.2 Purging electrical air conditioner compressor…………………………………………………………………………………………………………………….6644
7.2.3 Adapters for setting up purging circuits…………………………………………………………………………………………………………………………6648
8 Complaints………………………………………………………………………………………………………………………………………………………………6684
8.1 Possible complaints about refrigerant circuit………………………………………………………………………………………………………………………….6684
8.1.1 Test prerequisites:……………………………………………………………………………………………………………………………………………6684
8.1.2 Possible complaints……………………………………………………………………………………………………………………………………………6684
8.2 Smells from heater and air conditioner unit……………………………………………………………………………………………………………………………6685
8.2.1 Is the smell coming from evaporator or the heat exchanger?…………………………………………………………………………………………………………6685
8.2.2 Ultrasonic air conditioner cleaning unit -VAS 6189A-………………………………………………………………………………………………………………6686
8.2.3 Spraying the evaporator with the suction feed spray-gun -V.A.G 1538- and spray lance………………………………………………………………………………….6687
9 Connecting air conditioner service station………………………………………………………………………………………………………………………………….6688
9.1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit……………………………………………………………………….6688
9.1.1 Connecting air conditioner service station for measuring and checking……………………………………………………………………………………………….6688
10 Checking pressures on vehicles……………………………………………………………………………………………………………………………………………6689
10.1 Checking pressures in refrigerant circuit (using air conditioner service station)…………………………………………………………………………………………6689
10.1.1 Test prerequisites……………………………………………………………………………………………………………………………………………6689
10.1.2 Checking pressures……………………………………………………………………………………………………………………………………………6690
10.1.3 Continuation of checking pressures……………………………………………………………………………………………………………………………..6692
10.2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor)……………………………………………………………………..6692
10.2.1 Specifications:………………………………………………………………………………………………………………………………………………6693
10.3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor)………………………………………………………………..6697
10.3.1 Specifications:………………………………………………………………………………………………………………………………………………6697
10.4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor)……………………………………………………………………….6703
10.4.1 Test prerequisites……………………………………………………………………………………………………………………………………………6703
10.4.2 Checking…………………………………………………………………………………………………………………………………………………….6704
10.4.3 Specifications……………………………………………………………………………………………………………………………………………….6705
10.5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor)…………………….6705
10.5.1 Specifications:………………………………………………………………………………………………………………………………………………6705
10.6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor)…………………..6710
10.6.1 Specifications:………………………………………………………………………………………………………………………………………………6710
10.7 With expansion valve, receiver and electrical air conditioner compressor…………………………………………………………………………………………………6720
11 Renewing components……………………………………………………………………………………………………………………………………………………..6721
11.1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir)……………………………………………………………..6722
11.1.1 If the refrigerant circuit was completely empty………………………………………………………………………………………………………………….6722
11.1.2 If there is still refrigerant in the refrigerant circuit………………………………………………………………………………………………………….6722
11.2 Renewing air conditioner compressor………………………………………………………………………………………………………………………………….6723
11.2.1 Without needing to purge refrigerant circuit of contaminants (cleaning), e.g. in cases of external damage after an accident………………………………………………6723
11.2.2 Leaks or internal damage (e.g. noises or lack of power)…………………………………………………………………………………………………………..6725
11.3 Renewing receiver or reservoir, and restrictor………………………………………………………………………………………………………………………..6725
11.3.1 After purging refrigerant circuit of contaminants, e.g. due to moisture intrusion (because refrigerant circuit has stood open for a length of time) or due to dirt……………6725
11.3.2 Without needing to purge refrigerant circuit of contaminants (e.g. damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit….6726
12 Testing equipment and tools………………………………………………………………………………………………………………………………………………6727
12.1 List of test equipment, tools and materials…………………………………………………………………………………………………………………………..6727
12.1.1 Tools and materials available from distribution centre or importer…………………………………………………………………………………………………6727
12.1.2 Tools and materials commercially available………………………………………………………………………………………………………………………6729
12.1.3 Tools to be made locally………………………………………………………………………………………………………………………………………6730
12.1.4 Tools and materials available from distribution centre or importer…………………………………………………………………………………………………6730
Sharan2016-Auxiliary_heater………………………………………………………………………………………………………………………………………………………..6737
00 – Technical data……………………………………………………………………………………………………………………………………………………………6741
1 Notes on safety………………………………………………………………………………………………………………………………………………………….6741
1.1 Safety precautions when working on vehicles with auxiliary/supplementary heater……………………………………………………………………………………………6741
1.2 Safety measures when working on vehicles with a start/stop system………………………………………………………………………………………………………..6742
1.3 Safety precautions when working on the fuel system……………………………………………………………………………………………………………………..6742
1.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………6743
1.5 Safety precautions when using testers and measuring instruments during a road test…………………………………………………………………………………………6743
2 General notes……………………………………………………………………………………………………………………………………………………………6744
2.1 Starting conditions for auxiliary/supplementary heater………………………………………………………………………………………………………………….6744
2.1.1 Starting conditions for auxiliary/supplementary heater, auxiliary heater mode………………………………………………………………………………………..6744
2.1.2 Starting conditions for auxiliary/supplementary heater, supplementary heater mode…………………………………………………………………………………….6744
2.2 Notes for vehicles with a start/stop system……………………………………………………………………………………………………………………………6745
2.3 Rules for cleanliness when working on the auxiliary/supplementary heater and the fuel system………………………………………………………………………………..6745
2.4 Identification plates……………………………………………………………………………………………………………………………………………….6745
3 Repair notes…………………………………………………………………………………………………………………………………………………………….6747
3.1 General repair instructions………………………………………………………………………………………………………………………………………….6747
82 – Supplementary heating……………………………………………………………………………………………………………………………………………………..6748
1 Overview of fitting locations – auxiliary/supplementary heater………………………………………………………………………………………………………………..6748
1.1 Overview of fitting locations – components not located in passenger compartment……………………………………………………………………………………………6748
2 Auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………….6750
2.1 Overview of fitting locations – auxiliary/supplementary heater…………………………………………………………………………………………………………..6750
2.2 Assembly overview – auxiliary/supplementary heater attachments…………………………………………………………………………………………………………..6752
2.3 Assembly overview – auxiliary/supplementary heater, internal…………………………………………………………………………………………………………….6753
2.4 Removing and installing auxiliary/supplementary heater………………………………………………………………………………………………………………….6754
2.5 Dismantling and assembling auxiliary/supplementary heater……………………………………………………………………………………………………………….6758
2.6 Removing and installing air intake silencer……………………………………………………………………………………………………………………………6760
2.7 Removing and installing circulation pump -V55-…………………………………………………………………………………………………………………………6760
2.8 Removing and installing exhaust system………………………………………………………………………………………………………………………………..6763
2.9 Removing and installing bracket for auxiliary/supplementary heater……………………………………………………………………………………………………….6763
2.10 Removing and installing covers for auxiliary heater control unit -J364-………………………………………………………………………………………………….6764
2.11 Removing and installing glow plug with flame monitoring -Q8-……………………………………………………………………………………………………………6765
2.12 Removing and installing temperature sensor -G18- and overheating sensor -G189-……………………………………………………………………………………………6765
2.13 Connector pin assignment for supplementary heater……………………………………………………………………………………………………………………..6766
2.14 Dismantling and assembling burner unit……………………………………………………………………………………………………………………………….6766
2.15 Removing and installing auxiliary heater control unit -J364- with combustion air blower -V6-……………………………………………………………………………….6767
3 Coolant circuit with auxiliary/supplementary heater………………………………………………………………………………………………………………………….6769
3.1 Coolant hose schematic diagram……………………………………………………………………………………………………………………………………….6769
3.2 Bleeding coolant circuit of auxiliary/supplementary heater………………………………………………………………………………………………………………6769
3.3 Coolant hose routing on vehicles with 2nd heat exchanger………………………………………………………………………………………………………………..6770
3.4 Removing and installing coolant pipes for auxiliary/supplementary heater………………………………………………………………………………………………….6771
3.4.1 Removing and installing coolant pipe from heater coolant shut-off valve -N279-……………………………………………………………………………………….6771
3.4.2 Removing and installing coolant pipe between heat exchanger and auxiliary/supplementary heater…………………………………………………………………………6774
3.5 Removing and installing heater coolant shut-off valve -N279-…………………………………………………………………………………………………………….6776
4 Fuel supply……………………………………………………………………………………………………………………………………………………………..6779
4.1 Overview of fitting locations – fuel supply……………………………………………………………………………………………………………………………6779
4.2 Testing quantity of fuel delivered……………………………………………………………………………………………………………………………………6780
4.3 Removing and installing metering pump -V54-……………………………………………………………………………………………………………………………6781
5 Regulation of auxiliary/supplementary heater………………………………………………………………………………………………………………………………..6783
5.1 Functional description………………………………………………………………………………………………………………………………………………6783
5.2 Supplementary heating mode…………………………………………………………………………………………………………………………………………..6784
5.3 Auxiliary heating mode………………………………………………………………………………………………………………………………………………6784
5.4 Switching off auxiliary/supplementary heater…………………………………………………………………………………………………………………………..6784
6 Other controlling and regulating components…………………………………………………………………………………………………………………………………6786
6.1 Removing and installing ambient temperature sensor -G17-………………………………………………………………………………………………………………..6786
6.2 Removing and installing remote control receiver for auxiliary coolant heater -R149-………………………………………………………………………………………..6786
6.3 Functional description of remote control for auxiliary/supplementary heater……………………………………………………………………………………………….6787
Sharan2016-Brake_system……………………………………………………………………………………………………………………………………………………………6790
00 – Technical data……………………………………………………………………………………………………………………………………………………………6794
1 Notes on safety………………………………………………………………………………………………………………………………………………………….6794
1.1 Safety precautions during a road test using test and measuring equipment………………………………………………………………………………………………….6794
2 Identification…………………………………………………………………………………………………………………………………………………………..6795
2.1 Allocation of PR number – brakes……………………………………………………………………………………………………………………………………..6795
2.1.1 Front brakes………………………………………………………………………………………………………………………………………………….6795
2.1.2 Rear brakes…………………………………………………………………………………………………………………………………………………..6796
3 Technical data…………………………………………………………………………………………………………………………………………………………..6797
3.1 Technical data for brakes……………………………………………………………………………………………………………………………………………6797
3.1.1 Brake master cylinder and brake servo……………………………………………………………………………………………………………………………6797
4 Brake test………………………………………………………………………………………………………………………………………………………………6799
4.1 General information…………………………………………………………………………………………………………………………………………………6799
4.2 Checking vehicles with front-wheel drive………………………………………………………………………………………………………………………………6799
4.3 Checking vehicles with all-wheel drive………………………………………………………………………………………………………………………………..6799
4.3.1 On a regulated roller dynamometer with contra-rotating rollers for all-wheel drive vehicles……………………………………………………………………………6799
4.3.2 Without roller dynamometer for all-wheel drive vehicles……………………………………………………………………………………………………………6800
4.4 Checking parking brake………………………………………………………………………………………………………………………………………………6800
4.4.1 Checking electromechanical parking brake, vehicles with front-wheel drive……………………………………………………………………………………………6800
4.4.2 Checking electromechanical parking brake, vehicles with all-wheel drive……………………………………………………………………………………………..6801
45 – Anti-lock brake system…………………………………………………………………………………………………………………………………………………….6802
1 General information………………………………………………………………………………………………………………………………………………………6802
1.1 Repair instructions for repair work on ABS…………………………………………………………………………………………………………………………….6802
2 Overview of fitting locations……………………………………………………………………………………………………………………………………………..6805
2.1 Overview of fitting locations – ABS/ESP……………………………………………………………………………………………………………………………….6805
3 Control unit and hydraulic unit……………………………………………………………………………………………………………………………………………6807
3.1 Assembly overview – control unit and hydraulic unit…………………………………………………………………………………………………………………….6807
3.1.1 Assembly overview – control unit and hydraulic unit, left-hand drive………………………………………………………………………………………………..6807
3.2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-………………………………………………………………………………………………….6809
3.2.1 Removing and installing control unit and hydraulic unit, LHD……………………………………………………………………………………………………….6809
3.3 Connecting brake lines to hydraulic unit………………………………………………………………………………………………………………………………6814
3.3.1 Connecting brake lines to hydraulic unit, left-hand drive………………………………………………………………………………………………………….6814
4 Sensors…………………………………………………………………………………………………………………………………………………………………6816
4.1 Assembly overview – speed sensor on front axle…………………………………………………………………………………………………………………………6816
4.2 Assembly overview – speed sensor on rear axle………………………………………………………………………………………………………………………….6817
4.2.1 Assembly overview – speed sensor on rear axle, front-wheel drive……………………………………………………………………………………………………6817
4.2.2 Assembly overview – speed sensor on rear axle, all-wheel drive……………………………………………………………………………………………………..6818
4.3 Removing and installing speed sensors on front axle -G45-/-G47-………………………………………………………………………………………………………….6818
4.4 Removing and installing speed sensor on rear axle -G44-/-G46-……………………………………………………………………………………………………………6819
4.4.1 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with front-wheel drive…………………………………………………………………………6819
4.4.2 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with all-wheel drive…………………………………………………………………………..6820
4.5 Checking ABS sensor ring…………………………………………………………………………………………………………………………………………….6820
4.6 Removing and installing ESP sensor unit -G419-…………………………………………………………………………………………………………………………6821
46 – Brakes – mechanism………………………………………………………………………………………………………………………………………………………..6822
1 Front brakes…………………………………………………………………………………………………………………………………………………………….6822
1.1 Assembly overview – front brakes……………………………………………………………………………………………………………………………………..6822
1.1.1 Assembly overview- front brakes C60……………………………………………………………………………………………………………………………..6822
1.2 Removing and installing brake pads or linings………………………………………………………………………………………………………………………….6824
1.2.1 Removing and installing brake pads, front brakes C60………………………………………………………………………………………………………………6824
1.3 Removing and installing brake caliper…………………………………………………………………………………………………………………………………6827
1.3.1 Removing and installing brake caliper, front brakes C60……………………………………………………………………………………………………………6827
2 Rear brakes……………………………………………………………………………………………………………………………………………………………..6830
2.1 Assembly overview – rear brakes………………………………………………………………………………………………………………………………………6830
2.2 Removing and installing brake pads or linings………………………………………………………………………………………………………………………….6831
2.3 Removing and installing brake caliper…………………………………………………………………………………………………………………………………6834
3 Handbrake……………………………………………………………………………………………………………………………………………………………….6837
3.1 Assembly overview – parking brake…………………………………………………………………………………………………………………………………….6837
3.2 Removing and installing control unit for electromechanical parking brake -J540-……………………………………………………………………………………………6838
3.3 Removing and installing parking brake motor -V282-/-V283-……………………………………………………………………………………………………………….6838
4 Brake pedal……………………………………………………………………………………………………………………………………………………………..6841
4.1 Assembly overview – brake pedal………………………………………………………………………………………………………………………………………6841
4.1.1 Assembly overview – brake pedal, left-hand drive………………………………………………………………………………………………………………….6841
4.2 Separating brake pedal from brake servo……………………………………………………………………………………………………………………………….6842
4.3 Connecting brake pedal to brake servo…………………………………………………………………………………………………………………………………6843
4.4 Removing and installing brake pedal…………………………………………………………………………………………………………………………………..6843
47 – Brakes – hydraulics……………………………………………………………………………………………………………………………………………………….6844
1 Front brake caliper………………………………………………………………………………………………………………………………………………………6844
1.1 Assembly overview – front brake caliper……………………………………………………………………………………………………………………………….6844
1.1.1 Assembly overview – brake caliper C60……………………………………………………………………………………………………………………………6844
1.2 Removing and installing brake caliper piston…………………………………………………………………………………………………………………………..6845
1.2.1 Removing and installing C60 brake caliper piston………………………………………………………………………………………………………………….6845
2 Rear brake calipers………………………………………………………………………………………………………………………………………………………6847
2.1 Assembly overview – rear brake caliper………………………………………………………………………………………………………………………………..6847
2.2 Removing and installing brake caliper piston…………………………………………………………………………………………………………………………..6848
2.3 Pre-bleeding brake caliper…………………………………………………………………………………………………………………………………………..6850
3 Brake servo and brake master cylinder………………………………………………………………………………………………………………………………………6851
3.1 Assembly overview – brake servo/brake master cylinder…………………………………………………………………………………………………………………..6851
3.1.1 Assembly overview – brake servo/brake master cylinder, left-hand drive………………………………………………………………………………………………6851
3.2 Removing and installing brake light switch…………………………………………………………………………………………………………………………….6853
3.2.1 Removing and installing brake light switch, left-hand drive………………………………………………………………………………………………………..6853
3.3 Removing and installing brake master cylinder………………………………………………………………………………………………………………………….6854
3.3.1 Removing and installing brake master cylinder, left-hand drive……………………………………………………………………………………………………..6854
3.4 Removing and installing brake servo…………………………………………………………………………………………………………………………………..6857
3.4.1 Removing and installing brake servo, left-hand drive………………………………………………………………………………………………………………6857
4 Vacuum system……………………………………………………………………………………………………………………………………………………………6864
4.1 Assembly overview – vacuum pump………………………………………………………………………………………………………………………………………6864
4.1.1 Vacuum pump for brake servo, diesel vehicles……………………………………………………………………………………………………………………..6864
4.1.2 Brake servo vacuum pump, vehicles with 2.0l petrol engine………………………………………………………………………………………………………….6864
4.2 Checking non-return valve……………………………………………………………………………………………………………………………………………6865
4.3 Removing and installing vacuum sender -G608-…………………………………………………………………………………………………………………………..6865
4.4 Checking vacuum system………………………………………………………………………………………………………………………………………………6866
4.4.1 Connecting vacuum gauge for brake servo -VAS 6721-………………………………………………………………………………………………………………..6867
4.4.2 Checking vacuum generation……………………………………………………………………………………………………………………………………..6867
4.4.3 Checking for leaks…………………………………………………………………………………………………………………………………………….6868
5 Brake lines……………………………………………………………………………………………………………………………………………………………..6871
5.1 Connection points…………………………………………………………………………………………………………………………………………………..6871
5.2 Repairing brake lines……………………………………………………………………………………………………………………………………………….6871
5.2.1 Assembly overview – flanging tool……………………………………………………………………………………………………………………………….6873
5.2.2 Work instructions……………………………………………………………………………………………………………………………………………..6873
6 Hydraulic system…………………………………………………………………………………………………………………………………………………………6876
6.1 General notes on brake fluid…………………………………………………………………………………………………………………………………………6876
6.1.1 Changing brake fluid…………………………………………………………………………………………………………………………………………..6876
6.2 Pre-bleeding hydraulic system………………………………………………………………………………………………………………………………………..6876
6.3 Bleeding hydraulic system following standard procedure………………………………………………………………………………………………………………….6878
6.4 Subsequent bleeding of hydraulic system……………………………………………………………………………………………………………………………….6879
6.5 Testing for leaks…………………………………………………………………………………………………………………………………………………..6879
Sharan2016-Communication…………………………………………………………………………………………………………………………………………………………..6881
00 – Technical data……………………………………………………………………………………………………………………………………………………………6885
1 Repair instructions………………………………………………………………………………………………………………………………………………………6885
1.1 General repair instructions………………………………………………………………………………………………………………………………………….6885
1.2 Notes on repair of CAN bus wiring…………………………………………………………………………………………………………………………………….6885
1.3 Transmitting power and aerial fitting locations………………………………………………………………………………………………………………………..6885
91 – Communication…………………………………………………………………………………………………………………………………………………………….6887
1 Infotainment system………………………………………………………………………………………………………………………………………………………6888
1.1 Layout – infotainment system…………………………………………………………………………………………………………………………………………6888
1.2 Overview of fitting locations – infotainment system…………………………………………………………………………………………………………………….6892
1.3 Removing and installing information electronics control unit 1 -J794-…………………………………………………………………………………………………….6892
2 Sound system…………………………………………………………………………………………………………………………………………………………….6895
2.1 Overview – Sound system……………………………………………………………………………………………………………………………………………..6895
2.2 Overview of fitting locations – sound system…………………………………………………………………………………………………………………………..6895
2.3 Removing and installing digital sound package control unit/amplifier……………………………………………………………………………………………………..6896
2.4 Removing and installing rear treble loudspeakers -R14-/-R16-…………………………………………………………………………………………………………….6898
2.5 Removing and installing front treble loudspeakers -R20-/-R22-……………………………………………………………………………………………………………6899
2.6 Removing and installing rear bass loudspeakers -R15-/-R17-………………………………………………………………………………………………………………6900
2.7 Removing and installing front bass loudspeakers -R21-/-R23-……………………………………………………………………………………………………………..6901
3 Aerial systems…………………………………………………………………………………………………………………………………………………………..6903
3.1 Overview – aerial systems……………………………………………………………………………………………………………………………………………6903
3.2 Overview of fitting locations – aerial systems…………………………………………………………………………………………………………………………6903
3.3 Removing and installing aerial module…………………………………………………………………………………………………………………………………6904
3.4 Removing and installing roof aerial…………………………………………………………………………………………………………………………………..6906
4 Radio…………………………………………………………………………………………………………………………………………………………………..6908
4.1 Overview – Radio……………………………………………………………………………………………………………………………………………………6908
4.1.1 Layout – radio, Composition Colour version……………………………………………………………………………………………………………………….6908
4.1.2 Layout – radio, Composition Media version………………………………………………………………………………………………………………………..6908
4.2 Removing and installing radio………………………………………………………………………………………………………………………………………..6908
5 Telephone system…………………………………………………………………………………………………………………………………………………………6909
5.1 Mobile telephone preparation…………………………………………………………………………………………………………………………………………6909
5.1.1 Mobile telephone preparation, Bluetooth hands-free system………………………………………………………………………………………………………….6909
5.1.2 Mobile telephone preparation, Bluetooth car phone online…………………………………………………………………………………………………………..6909
5.2 Overview of fitting locations – telephone system……………………………………………………………………………………………………………………….6910
5.3 Removing and installing telephone microphone -R38-……………………………………………………………………………………………………………………..6911
5.4 Removing and installing operating unit for preparation for mobile phone…………………………………………………………………………………………………..6912
6 Navigation system………………………………………………………………………………………………………………………………………………………..6913
6.1 Overview – navigation system…………………………………………………………………………………………………………………………………………6913
6.2 Overview of fitting locations – navigation system………………………………………………………………………………………………………………………6913
6.3 Removing and installing navigation system……………………………………………………………………………………………………………………………..6914
7 Reversing camera system…………………………………………………………………………………………………………………………………………………..6915
7.1 Components of reversing camera system…………………………………………………………………………………………………………………………………6915
7.2 Overview of fitting locations – reversing camera system…………………………………………………………………………………………………………………6915
7.3 Removing and installing reversing camera -R189-………………………………………………………………………………………………………………………..6916
7.4 Removing and installing reversing camera system control unit -J772-………………………………………………………………………………………………………6916
7.5 Calibrating reversing camera system…………………………………………………………………………………………………………………………………..6917
7.5.1 Assembling and setting-up calibration unit -VAS 6350-……………………………………………………………………………………………………………..6917
7.5.2 Calibrating reversing camera -R189-……………………………………………………………………………………………………………………………..6920
8 Multifunction steering wheel………………………………………………………………………………………………………………………………………………6923
8.1 Overview – multifunction steering wheel……………………………………………………………………………………………………………………………….6923
8.2 Overview – multifunction steering wheel……………………………………………………………………………………………………………………………….6923
8.3 Removing and installing steering wheel multifunction buttons -E441-/-E440-………………………………………………………………………………………………..6925
8.4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438-………………………………………………………………………………………………….6927
9 Connection for external multimedia devices………………………………………………………………………………………………………………………………….6929
9.1 Removing and installing connection for external multimedia devices……………………………………………………………………………………………………….6929
9.1.1 Removing and installing connection for external multimedia devices, USB connection holder -R193-……………………………………………………………………….6929
9.1.2 Removing and installing connection for external multimedia devices, connection for external audio sources -R199-…………………………………………………………6930
10 Mobile online services…………………………………………………………………………………………………………………………………………………..6932
10.1 Overview – Mobile Online Services……………………………………………………………………………………………………………………………………6932
10.2 Overview of fitting locations – mobile online services…………………………………………………………………………………………………………………6932
10.3 Removing and installing emergency call module control unit and communication unit -J949-…………………………………………………………………………………..6933
10.4 Renewing control unit for emergency call module and communication unit -J949-…………………………………………………………………………………………….6935
Sharan2016-Electrical_system……………………………………………………………………………………………………………………………………………………….6938
00 – Technical data……………………………………………………………………………………………………………………………………………………………6946
1 Notes on safety………………………………………………………………………………………………………………………………………………………….6946
1.1 Safety precautions when working on vehicles with Start/Stop system……………………………………………………………………………………………………….6946
1.2 Safety precautions when using test and measuring equipment during a road test……………………………………………………………………………………………..6946
1.3 Operation and safety notes for gas discharge bulbs……………………………………………………………………………………………………………………..6947
2 Repair instructions………………………………………………………………………………………………………………………………………………………6949
2.1 Contact corrosion…………………………………………………………………………………………………………………………………………………..6949
2.2 Routing and securing wiring………………………………………………………………………………………………………………………………………….6949
3 Battery…………………………………………………………………………………………………………………………………………………………………6950
3.1 Battery – general notes……………………………………………………………………………………………………………………………………………..6950
3.2 Types of battery……………………………………………………………………………………………………………………………………………………6950
27 – Starter, current supply, CCS……………………………………………………………………………………………………………………………………………….6951
1 Battery…………………………………………………………………………………………………………………………………………………………………6951
1.1 Assembly overview – battery………………………………………………………………………………………………………………………………………….6951
1.2 Removing and installing battery………………………………………………………………………………………………………………………………………6952
1.3 Disconnecting and reconnecting battery………………………………………………………………………………………………………………………………..6955
1.4 Removing and installing battery tray………………………………………………………………………………………………………………………………….6957
1.5 Checking battery……………………………………………………………………………………………………………………………………………………6958
1.6 Charging battery……………………………………………………………………………………………………………………………………………………6958
1.7 Removing and installing earth cable with battery monitor control unit -J367-………………………………………………………………………………………………6958
1.8 Adapting battery monitor control unit -J367-…………………………………………………………………………………………………………………………..6960
2 Alternator………………………………………………………………………………………………………………………………………………………………6961
2.1 Assembly overview – alternator……………………………………………………………………………………………………………………………………….6961
2.1.1 Exploded view – alternator without sliding bushes…………………………………………………………………………………………………………………6961
2.1.2 Exploded view – alternator with sliding bushes……………………………………………………………………………………………………………………6962
2.2 Removing and installing alternator……………………………………………………………………………………………………………………………………6962
2.2.1 Removing and installing alternator, vehicles with 1.4 l TSI engine………………………………………………………………………………………………….6962
2.2.2 Removing and installing alternator, vehicles with 2.0 l TSI engine………………………………………………………………………………………………….6964
2.2.3 Removing and installing alternator, vehicles with 2.0 l TDI engine………………………………………………………………………………………………….6966
2.3 Checking alternator…………………………………………………………………………………………………………………………………………………6968
2.4 Removing and installing poly V-belt pulley…………………………………………………………………………………………………………………………….6968
2.4.1 Removing and installing poly V-belt pulley without freewheel……………………………………………………………………………………………………….6968
2.4.2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch……………………………………………………………………………………….6969
2.4.3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo……………………………………………………………………………………….6971
2.4.4 Removing and installing decoupled pulley with freewheel‏…………………………………………………………………………………………………………..6973
2.5 Removing and installing voltage regulator……………………………………………………………………………………………………………………………..6976
2.5.1 Removing and installing voltage regulator, manufacturer: Bosch……………………………………………………………………………………………………..6976
2.5.2 Removing and installing voltage regulator, manufacturer: Valeo……………………………………………………………………………………………………..6977
3 Starter…………………………………………………………………………………………………………………………………………………………………6979
3.1 Assembly overview – starter………………………………………………………………………………………………………………………………………….6979
3.1.1 Exploded view – starter (vehicles with manual gearbox)…………………………………………………………………………………………………………….6979
3.1.2 Assembly overview – starter (vehicles with dual clutch gearbox)…………………………………………………………………………………………………….6980
3.2 Removing and installing starter………………………………………………………………………………………………………………………………………6980
3.2.1 Removing and installing starter, vehicle with manual gearbox……………………………………………………………………………………………………….6980
3.2.2 Removing and installing starter, vehicles with dual clutch gearbox (DQ250-6F)………………………………………………………………………………………..6983
4 Cruise control system (CCS)……………………………………………………………………………………………………………………………………………….6985
5 Start/Stop system………………………………………………………………………………………………………………………………………………………..6986
5.1 General description – Start/Stop system……………………………………………………………………………………………………………………………….6986
5.2 Removing and installing voltage stabiliser…………………………………………………………………………………………………………………………….6986
6 Adaptive cruise control…………………………………………………………………………………………………………………………………………………..6987
6.1 Overview of fitting locations – adaptive cruise control…………………………………………………………………………………………………………………6987
6.2 Removing and installing automatic distance control unit…………………………………………………………………………………………………………………6988
6.2.1 Removing and installing control unit for adaptive cruise control, with retaining plate and adapter frame………………………………………………………………..6988
6.2.2 Removing control unit for adaptive cruise control from and installing to adapter frame………………………………………………………………………………..6989
6.3 Calibrating adaptive cruise control…………………………………………………………………………………………………………………………………..6989
90 – Gauges, instruments……………………………………………………………………………………………………………………………………………………….6990
1 Dash panel insert………………………………………………………………………………………………………………………………………………………..6990
1.1 Removing and installing dash panel insert -KX2-………………………………………………………………………………………………………………………..6990
2 Horn……………………………………………………………………………………………………………………………………………………………………6992
2.1 Removing and installing treble horn -H2- / bass horn -H7-……………………………………………………………………………………………………………….6992
92 – Windscreen wash/wipe system………………………………………………………………………………………………………………………………………………..6994
1 Windscreen wiper system…………………………………………………………………………………………………………………………………………………..6994
1.1 Assembly overview – windscreen wiper system……………………………………………………………………………………………………………………………6994
1.2 Moving wipers to service position…………………………………………………………………………………………………………………………………….6995
1.3 Removing and installing wiper blade…………………………………………………………………………………………………………………………………..6995
1.4 Removing and installing wiper arms……………………………………………………………………………………………………………………………………6996
1.5 Adjusting wiper arms………………………………………………………………………………………………………………………………………………..6997
1.6 Removing and installing wiper motor -V-……………………………………………………………………………………………………………………………….6999
1.7 Renewing wiper motor………………………………………………………………………………………………………………………………………………..7001
1.8 Deactivating APP function of wiper motor………………………………………………………………………………………………………………………………7004
1.9 Removing and installing rain and light sensor………………………………………………………………………………………………………………………….7004
2 Windscreen washer system………………………………………………………………………………………………………………………………………………….7007
2.1 Assembly overview – windscreen washer system…………………………………………………………………………………………………………………………..7007
2.2 Removing and installing filler neck with connecting pipe………………………………………………………………………………………………………………..7009
2.3 Removing and installing washer fluid reservoir…………………………………………………………………………………………………………………………7009
2.3.1 Removing and installing washer fluid reservoir, vehicles without headlight washer system………………………………………………………………………………7009
2.3.2 Removing and installing washer fluid reservoir, vehicles with headlight washer system…………………………………………………………………………………7011
2.4 Removing and installing windscreen washer fluid level sender…………………………………………………………………………………………………………….7014
2.5 Removing and installing windscreen washer pump…………………………………………………………………………………………………………………………7015
2.6 Removing and installing spray jets……………………………………………………………………………………………………………………………………7016
2.7 Adjusting spray jets………………………………………………………………………………………………………………………………………………..7017
3 Rear window wiper system………………………………………………………………………………………………………………………………………………….7018
3.1 Assembly overview – rear window wiper system…………………………………………………………………………………………………………………………..7018
3.2 Removing and installing wiper blade…………………………………………………………………………………………………………………………………..7019
3.3 Removing and installing wiper arm…………………………………………………………………………………………………………………………………….7019
3.4 Adjusting wiper arm…………………………………………………………………………………………………………………………………………………7020
3.5 Removing and installing rear window wiper motor -V12-…………………………………………………………………………………………………………………..7021
4 Rear window washer system…………………………………………………………………………………………………………………………………………………7023
4.1 Assembly overview – rear window washer system………………………………………………………………………………………………………………………….7023
4.2 Removing and installing washer fluid reservoir…………………………………………………………………………………………………………………………7024
4.3 Removing and installing rear window washer pump………………………………………………………………………………………………………………………..7024
4.4 Removing and installing washer jet……………………………………………………………………………………………………………………………………7024
4.5 Adjusting spray jet…………………………………………………………………………………………………………………………………………………7024
5 Headlight washer system…………………………………………………………………………………………………………………………………………………..7025
5.1 Assembly overview – headlight washer system……………………………………………………………………………………………………………………………7025
5.2 Removing and installing washer fluid reservoir…………………………………………………………………………………………………………………………7026
5.3 Removing and installing headlight washer system pump -V11-………………………………………………………………………………………………………………7026
5.4 Removing and installing pop-up cylinder……………………………………………………………………………………………………………………………….7026
5.5 Removing and installing spray jets……………………………………………………………………………………………………………………………………7028
5.6 Adjusting spray jets………………………………………………………………………………………………………………………………………………..7028
5.7 Bleeding headlight washer system……………………………………………………………………………………………………………………………………..7028
6 Washer fluid lines……………………………………………………………………………………………………………………………………………………….7030
6.1 Repairing washer fluid lines…………………………………………………………………………………………………………………………………………7030
94 – Lights, bulbs, switches – exterior………………………………………………………………………………………………………………………………………….7031
1 Headlight……………………………………………………………………………………………………………………………………………………………….7031
1.1 Assembly overview – headlight………………………………………………………………………………………………………………………………………..7031
1.1.1 Assembly overview – headlight, dual halogen headlight……………………………………………………………………………………………………………..7031
1.1.2 Assembly overview – headlight, gas discharge bulb…………………………………………………………………………………………………………………7033
1.2 Removing and installing headlight…………………………………………………………………………………………………………………………………….7035
1.3 Adjusting headlights………………………………………………………………………………………………………………………………………………..7036
1.3.1 Adjusting dual halogen headlight………………………………………………………………………………………………………………………………..7036
1.3.2 Adjusting gas discharge headlights………………………………………………………………………………………………………………………………7036
1.3.3 Adjusting fog lights…………………………………………………………………………………………………………………………………………..7037
1.3.4 Adjusting auxiliary headlights………………………………………………………………………………………………………………………………….7037
1.4 Adjusting headlight installation position……………………………………………………………………………………………………………………………..7037
1.5 Removing and installing front turn signal bulb -M5-/-M7-………………………………………………………………………………………………………………..7038
1.5.1 Removing and installing side light bulb -M1-/-M3- (dual halogen headlights)………………………………………………………………………………………….7038
1.5.2 Removing and installing front turn signal bulb -M5-/-M7- (gas discharge headlights)…………………………………………………………………………………..7039
1.6 Installing repair kit for headlight housing……………………………………………………………………………………………………………………………7041
1.6.1 Repairing upper retaining tab…………………………………………………………………………………………………………………………………..7041
1.6.2 Repairing side retaining tab……………………………………………………………………………………………………………………………………7042
1.6.3 Repairing rear retaining tab……………………………………………………………………………………………………………………………………7042
1.7 Changing headlights over from driving on right to driving on left………………………………………………………………………………………………………..7043
1.7.1 Changing headlights over from driving on right to driving on left (dual halogen headlights)……………………………………………………………………………7043
1.7.2 Changing headlights over from driving on right to driving on left (gas discharge headlights)…………………………………………………………………………..7045
1.8 Changing headlights over from driving on left to driving on right………………………………………………………………………………………………………..7046
1.8.1 Changing headlights over from driving on left to driving on right (dual halogen headlights)……………………………………………………………………………7046
1.8.2 Changing headlights over from driving on left to driving on right (gas discharge headlights)…………………………………………………………………………..7047
1.9 Removing and installing headlight range control motor -V48-/-V49-………………………………………………………………………………………………………..7048
1.9.1 Removing and installing headlight range control motor -V48-/-V49- (dual halogen headlights)……………………………………………………………………………7048
1.9.2 Removing and installing headlight range control motor -V48-/-V49- (gas discharge headlights)…………………………………………………………………………..7050
1.10 Removing and installing dipped beam bulb……………………………………………………………………………………………………………………………..7050
1.11 Removing and installing headlight main beam bulb -M30-/-M32-……………………………………………………………………………………………………………7052
1.12 Removing and installing gas discharge lamp -L13-/-L14-…………………………………………………………………………………………………………………7053
1.13 Removing and installing side light bulb -M1-/-M3-……………………………………………………………………………………………………………………..7054
1.13.1 Removing and installing side light bulb -M1-/-M3- (dual halogen headlights)…………………………………………………………………………………………7054
1.13.2 Removing and installing side light bulb -M1-/-M3-, gas discharge headlights…………………………………………………………………………………………7055
1.14 Removing and installing daytime running light bulb -L174-/-L175-………………………………………………………………………………………………………..7056
1.15 Removing and installing LED modules for daytime running light and side light -L176-/-L177-…………………………………………………………………………………7057
1.16 Removing and installing bulbs for cornering light -L148-/-L149-…………………………………………………………………………………………………………7057
1.16.1 Removing and installing bulb for static cornering light -L148-/-L149-, halogen twin headlights………………………………………………………………………..7057
1.16.2 Removing and installing bulb for static cornering light -L148-/-L149-, gas discharge headlight………………………………………………………………………..7058
1.17 Removing and installing gas discharge lamp control unit -J343-/-J344-……………………………………………………………………………………………………7059
1.18 Removing and installing output module for headlight -J667-/-J668-……………………………………………………………………………………………………….7060
1.19 Removing and installing control unit for daytime running light and side light -J860-/-J861-………………………………………………………………………………..7061
1.20 Removing and installing swivel module position sensor -G474-/-G475-……………………………………………………………………………………………………..7062
1.21 Removing and installing dynamic cornering light control motor -V318-/-V319-………………………………………………………………………………………………7062
1.22 Removing and installing headlight holder……………………………………………………………………………………………………………………………..7062
2 Fog lights………………………………………………………………………………………………………………………………………………………………7064
2.1 Assembly overview – fog lights……………………………………………………………………………………………………………………………………….7064
2.2 Removing and installing fog light…………………………………………………………………………………………………………………………………….7064
2.3 Removing and installing fog light bulb -L22-/-L23-……………………………………………………………………………………………………………………..7066
3 Lights in exterior mirror…………………………………………………………………………………………………………………………………………………7068
3.1 Assembly overview – lights in exterior mirror………………………………………………………………………………………………………………………….7068
3.2 Removing and installing turn signal…………………………………………………………………………………………………………………………………..7069
3.3 Removing and installing turn signal repeater bulb -L131-/-L132-………………………………………………………………………………………………………….7071
3.4 Removing and installing entry light in exterior mirror………………………………………………………………………………………………………………….7071
3.5 Removing and installing bulb for entry light…………………………………………………………………………………………………………………………..7071
4 Tail lights……………………………………………………………………………………………………………………………………………………………..7073
4.1 Assembly overview – tail lights in body……………………………………………………………………………………………………………………………….7073
4.2 Assembly overview – tail lights in rear lid……………………………………………………………………………………………………………………………7074
4.3 Removing and installing tail light in rear lid…………………………………………………………………………………………………………………………7074
4.4 Adjusting installation position of tail light………………………………………………………………………………………………………………………….7076
4.5 Removing and installing tail light……………………………………………………………………………………………………………………………………7078
4.6 Removing and installing tail light bulb -M2-/-M4-………………………………………………………………………………………………………………………7080
4.7 Removing and installing rear fog light bulb -L46-/-L47-…………………………………………………………………………………………………………………7080
4.8 Removing and installing brake and tail light bulb -M21-/-M22-……………………………………………………………………………………………………………7081
4.9 Removing and installing reversing light bulb…………………………………………………………………………………………………………………………..7081
4.10 Removing and installing turn signal bulb……………………………………………………………………………………………………………………………..7082
5 High-level brake light……………………………………………………………………………………………………………………………………………………7084
5.1 Assembly overview – high-level brake light…………………………………………………………………………………………………………………………….7084
5.2 Removing and installing high-level brake light…………………………………………………………………………………………………………………………7084
6 Number plate light……………………………………………………………………………………………………………………………………………………….7087
6.1 Removing and installing number plate light -X4-/-X5-……………………………………………………………………………………………………………………7087
6.2 Removing and installing bulb for number plate light -X4-/-X5-……………………………………………………………………………………………………………7088
7 Entry and start authorisation system……………………………………………………………………………………………………………………………………….7089
7.1 Overview of fitting locations – keyless entry system……………………………………………………………………………………………………………………7089
7.2 Removing and installing entry and start authorisation control unit -J518-…………………………………………………………………………………………………7091
7.2.1 Removing and installing entry and start authorisation control unit -J518-, left-hand drive…………………………………………………………………………….7091
7.2.2 Removing and installing entry and start authorisation control unit -J518-, right-hand drive……………………………………………………………………………7093
7.3 Removing and installing door exterior handle touch sensor -G415-/-G416-…………………………………………………………………………………………………..7094
7.4 Removing and installing driver side aerial for entry and start authorisation -R134-………………………………………………………………………………………..7094
7.5 Removing and installing front passenger side aerial for entry and start authorisation -R135-………………………………………………………………………………..7094
7.6 Removing and installing rear bumper aerial for entry and start system -R136-………………………………………………………………………………………………7095
7.7 Removing and installing luggage compartment aerial for entry and start authorisation -R137-…………………………………………………………………………………7095
7.8 Removing and installing interior aerial 1 for entry and start authorisation -R138-…………………………………………………………………………………………7096
7.9 Removing and installing interior aerial 2 for entry and start authorisation -R139-…………………………………………………………………………………………7096
7.10 Removing and installing rear lid power opening control unit -J938-………………………………………………………………………………………………………7097
8 Steering column switch module……………………………………………………………………………………………………………………………………………..7099
8.1 Assembly overview – steering column switch module………………………………………………………………………………………………………………………7099
8.1.1 Assembly overview – steering column switch module, with mechanical ignition lock……………………………………………………………………………………..7099
8.1.2 Assembly overview – steering column switch module, with electronic ignition lock……………………………………………………………………………………..7101
8.2 Removing and installing lock cylinder…………………………………………………………………………………………………………………………………7101
8.3 Removing and installing ignition key withdrawal lock solenoid -N376-……………………………………………………………………………………………………..7103
8.4 Removing and installing ignition/starter switch………………………………………………………………………………………………………………………..7104
8.5 Removing and installing steering column electronics control unit -J527-…………………………………………………………………………………………………..7105
8.5.1 Removing and installing steering column electronics control unit -J527-, Kostal………………………………………………………………………………………7105
8.5.2 Removing and installing steering column electronics control unit -J527-, Valeo……………………………………………………………………………………….7107
8.6 Removing and installing steering column combination switch………………………………………………………………………………………………………………7109
8.6.1 Removing and installing steering column combination switch, Kostal………………………………………………………………………………………………….7109
8.6.2 Removing and installing steering column combination switch, Valeo…………………………………………………………………………………………………..7109
8.7 Removing and installing turn signal switch -E2-………………………………………………………………………………………………………………………..7110
8.8 Removing and installing cruise control system switch -E45-………………………………………………………………………………………………………………7110
8.9 Removing and installing intermittent wiper switch -E22-…………………………………………………………………………………………………………………7110
8.10 Removing and installing base for steering column combination switch……………………………………………………………………………………………………..7111
8.10.1 Removing and installing base for steering column combination switch, vehicles with ignition key……………………………………………………………………….7111
8.10.2 Removing and installing base for steering column combination switch, vehicles with Keyless Access locking and starting system…………………………………………….7111
8.11 Removing and installing steering lock housing…………………………………………………………………………………………………………………………7111
9 Parking aid……………………………………………………………………………………………………………………………………………………………..7113
9.1 Assembly overview – parking aid………………………………………………………………………………………………………………………………………7113
9.2 Removing and installing parking aid control unit -J446-…………………………………………………………………………………………………………………7114
9.3 Removing and installing parking aid loudspeaker -R169-………………………………………………………………………………………………………………….7115
9.4 Removing and installing rear parking aid loudspeaker -R194-……………………………………………………………………………………………………………..7115
9.4.1 Removing and installing rear parking aid loudspeaker -R194-, vehicles without reversing camera…………………………………………………………………………7115
9.4.2 Removing and installing rear parking aid loudspeaker -R194-, vehicles with reversing camera……………………………………………………………………………7116
9.5 Removing and installing front parking aid senders………………………………………………………………………………………………………………………7116
9.6 Removing and installing rear parking aid senders……………………………………………………………………………………………………………………….7117
10 Park assist steering…………………………………………………………………………………………………………………………………………………….7118
10.1 Assembly overview – park assist steering……………………………………………………………………………………………………………………………..7118
10.2 Removing and installing control unit…………………………………………………………………………………………………………………………………7118
10.3 Removing and installing front senders………………………………………………………………………………………………………………………………..7119
10.4 Removing and installing rear senders…………………………………………………………………………………………………………………………………7119
11 Automatic headlight range control…………………………………………………………………………………………………………………………………………7120
11.1 Assembly overview – automatic headlight range control………………………………………………………………………………………………………………….7120
11.2 Removing and installing headlight range control unit…………………………………………………………………………………………………………………..7120
12 Towing bracket………………………………………………………………………………………………………………………………………………………….7122
12.1 Assembly overview – towing bracket socket…………………………………………………………………………………………………………………………….7122
12.2 Trailer socket -U10-……………………………………………………………………………………………………………………………………………….7122
12.3 Removing and installing trailer detector control unit -J345-……………………………………………………………………………………………………………7123
13 Blind Spot Monitor (Blind Spot Detection)………………………………………………………………………………………………………………………………….7124
13.1 Assembly overview – Blind Spot Monitor (Blind Spot Detection)…………………………………………………………………………………………………………..7124
13.2 Removing and installing warning lamp for Blind Spot Monitor -K303-/-K304-………………………………………………………………………………………………..7124
13.3 Removing and installing Blind Spot Monitor control unit -J1086-/-J1087-………………………………………………………………………………………………….7125
13.4 Calibrating Blind Spot Monitor………………………………………………………………………………………………………………………………………7125
13.4.1 Measurement location………………………………………………………………………………………………………………………………………….7125
13.4.2 Preparatory measures for calibration……………………………………………………………………………………………………………………………7126
13.4.3 Calibrating Blind Spot Monitor control unit -J1086-/-J1087-……………………………………………………………………………………………………….7130
96 – Lights, bulbs, switches – interior………………………………………………………………………………………………………………………………………….7132
1 Lights………………………………………………………………………………………………………………………………………………………………….7132
1.1 Removing and installing glove compartment light -W6-……………………………………………………………………………………………………………………7132
1.2 Replacing bulb for glove compartment light -W6-………………………………………………………………………………………………………………………..7133
1.3 Removing and installing front footwell light -K268-/-K269-………………………………………………………………………………………………………………7133
1.3.1 Removing and installing front footwell light -K268-, driver side……………………………………………………………………………………………………7133
1.3.2 Removing and installing front footwell light -K269-, front passenger side……………………………………………………………………………………………7134
1.4 Removing and installing front footwell illumination bulb -L151-/-L152-……………………………………………………………………………………………………7134
1.5 Removing and installing central locking deadlock function warning lamp -SAFE- -K133-……………………………………………………………………………………….7135
1.6 Removing and installing front entry light -W31-/-W32-…………………………………………………………………………………………………………………..7135
1.7 Removing and installing bulb for entry light…………………………………………………………………………………………………………………………..7137
1.8 Removing and installing door warning lamp -W30-/-W36-…………………………………………………………………………………………………………………..7137
1.9 Removing and installing rear entry light -W33-/-W34-……………………………………………………………………………………………………………………7138
1.10 Removing and installing rear door warning lamp -W37-/-W38-……………………………………………………………………………………………………………..7138
1.11 Removing and installing selector lever position display -Y26-…………………………………………………………………………………………………………..7138
1.12 Removing and installing luggage compartment light -W3-…………………………………………………………………………………………………………………7138
1.13 Removing and installing bulb for luggage compartment light -W3-…………………………………………………………………………………………………………7139
1.14 Removing and installing illuminated vanity mirror -W20-/-W14-…………………………………………………………………………………………………………..7140
1.15 Removing and installing bulb for illuminated vanity mirror……………………………………………………………………………………………………………..7140
1.16 Removing and installing bulb for front interior light -W1-……………………………………………………………………………………………………………..7141
1.17 Removing and installing bulb for rear interior light -W43-……………………………………………………………………………………………………………..7142
1.18 Renewing bulb of rear interior light -W47-/-W48-………………………………………………………………………………………………………………………7142
1.19 Removing and installing warning lamp for airbag deactivated on front passenger side -K145-…………………………………………………………………………………7143
2 Controls………………………………………………………………………………………………………………………………………………………………..7145
2.1 Removing and installing rotary light switch -EX1-………………………………………………………………………………………………………………………7146
2.2 Removing and installing headlight range control regulator -E102-…………………………………………………………………………………………………………7147
2.3 Removing and installing rear lid remote release button -E233-……………………………………………………………………………………………………………7148
2.4 Removing and installing TCS and ESP button -E256-………………………………………………………………………………………………………………………7148
2.5 Removing and installing parking aid button -E266-………………………………………………………………………………………………………………………7148
2.6 Removing and installing sunroof button -E325-………………………………………………………………………………………………………………………….7148
2.7 Removing and installing the starter button -E378-………………………………………………………………………………………………………………………7149
2.8 Removing and installing shock absorber damping adjustment button -E387-…………………………………………………………………………………………………..7149
2.9 Removing and installing button to close rear lid in luggage compartment -E406-…………………………………………………………………………………………….7149
2.10 Removing and installing right sliding door button -E482-……………………………………………………………………………………………………………….7150
2.11 Removing and installing tyre pressure monitor display button -E492-……………………………………………………………………………………………………..7150
2.12 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540-………………………………………………………………………………7150
2.13 Removing and installing park assist steering button -E581-……………………………………………………………………………………………………………..7151
2.14 Removing and installing start/stop operation switch -E693-……………………………………………………………………………………………………………..7152
2.15 Removing and installing left sliding door button -E731-………………………………………………………………………………………………………………..7152
2.16 Removing and installing operating unit in front of centre console -E461-…………………………………………………………………………………………………7152
2.17 Removing and installing hazard warning light switch -E3-……………………………………………………………………………………………………………….7153
2.18 Removing and installing buttons for seat heating -E653-/-E654-………………………………………………………………………………………………………….7154
2.19 Removing and installing glove compartment light switch -E26-……………………………………………………………………………………………………………7154
2.20 Removing and installing exterior mirror adjuster -EX11-………………………………………………………………………………………………………………..7155
2.21 Removing and installing operating unit for window regulator in driver door -E512-…………………………………………………………………………………………7156
2.22 Removing and installing window regulator switch in front passenger door -E107-……………………………………………………………………………………………7158
2.23 Removing and installing rear window regulator button -E700-/-E705-………………………………………………………………………………………………………7159
2.24 Removing and installing driver side interior locking button for central locking system -E308-………………………………………………………………………………7160
2.25 Removing and installing button for deactivating interior monitoring and vehicle inclination sensor -E616-……………………………………………………………………7162
2.26 Removing and installing door contact switch -F2-/-F3-………………………………………………………………………………………………………………….7163
2.27 Removing and installing rear door contact switches -F10-/-F11-………………………………………………………………………………………………………….7163
2.28 Removing and installing rear lid contact switch……………………………………………………………………………………………………………………….7163
2.29 Removing and installing rear lid warning buzzer -H32-………………………………………………………………………………………………………………….7163
2.30 Removing and installing front interior light/reading light……………………………………………………………………………………………………………..7164
2.31 Removing and installing rear interior light/reading light………………………………………………………………………………………………………………7165
2.32 Removing and installing rear interior light -W47-/-W48-………………………………………………………………………………………………………………..7166
2.33 Removing and installing front reading light button -E457-/-E458-………………………………………………………………………………………………………..7168
2.34 Removing and installing key-operated switch to deactivate front passenger side airbag -E224-……………………………………………………………………………….7168
3 Anti-theft alarm system…………………………………………………………………………………………………………………………………………………..7170
3.1 Assembly overview – interior monitor………………………………………………………………………………………………………………………………….7170
3.2 Removing and installing alarm horn -H12-………………………………………………………………………………………………………………………………7171
3.3 Activating and deactivating anti-theft alarm…………………………………………………………………………………………………………………………..7172
3.4 Removing and installing anti-theft alarm sensor -G578-………………………………………………………………………………………………………………….7172
4 Immobilizer……………………………………………………………………………………………………………………………………………………………..7174
4.1 Removing and installing immobiliser control unit……………………………………………………………………………………………………………………….7174
4.2 Removing and installing immobiliser reader coil………………………………………………………………………………………………………………………..7174
4.2.1 Removing and installing immobiliser reader coil, vehicles with ignition key………………………………………………………………………………………….7174
4.2.2 Removing and installing immobiliser reader coil, vehicles with Keyless Access locking and starting system……………………………………………………………….7174
5 Front camera for assist systems……………………………………………………………………………………………………………………………………………7175
5.1 Removing and installing front camera for driver assist systems…………………………………………………………………………………………………………..7175
6 Cigarette lighter, socket…………………………………………………………………………………………………………………………………………………7176
6.1 Assembly overview – DC/AC converter with socket, 12 V – 230 V……………………………………………………………………………………………………………7176
6.2 Removing and installing cigarette lighter -U1-…………………………………………………………………………………………………………………………7177
6.3 Removing and installing socket illumination bulb -L42-………………………………………………………………………………………………………………….7177
6.4 Removing and installing rear cigarette lighter illumination bulb -L32-……………………………………………………………………………………………………7177
6.5 Removing and installing 12 V socket 2 -U18-……………………………………………………………………………………………………………………………7177
6.6 Removing and installing AC/DC converter with socket, 12 V – 230 V -U13-…………………………………………………………………………………………………..7177
97 – Wiring…………………………………………………………………………………………………………………………………………………………………..7179
1 Relay carriers, fuse holders, E-boxes………………………………………………………………………………………………………………………………………7179
1.1 Removing and installing electronics box (E-box)………………………………………………………………………………………………………………………..7179
1.2 Removing and installing relay and fuse holder in E-box………………………………………………………………………………………………………………….7180
1.3 Removing and installing relay and fuse holder behind dash panel on driver side…………………………………………………………………………………………….7182
1.3.1 Removing and installing fuse carrier in dash panel………………………………………………………………………………………………………………..7182
1.3.2 Removing and installing additional relay carrier on left of dash panel………………………………………………………………………………………………7182
1.3.3 Removing and installing relay carrier on left of dash panel………………………………………………………………………………………………………..7183
2 Control units……………………………………………………………………………………………………………………………………………………………7184
2.1 Removing and installing onboard supply control unit -J519-………………………………………………………………………………………………………………7184
2.2 Removing and installing data bus diagnostic interface -J533-…………………………………………………………………………………………………………….7184
2.2.1 Removing and installing (left-hand drive models) data bus diagnostic interface -J533-…………………………………………………………………………………7184
2.2.2 Removing and installing data bus diagnostic interface -J533-, right-hand drive……………………………………………………………………………………….7185
2.3 Removing and installing rear lid control unit -J605-……………………………………………………………………………………………………………………7186
3 Connectors………………………………………………………………………………………………………………………………………………………………7188
3.1 Repairing electrical wiring harnesses and plug-in connections……………………………………………………………………………………………………………7188
3.1.1 Repairs to wiring harnesses and connectors……………………………………………………………………………………………………………………….7188
3.1.2 Repairing connector housings and electrical connectors…………………………………………………………………………………………………………….7188
4 Releasing and dismantling connector housings………………………………………………………………………………………………………………………………..7189
5 Repairing aerial cables…………………………………………………………………………………………………………………………………………………..7190
6 Vehicle diagnosis, testing and information systems…………………………………………………………………………………………………………………………..7191
Sharan2016-Fuel_supply_system_-_Diesel_engines……………………………………………………………………………………………………………………………………….7192
00 – Technical data……………………………………………………………………………………………………………………………………………………………7196
1 Safety instructions………………………………………………………………………………………………………………………………………………………7196
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………..7196
1.2 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………7197
1.3 Safety precautions when working on vehicles with a Start/Stop system……………………………………………………………………………………………………..7197
2 Identification…………………………………………………………………………………………………………………………………………………………..7198
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………..7198
3 General notes……………………………………………………………………………………………………………………………………………………………7199
3.1 Cleanliness specifications for working on the auxiliary/supplementary heater and fuel system………………………………………………………………………………..7199
4 Repair instructions………………………………………………………………………………………………………………………………………………………7200
4.1 Routing and securing lines…………………………………………………………………………………………………………………………………………..7200
4.2 General repair notes………………………………………………………………………………………………………………………………………………..7200
20 – Fuel supply system………………………………………………………………………………………………………………………………………………………..7201
1 Procedure after filling with incorrect fuel…………………………………………………………………………………………………………………………………7201
1.1 Step 1, engine was started with incorrect fuel…………………………………………………………………………………………………………………………7201
1.2 Step 2, engine was not started with incorrect fuel……………………………………………………………………………………………………………………..7202
1.3 Step 3, there are metal particles in fuel delivery unit and fuel tank…………………………………………………………………………………………………….7203
1.4 Step 4, there are no metal particles in fuel delivery unit and fuel tank………………………………………………………………………………………………….7203
1.5 Step 5, there are metal particles in high-pressure pump…………………………………………………………………………………………………………………7204
1.6 Step 6, there are no metal particles in high-pressure pump………………………………………………………………………………………………………………7205
1.7 Step 6, there are no metal particles in high-pressure pump………………………………………………………………………………………………………………7205
2 Fuel tank……………………………………………………………………………………………………………………………………………………………….7206
2.1 Assembly overview – fuel tank………………………………………………………………………………………………………………………………………..7206
2.2 Emptying fuel tank………………………………………………………………………………………………………………………………………………….7207
2.2.1 Emptying fuel tank when fuel pump is defective……………………………………………………………………………………………………………………7207
2.2.2 Emptying fuel tank when fuel pump is intact………………………………………………………………………………………………………………………7210
2.3 Removing and installing fuel tank…………………………………………………………………………………………………………………………………….7211
3 Fuel delivery unit and fuel gauge sender……………………………………………………………………………………………………………………………………7215
3.1 Assembly overview – fuel delivery unit and fuel gauge sender…………………………………………………………………………………………………………….7215
3.1.1 Assembly overview – fuel delivery unit and fuel gauge sender……………………………………………………………………………………………………….7215
3.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater………………………………………………………………………………7216
3.2 Removing and installing fuel delivery unit, fuel gauge sender……………………………………………………………………………………………………………7217
3.2.1 Removing and installing fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………7217
3.2.2 Removing and installing fuel line for auxiliary/supplementary heater………………………………………………………………………………………………..7219
4 Plug-in connectors……………………………………………………………………………………………………………………………………………………….7221
4.1 Separating plug-in connectors………………………………………………………………………………………………………………………………………..7221
5 Fuel filter……………………………………………………………………………………………………………………………………………………………..7225
5.1 Assembly overview – fuel filter………………………………………………………………………………………………………………………………………7225
5.2 Removing and installing fuel filter…………………………………………………………………………………………………………………………………..7226
5.2.1 Removing and installing fuel filter, engine codes CFFA, CFFB, CFFE, CFGB, CFGC……………………………………………………………………………………….7226
5.2.2 Removing and installing fuel filter, engine codes CUVA, CUVC, CUVE, CUWA…………………………………………………………………………………………….7227
5.3 Fuel hoses in engine compartment……………………………………………………………………………………………………………………………………..7230
6 Accelerator mechanism…………………………………………………………………………………………………………………………………………………….7231
6.1 Assembly overview – accelerator module………………………………………………………………………………………………………………………………..7231
6.2 Removing and installing accelerator module -GX2-……………………………………………………………………………………………………………………….7231
7 Fuel pump……………………………………………………………………………………………………………………………………………………………….7234
7.1 Checking fuel system pressurisation pump -G6-………………………………………………………………………………………………………………………….7234
7.1.1 Checking delivery pressure and quantity for fuel system pressurisation pump -G6-……………………………………………………………………………………..7234
8 Senders and sensors………………………………………………………………………………………………………………………………………………………7239
8.1 Removing and installing fuel gauge sender -G-………………………………………………………………………………………………………………………….7239
Sharan2016-General_information__Paint (1)……………………………………………………………………………………………………………………………………………7241
00 – Technical data……………………………………………………………………………………………………………………………………………………………7247
1 Safety information……………………………………………………………………………………………………………………………………………………….7247
1.1 Safety precautions when painting natural gas-powered vehicles……………………………………………………………………………………………………………7247
1.2 Safety precautions when painting electric drive vehicles………………………………………………………………………………………………………………..7248
2 General notes……………………………………………………………………………………………………………………………………………………………7249
2.1 Paintwork structure of a factory finish……………………………………………………………………………………………………………………………….7249
2.2 Paintwork in Aftersales……………………………………………………………………………………………………………………………………………..7250
2.3 Reduced paint structure in engine compartment and inside of bonnet……………………………………………………………………………………………………….7253
2.4 Instructions for work on underbody and stone chip protection…………………………………………………………………………………………………………….7253
2.5 Preparing bonding surfaces with 2-pack epoxy primer surfacer when renewing laser-welded roofs……………………………………………………………………………….7255
2.6 Corrosion protection measures for wing surface in contact with wheel housing liner…………………………………………………………………………………………7256
2.7 Notes on treating corroded fold areas…………………………………………………………………………………………………………………………………7257
2.8 Corrosion protection for body components, add-on components and welded components………………………………………………………………………………………….7259
3 Genuine products…………………………………………………………………………………………………………………………………………………………7261
3.1 General application instructions for repair and painting systems…………………………………………………………………………………………………………7261
3.1.1 Aqua-Premium – application instructions for water-based products……………………………………………………………………………………………………7261
3.1.2 Setting the gloss level of HS clear coats and HS top coats…………………………………………………………………………………………………………7264
3.1.3 Repair paintwork system for matt-finished vehicles………………………………………………………………………………………………………………..7272
3.1.4 Paintwork system for plastic components………………………………………………………………………………………………………………………….7277
3.1.5 Aqua Premium system, blending system for 2-stage colours…………………………………………………………………………………………………………..7283
3.1.6 Aqua Premium system, blending system for 3-stage colours…………………………………………………………………………………………………………..7288
3.1.7 Aquaplus design and multi-colour painting………………………………………………………………………………………………………………………..7293
3.2 Filler…………………………………………………………………………………………………………………………………………………………….7297
3.2.1 2-pack steel filler set………………………………………………………………………………………………………………………………………..7297
3.2.2 2-pack fine filler…………………………………………………………………………………………………………………………………………….7300
3.2.3 2-pack fine filler, flexible……………………………………………………………………………………………………………………………………7303
3.2.4 2-pack spray filler……………………………………………………………………………………………………………………………………………7306
3.2.5 2-pack IR Premium filler……………………………………………………………………………………………………………………………………….7310
3.2.6 2-pack diamond aluminium filler…………………………………………………………………………………………………………………………………7313
3.3 Priming metal………………………………………………………………………………………………………………………………………………………7316
3.3.1 1-pack anti-corrosion wash primer……………………………………………………………………………………………………………………………….7316
3.3.2 1-pack wash primer…………………………………………………………………………………………………………………………………………….7320
3.3.3 2-pack wash primer…………………………………………………………………………………………………………………………………………….7324
3.4 Priming plastic materials……………………………………………………………………………………………………………………………………………7327
3.4.1 Adhesion promoter (transparent)…………………………………………………………………………………………………………………………………7327
3.5 Surfacer…………………………………………………………………………………………………………………………………………………………..7331
3.5.1 2-pack HS Vario surfacer……………………………………………………………………………………………………………………………………….7331
3.5.2 2-pack HS premium surfacer……………………………………………………………………………………………………………………………………..7339
3.5.3 2-pack HS mixture surfacer……………………………………………………………………………………………………………………………………..7346
3.5.4 2-pack HS Performance surfacer………………………………………………………………………………………………………………………………….7358
3.5.5 2-pack plastic adhesion surfacer………………………………………………………………………………………………………………………………..7364
3.5.6 2-pack HS wet-on-wet surfacer…………………………………………………………………………………………………………………………………..7369
3.6 Top coats………………………………………………………………………………………………………………………………………………………….7373
3.6.1 2-pack HS top coat…………………………………………………………………………………………………………………………………………….7373
3.6.2 Aquaplus system, uni (solid-colour) and metallic colours…………………………………………………………………………………………………………..7379
3.6.3 Aquaplus system (pearlescent and heliochrome)…………………………………………………………………………………………………………………….7385
3.6.4 Aquaplus blending system……………………………………………………………………………………………………………………………………….7391
3.6.5 Aqua Premium system……………………………………………………………………………………………………………………………………………7395
3.6.6 Aqua Premium blending system……………………………………………………………………………………………………………………………………7405
3.6.7 Aqua Premium system (painting rims)……………………………………………………………………………………………………………………………..7410
3.7 Clear coats………………………………………………………………………………………………………………………………………………………..7417
3.7.1 2-pack HS clear coat…………………………………………………………………………………………………………………………………………..7417
3.7.2 2-pack MS matt clear coat………………………………………………………………………………………………………………………………………7423
3.7.3 2-pack HS Vario clear coat……………………………………………………………………………………………………………………………………..7426
3.7.4 2-pack HS Optimum clear coat……………………………………………………………………………………………………………………………………7432
3.7.5 2-pack HS Optimum Plus clear coat……………………………………………………………………………………………………………………………….7435
3.7.6 2-pack HS Brillant clear coat…………………………………………………………………………………………………………………………………..7439
3.7.7 2-pack HS Brillant plus clear coat………………………………………………………………………………………………………………………………7443
3.7.8 2-pack HS Performance clear coat………………………………………………………………………………………………………………………………..7447
3.7.9 Blender………………………………………………………………………………………………………………………………………………………7451
3.8 Hardener…………………………………………………………………………………………………………………………………………………………..7455
3.8.1 2-pack HS hardener…………………………………………………………………………………………………………………………………………….7455
3.8.2 2-pack VHS hardeners and 2-pack VHS Performance hardeners………………………………………………………………………………………………………….7458
3.8.3 Hardener for 2-pack primer surfacer……………………………………………………………………………………………………………………………..7463
3.8.4 Aqua Premium hardener………………………………………………………………………………………………………………………………………….7463
3.9 Thinners…………………………………………………………………………………………………………………………………………………………..7463
3.9.1 2-pack thinner………………………………………………………………………………………………………………………………………………..7463
3.9.2 HS spot thinner……………………………………………………………………………………………………………………………………………….7467
3.9.3 Demineralised water……………………………………………………………………………………………………………………………………………7469
3.10 Anti-corrosion materials……………………………………………………………………………………………………………………………………………7469
3.10.1 Anti-corrosion wax……………………………………………………………………………………………………………………………………………7469
3.10.2 Cavity-preservative agent……………………………………………………………………………………………………………………………………..7470
3.10.3 Anti-corrosion wax (in aerosol can)…………………………………………………………………………………………………………………………….7473
3.11 Underbody protection……………………………………………………………………………………………………………………………………………….7474
3.11.1 Permanent underbody protection -D 314 D36 M2-, grey………………………………………………………………………………………………………………7474
3.11.2 Permanent underbody protection -D 314 D37 M2-, black……………………………………………………………………………………………………………..7477
3.11.3 Permanent underbody protection -D 314 D38 M2-, light……………………………………………………………………………………………………………..7480
3.12 Stone chip guard…………………………………………………………………………………………………………………………………………………..7483
3.12.1 Stone chip guard -AKR 311 KD1 05-………………………………………………………………………………………………………………………………7483
3.12.2 Stone chip guard -AKR 311 KD1 10-………………………………………………………………………………………………………………………………7485
3.13 Wax-based underseal………………………………………………………………………………………………………………………………………………..7490
3.13.1 Wax-based underseal -D 316 D38 A2-……………………………………………………………………………………………………………………………..7490
3.13.2 Wax-based underseal -D 316 000 A1-……………………………………………………………………………………………………………………………..7492
3.13.3 Spray wax (spraying wax) -D 322 100 M2-…………………………………………………………………………………………………………………………7493
3.14 Sealing materials………………………………………………………………………………………………………………………………………………….7495
3.14.1 Polyurethane adhesive sealant (bonding compound)…………………………………………………………………………………………………………………7495
3.14.2 Sprayable sealant…………………………………………………………………………………………………………………………………………….7497
3.14.3 Adhesive sealant……………………………………………………………………………………………………………………………………………..7500
3.15 Cleaning agents……………………………………………………………………………………………………………………………………………………7502
3.15.1 Silicone remover……………………………………………………………………………………………………………………………………………..7502
3.15.2 Cleaner for plastics………………………………………………………………………………………………………………………………………….7504
3.15.3 Cleaner for plastics, antistatic……………………………………………………………………………………………………………………………….7505
3.15.4 Industrial dirt remover……………………………………………………………………………………………………………………………………….7505
3.16 SprayMax System……………………………………………………………………………………………………………………………………………………7507
3.16.1 1-pack anti-corrosion primer…………………………………………………………………………………………………………………………………..7507
3.16.2 1-pack test paint…………………………………………………………………………………………………………………………………………….7510
3.16.3 1-pack clear coat…………………………………………………………………………………………………………………………………………….7512
3.16.4 1-pack wash primer……………………………………………………………………………………………………………………………………………7515
3.16.5 1-pack fill clean spray can -LLS MAX 099-, -LLS MAX 100-, Aquaplus system…………………………………………………………………………………………..7518
3.16.6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system…………………………………………………………………………………………………….7524
3.16.7 2-pack surfacer………………………………………………………………………………………………………………………………………………7530
3.16.8 2-pack clear coat…………………………………………………………………………………………………………………………………………….7537
3.16.9 2-pack epoxy primer surfacer…………………………………………………………………………………………………………………………………..7541
3.16.10 2-pack wash primer…………………………………………………………………………………………………………………………………………..7546
3.16.11 Silicone remover -LLS MAX 007-………………………………………………………………………………………………………………………………..7550
3.16.12 Slow-drying silicone remover -LLS MAX 008-……………………………………………………………………………………………………………………..7553
3.16.13 Blender…………………………………………………………………………………………………………………………………………………….7555
3.16.14 Adhesion promoter……………………………………………………………………………………………………………………………………………7557
3.17 Additional materials……………………………………………………………………………………………………………………………………………….7560
3.17.1 Matting additive -ALN 775 106-…………………………………………………………………………………………………………………………………7560
3.17.2 Matting additive -LVM 769 810 A2-………………………………………………………………………………………………………………………………7566
3.17.3 Texture additive……………………………………………………………………………………………………………………………………………..7568
3.17.4 Blending additive for Aquaplus…………………………………………………………………………………………………………………………………7573
3.17.5 Additive for Aqua Premium……………………………………………………………………………………………………………………………………..7573
4 Workshop equipment……………………………………………………………………………………………………………………………………………………….7575
4.1 Tools……………………………………………………………………………………………………………………………………………………………..7575
4.1.1 Spray can filling device -VAS 6425-……………………………………………………………………………………………………………………………..7575
4.1.2 Paint thickness tester -VAS 6272-……………………………………………………………………………………………………………………………….7576
4.1.3 Paint thickness tester -VAS 6197-……………………………………………………………………………………………………………………………….7576
4.1.4 Paint thickness tester -VAS 5278-……………………………………………………………………………………………………………………………….7576
4.1.5 Stone chip tester -VAS 5102A-…………………………………………………………………………………………………………………………………..7578
4.1.6 Pneumatic brush grinder set -VAS 6446-…………………………………………………………………………………………………………………………..7579
4.1.7 Brush grinder set -VAS 6776-……………………………………………………………………………………………………………………………………7580
4.1.8 Suction feed spray-gun -V.A.G 1538-……………………………………………………………………………………………………………………………..7581
4.1.9 Infrared heater -VAS 6873-……………………………………………………………………………………………………………………………………..7582
4.1.10 Stand -VAS 6873/1-……………………………………………………………………………………………………………………………………………7582
4.1.11 Infrared heater -VAS 6874-…………………………………………………………………………………………………………………………………….7583
4.1.12 Infrared heater -VAS 6875-…………………………………………………………………………………………………………………………………….7583
4.1.13 Infrared heater -VAS 6876-…………………………………………………………………………………………………………………………………….7584
4.1.14 Infrared heater -VAS 6877-…………………………………………………………………………………………………………………………………….7584
4.1.15 Infrared heater -VAS 6878-…………………………………………………………………………………………………………………………………….7585
4.1.16 Infrared heater -VAS 6879-…………………………………………………………………………………………………………………………………….7585
4.2 Tack cloths………………………………………………………………………………………………………………………………………………………..7586
4.2.1 Tack cloth -VAS 6177-………………………………………………………………………………………………………………………………………….7586
4.2.2 Buffing cloth, white -VAS 6176-…………………………………………………………………………………………………………………………………7586
4.2.3 Primary tack cloth -VAS 5542-…………………………………………………………………………………………………………………………………..7587
4.2.4 Professional cleaning cloth -VAS 6006-…………………………………………………………………………………………………………………………..7587
Sharan2016-Heating__air_conditioning………………………………………………………………………………………………………………………………………………..7588
00 – Technical data……………………………………………………………………………………………………………………………………………………………7594
1 Notes on safety………………………………………………………………………………………………………………………………………………………….7594
1.1 Safety precautions when working on air conditioning systems……………………………………………………………………………………………………………..7594
1.2 Safety measures for when working on vehicles with a start-stop system…………………………………………………………………………………………………….7594
1.3 Safety precautions when working on cooling system………………………………………………………………………………………………………………………7594
2 General notes……………………………………………………………………………………………………………………………………………………………7596
2.1 Notes concerning odours in air conditioned vehicles…………………………………………………………………………………………………………………….7596
2.2 Notes for vehicles with start-stop system……………………………………………………………………………………………………………………………..7596
2.3 Identification plates……………………………………………………………………………………………………………………………………………….7597
3 Repair notes…………………………………………………………………………………………………………………………………………………………….7598
3.1 Working on refrigerant circuit……………………………………………………………………………………………………………………………………….7598
3.2 Refrigerant circuit seals……………………………………………………………………………………………………………………………………………7598
3.3 Check cooling performance……………………………………………………………………………………………………………………………………………7599
3.4 Notes on control motors……………………………………………………………………………………………………………………………………………..7599
3.4.1 Notes on control motors………………………………………………………………………………………………………………………………………..7599
3.4.2 Inserting link into the shaft of a control motor………………………………………………………………………………………………………………….7601
3.4.3 Activating control motor using adapter cable……………………………………………………………………………………………………………………..7603
3.4.4 Locally manufacturing an adapter cable to activate control motors…………………………………………………………………………………………………..7604
4 Technical data…………………………………………………………………………………………………………………………………………………………..7605
4.1 Capacities for refrigerant R134a……………………………………………………………………………………………………………………………………..7605
4.2 Refrigerant oil…………………………………………………………………………………………………………………………………………………….7605
4.3 Oil distribution……………………………………………………………………………………………………………………………………………………7605
80 – Heating………………………………………………………………………………………………………………………………………………………………….7607
1 Heating…………………………………………………………………………………………………………………………………………………………………7607
87 – Air conditioning system……………………………………………………………………………………………………………………………………………………7608
1 Overview of fitting locations – air conditioning system………………………………………………………………………………………………………………………7608
1.1 Overview of fitting locations – components not located in passenger compartment……………………………………………………………………………………………7608
1.1.1 Overview of fitting locations – components located outside the passenger compartment, air conditioning system with electric/manual controls…………………………………7608
1.1.2 Overview of fitting locations – components not located in passenger compartment, Climatronic…………………………………………………………………………..7610
1.2 Overview of fitting locations – components located in front section of passenger compartment………………………………………………………………………………..7611
1.2.1 Overview of fitting locations – components located in front section of passenger compartment, air conditioning system with electric/manual controls………………………….7611
1.2.2 Overview – components inside front passenger compartment, Climatronic……………………………………………………………………………………………….7613
1.3 Fittings locations overview – components located in rear section of passenger compartment…………………………………………………………………………………..7615
2 Refrigerant circuit………………………………………………………………………………………………………………………………………………………7616
2.1 System overview – refrigerant circuit…………………………………………………………………………………………………………………………………7616
2.2 Assembly overview – condenser………………………………………………………………………………………………………………………………………..7618
2.3 Removing and installing high-pressure sender -G65-……………………………………………………………………………………………………………………..7618
2.4 Removing and installing expansion valve……………………………………………………………………………………………………………………………….7620
2.4.1 Removing and installing front expansion valve…………………………………………………………………………………………………………………….7620
2.4.2 Removing and installing rear expansion valve……………………………………………………………………………………………………………………..7622
2.5 Removing and installing condenser…………………………………………………………………………………………………………………………………….7624
2.6 Removing and installing desiccant bag or cartridge……………………………………………………………………………………………………………………..7626
2.7 Removing and installing evacuating and charging valves on low and high-pressure side……………………………………………………………………………………….7629
2.8 Removing and installing refrigerant line between condenser and expansion valve…………………………………………………………………………………………….7631
2.9 Removing and installing refrigerant line between condenser and air conditioner compressor…………………………………………………………………………………..7633
2.10 Removing and installing refrigerant line between air conditioner compressor and expansion valve…………………………………………………………………………….7635
2.11 Removing and installing refrigerant line to second heater unit, high-pressure section……………………………………………………………………………………..7636
2.12 Removing and installing refrigerant line to second heater unit, low-pressure section………………………………………………………………………………………7638
2.13 Removing and installing refrigerant line from second heater unit………………………………………………………………………………………………………..7640
3 Air conditioner compressor………………………………………………………………………………………………………………………………………………..7643
3.1 Assembly overview – drive unit of air conditioner compressor…………………………………………………………………………………………………………….7643
3.2 Assembly overview – belt pulley………………………………………………………………………………………………………………………………………7644
3.2.1 Assembly overview – Denso belt pulley……………………………………………………………………………………………………………………………7644
3.3 Removing air conditioner compressor from and installing on bracket……………………………………………………………………………………………………….7645
3.4 Removing and installing air conditioner compressor……………………………………………………………………………………………………………………..7646
3.5 Checking excess pressure relief valve on air conditioner compressor………………………………………………………………………………………………………7651
3.6 Removing and installing belt pulley…………………………………………………………………………………………………………………………………..7651
3.6.1 Removing and installing belt pulley – Denso………………………………………………………………………………………………………………………7651
4 Control motors…………………………………………………………………………………………………………………………………………………………..7653
4.1 Overview of fitting locations – front control motors……………………………………………………………………………………………………………………7653
4.1.1 Overview of fitting locations – front control motors, air conditioning system with electric and manual controls………………………………………………………….7653
4.1.2 Overview of fitting locations – front control motors, Climatronic…………………………………………………………………………………………………..7654
4.2 Removing and installing temperature flap control motor -V68-…………………………………………………………………………………………………………….7655
4.3 Removing and installing defroster flap control motor -V107-……………………………………………………………………………………………………………..7657
4.4 Removing and installing air recirculation flap control motor -V113-………………………………………………………………………………………………………7659
4.5 Removing and installing rear temperature flap control motor -V137-……………………………………………………………………………………………………….7660
4.6 Removing and installing left temperature flap control motor -V158-……………………………………………………………………………………………………….7661
4.7 Removing and installing right temperature flap control motor -V159-………………………………………………………………………………………………………7662
4.8 Removing and installing fresh air/recirculated air, air flow flap control motor -V425-……………………………………………………………………………………..7664
4.9 Removing and installing front air distribution flap control motor -V426-………………………………………………………………………………………………….7665
4.10 Removing and installing rear air distribution flap control motor -V427- with potentiometer for rear air distribution flap control motor -G643-…………………………………..7666
4.11 Removing and installing air distribution flap control motor -V428-………………………………………………………………………………………………………7667
5 Front heater and air conditioning unit……………………………………………………………………………………………………………………………………..7668
5.1 Assembly overview – heater and air conditioning unit……………………………………………………………………………………………………………………7668
5.1.1 Assembly overview – heater and air conditioning unit, manually controlled air conditioning system………………………………………………………………………7668
5.1.2 Assembly overview – heater and air conditioning unit, Climatronic…………………………………………………………………………………………………..7671
5.2 Removing and installing auxiliary air heater element -Z35-………………………………………………………………………………………………………………7672
5.3 Removing and installing heater and air conditioning unit………………………………………………………………………………………………………………..7673
5.4 Dismantling and assembling heater and air conditioning unit……………………………………………………………………………………………………………..7678
5.5 Assembly overview – evaporator housing………………………………………………………………………………………………………………………………..7681
5.6 Removing and installing evaporator……………………………………………………………………………………………………………………………………7681
5.7 Removing and installing dust and pollen filter…………………………………………………………………………………………………………………………7682
5.8 Removing and installing fresh air blower -V2-………………………………………………………………………………………………………………………….7683
5.9 Removing and installing heat exchanger………………………………………………………………………………………………………………………………..7684
5.10 Removing and installing evaporator temperature sensor -G308-……………………………………………………………………………………………………………7689
5.11 Removing and installing condensate drain hose…………………………………………………………………………………………………………………………7689
5.12 Checking condensation drainage………………………………………………………………………………………………………………………………………7690
5.13 Removing and installing fresh air blower series resistor with overheating fuse -N24-………………………………………………………………………………………7691
5.14 Removing and installing glove box cooling…………………………………………………………………………………………………………………………….7691
6 Rear heater and air conditioning unit………………………………………………………………………………………………………………………………………7693
6.1 Assembly overview – heater and air conditioning unit……………………………………………………………………………………………………………………7693
6.2 Removing and installing heater and air conditioning unit………………………………………………………………………………………………………………..7694
6.3 Dismantling and assembling heater and air conditioning unit……………………………………………………………………………………………………………..7696
6.4 Removing and installing rear fresh air blower -V80-…………………………………………………………………………………………………………………….7699
6.5 Removing and installing rear fresh air blower control unit -J391-………………………………………………………………………………………………………..7699
6.6 Removing and installing heat exchanger………………………………………………………………………………………………………………………………..7699
7 Air duct………………………………………………………………………………………………………………………………………………………………..7703
7.1 Assembly overview – air duct and air distribution in passenger compartment………………………………………………………………………………………………..7703
7.2 Removing and installing air ducts…………………………………………………………………………………………………………………………………….7704
7.2.1 Removing and installing side vent air ducts………………………………………………………………………………………………………………………7704
7.2.2 Removing and installing centre vent air duct……………………………………………………………………………………………………………………..7704
7.2.3 Removing and installing rear air ducts…………………………………………………………………………………………………………………………..7705
7.2.4 Removing and installing footwell vent air ducts for 2nd row of seats………………………………………………………………………………………………..7706
7.2.5 Removing and installing footwell vent air ducts for 3rd row of seats………………………………………………………………………………………………..7708
7.2.6 Removing and installing air ducting from rear heater and air conditioning unit to moulded headliner…………………………………………………………………….7709
7.3 Removing and installing exhaust ventilation for passenger compartment…………………………………………………………………………………………………….7709
7.4 Checking exhaust ventilation for passenger compartment………………………………………………………………………………………………………………….7710
7.5 Removing and installing fresh air intake………………………………………………………………………………………………………………………………7710
7.6 Removing and installing driver side footwell vents……………………………………………………………………………………………………………………..7711
7.7 Removing and installing front passenger side footwell vents……………………………………………………………………………………………………………..7712
7.8 Removing and installing long rear vent………………………………………………………………………………………………………………………………..7713
7.9 Removing and installing short rear vent……………………………………………………………………………………………………………………………….7713
7.10 Removing and installing footwell vents for 3rd row of seats…………………………………………………………………………………………………………….7714
8 Coolant circuit………………………………………………………………………………………………………………………………………………………….7716
8.1 Checking 2nd heat exchanger switch-off valve -N317-…………………………………………………………………………………………………………………….7716
8.2 Removing and installing 2nd heat exchanger switch-off valve -N317-……………………………………………………………………………………………………….7717
9 Operating and display unit………………………………………………………………………………………………………………………………………………..7718
9.1 Overview of operating and display unit………………………………………………………………………………………………………………………………..7718
9.1.1 Overview – control and display unit, air conditioning system with electric/manual controls…………………………………………………………………………….7718
9.1.2 Overview of operating and display unit, Climatronic……………………………………………………………………………………………………………….7720
9.1.3 Overview of operating and display unit, rear……………………………………………………………………………………………………………………..7723
9.2 Removing and installing operating and display unit……………………………………………………………………………………………………………………..7723
9.2.1 Removing and installing operating and display unit, front………………………………………………………………………………………………………….7723
9.2.2 Removing and installing operating and display unit, rear…………………………………………………………………………………………………………..7724
10 Other controlling and regulating components………………………………………………………………………………………………………………………………..7726
10.1 Removing and installing sunlight penetration photosensor -G107-…………………………………………………………………………………………………………7726
10.2 Working principles of air quality sensor -G238-……………………………………………………………………………………………………………………….7727
10.3 Removing and installing air quality sensor -G238-……………………………………………………………………………………………………………………..7728
10.4 Removing and installing ambient temperature sensor -G17-……………………………………………………………………………………………………………….7729
10.5 Removing and installing left vent temperature sender -G150-…………………………………………………………………………………………………………….7729
10.6 Removing and installing right vent temperature sender -G151-……………………………………………………………………………………………………………7730
10.7 Removing and installing left footwell vent temperature sender -G261-…………………………………………………………………………………………………….7730
10.8 Removing and installing right footwell vent temperature sender -G262-……………………………………………………………………………………………………7731
10.9 Removing and installing rear vent temperature sender -G174-…………………………………………………………………………………………………………….7731
Sharan2016-Manual_for_Troubleshooting_and_Diagnosing_Noises……………………………………………………………………………………………………………………………7733
00 – Technical data……………………………………………………………………………………………………………………………………………………………7737
1 Introduction…………………………………………………………………………………………………………………………………………………………….7737
1.1 Definition of sound…………………………………………………………………………………………………………………………………………………7737
1.2 Acoustic range……………………………………………………………………………………………………………………………………………………..7737
1.3 Physical characteristics of sound…………………………………………………………………………………………………………………………………….7739
1.3.1 Pitch………………………………………………………………………………………………………………………………………………………..7739
1.3.2 Intensity…………………………………………………………………………………………………………………………………………………….7739
1.3.3 Duration……………………………………………………………………………………………………………………………………………………..7740
1.3.4 Timbre……………………………………………………………………………………………………………………………………………………….7740
1.4 Characteristics of a sound wave………………………………………………………………………………………………………………………………………7740
1.4.2 Period……………………………………………………………………………………………………………………………………………………….7740
1.4.3 Frequency…………………………………………………………………………………………………………………………………………………….7740
1.4.4 Resonance…………………………………………………………………………………………………………………………………………………….7741
2 Definition of noise………………………………………………………………………………………………………………………………………………………7742
2.1 Types of noises…………………………………………………………………………………………………………………………………………………….7742
2.1.1 Audible noise…………………………………………………………………………………………………………………………………………………7742
2.1.2 Inaudible noise……………………………………………………………………………………………………………………………………………….7742
2.2 Acoustic considerations during vehicle development……………………………………………………………………………………………………………………..7743
2.2.1 Vibration insulation film………………………………………………………………………………………………………………………………………7743
2.2.2 Insulation……………………………………………………………………………………………………………………………………………………7745
3 General procedure for identifying noises……………………………………………………………………………………………………………………………………7746
3.1 General procedure…………………………………………………………………………………………………………………………………………………..7746
3.2 Identifying a noise…………………………………………………………………………………………………………………………………………………7746
3.2.2 Identifying the type of noise…………………………………………………………………………………………………………………………………..7746
3.2.3 Identifying the point in time when the noise occurs……………………………………………………………………………………………………………….7747
3.2.4 Identifying the noise by definition or designation………………………………………………………………………………………………………………..7747
3.3 Checklist………………………………………………………………………………………………………………………………………………………….7747
4 Examples………………………………………………………………………………………………………………………………………………………………..7751
5 Volkswagen equipment for localising noises………………………………………………………………………………………………………………………………….7753
5.1 Ultrasonic tester -VAG 1842-…………………………………………………………………………………………………………………………………………7753
5.1.2 Procedure for identifying noises using ultrasound…………………………………………………………………………………………………………………7757
5.2 Wireless fault detector -SAT 4500-……………………………………………………………………………………………………………………………………7760
5.2.2 Procedure for identifying noises using the wireless fault detector………………………………………………………………………………………………….7761
5.3 Endoscope -VAS 6748A-……………………………………………………………………………………………………………………………………………….7763
5.3.1 Design of the endoscope -VAS 6748A-……………………………………………………………………………………………………………………………..7763
5.3.2 Procedure for identifying noises using the endoscope………………………………………………………………………………………………………………7766
5.4 Assistance for identifying noises by listening to audio tracks…………………………………………………………………………………………………………..7767
5.4.1 Preparing the audio CD using downloaded files…………………………………………………………………………………………………………………….7767
5.4.2 List of audio tracks…………………………………………………………………………………………………………………………………………..7767
5.4.3 List of volume levels………………………………………………………………………………………………………………………………………….7768
5.4.4 Conditions for performing the audio test…………………………………………………………………………………………………………………………7768
6 Attachments……………………………………………………………………………………………………………………………………………………………..7770
6.1 Checklist………………………………………………………………………………………………………………………………………………………….7770
6.2 Designations for noises……………………………………………………………………………………………………………………………………………..7772
6.2.1 Common noises…………………………………………………………………………………………………………………………………………………7772
6.2.2 Uncommon noises……………………………………………………………………………………………………………………………………………….7776
Sharan2016-Manual_on_Localising_the_Ingress_of_Water………………………………………………………………………………………………………………………………….7780
00 – Technical data……………………………………………………………………………………………………………………………………………………………7784
1 Introduction…………………………………………………………………………………………………………………………………………………………….7784
2 Identifying the type of water ingress………………………………………………………………………………………………………………………………………7785
2.1 External factors……………………………………………………………………………………………………………………………………………………7785
2.2 Vehicle fluids……………………………………………………………………………………………………………………………………………………..7785
3 Causes for the ingress of water……………………………………………………………………………………………………………………………………………7786
4 General procedure for localising the ingress of water………………………………………………………………………………………………………………………..7789
4.1 General procedure…………………………………………………………………………………………………………………………………………………..7789
4.2 Localising the ingress of water………………………………………………………………………………………………………………………………………7789
4.2.2 Circumstances under which the water enters……………………………………………………………………………………………………………………….7790
4.2.3 Type of fluid…………………………………………………………………………………………………………………………………………………7790
4.3 Checklist………………………………………………………………………………………………………………………………………………………….7790
4.3.1 Notes on acquiring data………………………………………………………………………………………………………………………………………..7790
4.3.2 Description of the checklist……………………………………………………………………………………………………………………………………7791
5 Examples………………………………………………………………………………………………………………………………………………………………..7792
6 Volkswagen equipment for localising the ingress of water……………………………………………………………………………………………………………………..7794
6.1 Ultrasonic tester -VAG 1842S-………………………………………………………………………………………………………………………………………..7794
6.1.2 Procedure for localising the ingress of water…………………………………………………………………………………………………………………….7797
6.2 Endoscope -VAS 6748A-……………………………………………………………………………………………………………………………………………….7798
6.2.1 Components of the endoscope -VAS 6748A-………………………………………………………………………………………………………………………….7798
6.2.2 Procedure for identifying the ingress of water using the endoscope………………………………………………………………………………………………….7801
6.3 Cleaning and insertion aid -VAS 6620-…………………………………………………………………………………………………………………………………7801
7 Attachments……………………………………………………………………………………………………………………………………………………………..7802
7.1 Checklist………………………………………………………………………………………………………………………………………………………….7802
Sharan2016-Vehicle-specific_paint_information………………………………………………………………………………………………………………………………………..7804
00 – Technical data……………………………………………………………………………………………………………………………………………………………7808
1 Explanation of symbols……………………………………………………………………………………………………………………………………………………7808
1.1 Sanding……………………………………………………………………………………………………………………………………………………………7808
1.2 Seam seals…………………………………………………………………………………………………………………………………………………………7808
1.3 Cavity sealing……………………………………………………………………………………………………………………………………………………..7810
2 Areas exposed to stone chipping……………………………………………………………………………………………………………………………………………7811
2.1 Areas exposed to stone chipping – overview…………………………………………………………………………………………………………………………….7811
3 Masking areas……………………………………………………………………………………………………………………………………………………………7812
3.1 Masking areas, front body……………………………………………………………………………………………………………………………………………7812
3.2 Masking areas, rear body…………………………………………………………………………………………………………………………………………….7813
4 Seam seals………………………………………………………………………………………………………………………………………………………………7815
4.1 Seam seals, front body………………………………………………………………………………………………………………………………………………7815
4.2 Seam seals, body middle……………………………………………………………………………………………………………………………………………..7818
4.3 Seam seals, rear body……………………………………………………………………………………………………………………………………………….7821
5 Underseal……………………………………………………………………………………………………………………………………………………………….7823
5.1 Underseal, body – overview with differing layer thicknesses……………………………………………………………………………………………………………..7823
5.2 Undersealed areas…………………………………………………………………………………………………………………………………………………..7824
6 Cavity sealing…………………………………………………………………………………………………………………………………………………………..7827
6.1 Cavity sealing, body – overview………………………………………………………………………………………………………………………………………7827
6.2 Cavity sealing, doors……………………………………………………………………………………………………………………………………………….7827
Sharan20111-Propshaft_and_rear_final_drive…………………………………………………………………………………………………………………………………………..7829
00 – Technical data……………………………………………………………………………………………………………………………………………………………7835
1 Identifying rear final drive………………………………………………………………………………………………………………………………………………7835
2 Identification codes, assembly allocation, capacities – Golf 2004 ►……………………………………………………………………………………………………………7836
3 Identification codes, assembly allocation, capacities, Passat 2006 ►…………………………………………………………………………………………………………..7838
3.1 Passat with rear final drive 02D/0AV………………………………………………………………………………………………………………………………….7838
3.2 Passat with rear final drive 01Z……………………………………………………………………………………………………………………………………..7839
3.3 Passat with rear final drive 0BS……………………………………………………………………………………………………………………………………..7839
4 Identification codes, assembly allocation, capacities, Tiguan 2008 ►…………………………………………………………………………………………………………..7841
5 Identification codes, assembly allocation, capacities, Passat CC, CC 2010 ►…………………………………………………………………………………………………….7842
6 Identification codes, assembly allocation, capacities, Golf 2009 ►…………………………………………………………………………………………………………….7843
7 Identification codes, assembly allocation, capacities, Sharan 2011 ►…………………………………………………………………………………………………………..7844
8 General repair notes……………………………………………………………………………………………………………………………………………………..7845
8.1 Oil……………………………………………………………………………………………………………………………………………………………….7845
8.2 Components…………………………………………………………………………………………………………………………………………………………7845
8.2.1 Rear final drive………………………………………………………………………………………………………………………………………………7845
8.2.3 O-ring, seals, gaskets…………………………………………………………………………………………………………………………………………7846
8.2.4 Locking devices……………………………………………………………………………………………………………………………………………….7847
8.2.5 Nuts and bolts………………………………………………………………………………………………………………………………………………..7847
8.2.6 Bearings……………………………………………………………………………………………………………………………………………………..7847
8.2.7 Shims………………………………………………………………………………………………………………………………………………………..7847
9 Genuine parts……………………………………………………………………………………………………………………………………………………………7848
39 – Final drive – rear differential…………………………………………………………………………………………………………………………………………….7849
1 Vehicle diagnosis, testing and information system -VAS 5051-: Connecting and selecting function…………………………………………………………………………………..7849
2 Propshaft – Golf 2004 ► up to calendar week 26/07……………………………………………………………………………………………………………………………7851
2.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7851
2.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7852
2.3 Repairing propshaft…………………………………………………………………………………………………………………………………………………7857
2.4 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………7863
3 Propshaft – Golf 2004 ► from calendar week 27/07 onwards……………………………………………………………………………………………………………………..7867
3.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7867
3.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7868
4 Propshaft – Passat 2006 ► up to calendar week 26/07………………………………………………………………………………………………………………………….7872
4.1 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7872
4.2 Removing and installing front propshaft tube with flexible coupling………………………………………………………………………………………………………7877
4.3 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………7879
4.4 Repairing propshaft…………………………………………………………………………………………………………………………………………………7884
4.5 Specified torques…………………………………………………………………………………………………………………………………………………..7889
5 Propshaft – Passat 2006 ► from calendar week 27/07 onwards……………………………………………………………………………………………………………………7890
5.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7890
5.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7891
6 Propshaft Tiguan 2008 ►…………………………………………………………………………………………………………………………………………………..7895
6.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7895
6.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7896
6.3 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………7900
7 Propshaft – Passat CC, CC 2010 ► and Golf 2009 ►…………………………………………………………………………………………………………………………….7904
7.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7904
7.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7905
7.3 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………7908
8 Propshaft – Sharan 2011 ► ………………………………………………………………………………………………………………………………………………..7913
8.1 Assembly overview – propshaft………………………………………………………………………………………………………………………………………..7913
8.2 Removing and installing propshaft…………………………………………………………………………………………………………………………………….7914
8.3 Removing and installing rear flexible coupling…………………………………………………………………………………………………………………………7917
9 Removing and installing rear final drive, Golf 2004 ►………………………………………………………………………………………………………………………..7921
9.1 Removing rear final drive……………………………………………………………………………………………………………………………………………7921
9.2 Installing rear final drive………………………………………………………………………………………………………………………………………….7923
10 Removing and installing rear final drive, Passat 2006 ►……………………………………………………………………………………………………………………..7924
10.1 Removing rear final drive 02D or 0AV…………………………………………………………………………………………………………………………………7924
10.2 Installing rear final drive 02D or 0AV……………………………………………………………………………………………………………………………….7928
10.3 Removing rear final drive 01Z……………………………………………………………………………………………………………………………………….7930
10.4 Installing rear final drive 01Z……………………………………………………………………………………………………………………………………..7933
11 Removing and installing rear final drive, Tiguan 2008 ►……………………………………………………………………………………………………………………..7936
11.1 Removing………………………………………………………………………………………………………………………………………………………….7936
11.2 Installing………………………………………………………………………………………………………………………………………………………..7942
12 Removing and installing rear final drive, Passat CC, CC 2010 ►……………………………………………………………………………………………………………….7945
12.1 Removing………………………………………………………………………………………………………………………………………………………….7945
12.2 Installing………………………………………………………………………………………………………………………………………………………..7950
13 Removing and installing rear final drive, Golf 2009 ►……………………………………………………………………………………………………………………….7953
13.1 Removing………………………………………………………………………………………………………………………………………………………….7953
13.2 Installing………………………………………………………………………………………………………………………………………………………..7957
14 Removing and installing rear final drive, Sharan 2011 ►……………………………………………………………………………………………………………………..7961
15 Renewing bonded rubber bush on rear final drive…………………………………………………………………………………………………………………………….7964
15.1 Renewing bonded rubber bush on rear final drive, Passat with final drive 01Z, Tiguan, Passat CC, CC 2010 ► and Sharan 201
►…………………………………………………..7964
15.2 Assembly overview – bonded rubber mounting……………………………………………………………………………………………………………………………7964
15.3 Removing bonded rubber mounting……………………………………………………………………………………………………………………………………..7966
15.4 Installing bonded rubber mounting……………………………………………………………………………………………………………………………………7968
15.5 Renewing bonded rubber mountings on rear final drive, Golf 2004 ► and Passat 2006 ► with final drive 02D/0AV and Golf 2009 ►…………………………………………………..7968
15.6 Assembly overview – bonded rubber mounting……………………………………………………………………………………………………………………………7968
15.7 Removing and installing bonded rubber mounting………………………………………………………………………………………………………………………..7970
16 Renewing oil seals for flange shafts………………………………………………………………………………………………………………………………………7974
16.1 Removing flange shaft oil seal………………………………………………………………………………………………………………………………………7974
16.2 Installing flange shaft oil seal…………………………………………………………………………………………………………………………………….7975
17 Renewing propshaft flange oil seal on rear final drive (final drive installed)…………………………………………………………………………………………………7977
17.1 Removing………………………………………………………………………………………………………………………………………………………….7978
17.2 Installing………………………………………………………………………………………………………………………………………………………..7979
17.2.1 Torque setting……………………………………………………………………………………………………………………………………………….7980
18 Checking function of Haldex coupling “Haldex generation II”………………………………………………………………………………………………………………….7981
18.1 Checking function of Haldex coupling – vehicles with manual gearbox……………………………………………………………………………………………………..7981
18.1.1 Checking function of closed Haldex coupling……………………………………………………………………………………………………………………..7981
18.1.2 Checking function of open Haldex coupling……………………………………………………………………………………………………………………….7981
18.2 Checking function of Haldex coupling – vehicles with dual clutch gearbox…………………………………………………………………………………………………7982
18.2.1 Checking function of closed Haldex coupling……………………………………………………………………………………………………………………..7982
18.2.2 Checking function of open Haldex coupling……………………………………………………………………………………………………………………….7983
18.3 Checking function of Haldex coupling – vehicles with automatic gearbox…………………………………………………………………………………………………..7984
18.3.1 Testing operation…………………………………………………………………………………………………………………………………………….7984
19 Checking function of Haldex coupling “generation Haldex IV”………………………………………………………………………………………………………………….7985
19.1 Testing operation………………………………………………………………………………………………………………………………………………….7985
20 Electrical and electronic components and their locations…………………………………………………………………………………………………………………….7986
20.1 Electrical and electronic components and their locations, Golf 2004 ►……………………………………………………………………………………………………7986
20.2 Electrical and electronic components and their locations, Passat 2006 ►………………………………………………………………………………………………….7987
20.3 Electrical and electronic components and their fitting locations, Tiguan, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 20 9 ►………………………………………………….7989
21 Assembly overview – all-wheel drive control unit -J492-, Golf 2004 ► and Passat 2006 ►………………………………………………………………………………………….7991
21.1 Removing and installing all-wheel drive control unit -J492-…………………………………………………………………………………………………………….7992
21.1.1 Removing all-wheel drive control unit -J492-…………………………………………………………………………………………………………………….7992
21.1.2 Installing…………………………………………………………………………………………………………………………………………………..7994
21.2 Removing and installing Haldex coupling pump -V181-……………………………………………………………………………………………………………………7996
21.2.1 Removing…………………………………………………………………………………………………………………………………………………….7996
21.2.2 Installing…………………………………………………………………………………………………………………………………………………..7998
21.2.3 Torque setting……………………………………………………………………………………………………………………………………………….7999
22 Assembly overview – all-wheel drive control unit -J492-, Tiguan, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ►……………………………………………………………….8000
22.1 Removing and installing all-wheel drive control unit -J492-…………………………………………………………………………………………………………….8001
22.1.1 Removing all-wheel drive control unit -J492-…………………………………………………………………………………………………………………….8001
22.1.2 Installing…………………………………………………………………………………………………………………………………………………..8002
22.2 Removing and installing Haldex coupling pump -V181-……………………………………………………………………………………………………………………8004
22.2.1 Removing…………………………………………………………………………………………………………………………………………………….8005
22.2.2 Installing…………………………………………………………………………………………………………………………………………………..8006
22.2.3 Torque setting……………………………………………………………………………………………………………………………………………….8007
23 Assembly overview – Haldex coupling……………………………………………………………………………………………………………………………………….8008
24 Removing and installing Haldex coupling, Golf 2004 ► and Passat 2006 ►………………………………………………………………………………………………………..8009
24.1 Removing Haldex coupling……………………………………………………………………………………………………………………………………………8009
24.2 Installing Haldex coupling………………………………………………………………………………………………………………………………………….8010
25 Removing and installing Haldex coupling – Tiguan, Passat CC, CC 2010 ► and Golf 2009 ►………………………………………………………………………………………….8012
25.1 Removing Haldex coupling……………………………………………………………………………………………………………………………………………8012
25.2 Installing Haldex coupling………………………………………………………………………………………………………………………………………….8015
26 Removing and installing Haldex coupling, Sharan 2011 ►………………………………………………………………………………………………………………………8018
26.1 Removing Haldex coupling……………………………………………………………………………………………………………………………………………8018
26.2 Installing Haldex coupling………………………………………………………………………………………………………………………………………….8021
27 Assembly overview – dismantling and assembling Haldex coupling (generation II), Golf 2004 ► and Passat 2006 ►……………………………………………………………………..8023
27.1 Renewing deep groove ball bearing for Haldex coupling………………………………………………………………………………………………………………….8025
28 Assembly overview – dismantling and assembling Haldex coupling (generation IV) – Tiguan, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ►………………………………………….8030
29 Removing and installing oil filter for Haldex coupling, Golf 2004 ► and Passat 2006 ►…………………………………………………………………………………………..8032
29.1 Removing………………………………………………………………………………………………………………………………………………………….8032
29.2 Installing………………………………………………………………………………………………………………………………………………………..8032
30 Checking oil level or topping up oil in rear final drive, Golf 2004 ► and Passat 2006 ►…………………………………………………………………………………………8034
30.1 Specified torques………………………………………………………………………………………………………………………………………………….8035
31 Checking oil level or topping up oil in rear final drive, Tiguan, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ►………………………………………………………………8036
32 Checking oil level or topping up oil in Haldex coupling (generation II), Golf 2004 ► and Passat 2006 ►……………………………………………………………………………8038
32.1 Checking oil level in Haldex coupling………………………………………………………………………………………………………………………………..8038
32.2 Topping up oil in Haldex coupling……………………………………………………………………………………………………………………………………8039
33 Checking oil level or topping up oil in Haldex coupling (generation IV) – Tiguan, Passat CC, CC 2010 ►, Sharan 2011 ► and Golf 2009 ►………………………………………………..8042
33.1 Checking oil level in Haldex coupling………………………………………………………………………………………………………………………………..8042
33.2 Topping up oil in Haldex coupling……………………………………………………………………………………………………………………………………8043