Volkswagen Touran 2016 Workshop Manuals

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Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

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Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

Language : English
Pages : 6161
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Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

The Volkswagen Touran 2016 Workshop Manual is a comprehensive guide to the maintenance, repair, and service of the Volkswagen Touran. This manual is designed to provide technicians, DIY enthusiasts, and owners of Volkswagen Touran vehicles with the information and guidance they need to keep their vehicles in top condition.
The Volkswagen Touran 2016 Workshop Manual provides detailed instructions and procedures for performing routine maintenance tasks, as well as more complex repair tasks, on the Volkswagen Touran. This manual covers the mechanical components of the vehicle, including the engine, transmission, suspension, brakes, and much more. The manual also includes detailed procedures for performing routine maintenance tasks, such as oil changes, tire rotations, and brake inspections.
The Volkswagen Touran 2016 Workshop Manual includes a wealth of technical information and diagrams that provide a clear understanding of the mechanical components of the Volkswagen Touran. This manual also includes a glossary of technical terms and a reference section that provides information on tools and equipment needed for maintenance and repair tasks.
The Volkswagen Touran 2016 Workshop Manual is an essential resource for anyone working on the maintenance and repair of a Volkswagen Touran. Whether a professional technician or a DIY enthusiast, this manual provides the information and guidance needed to ensure that the mechanical components of the Volkswagen Touran are maintained and repaired correctly, and that mechanical problems are diagnosed and resolved quickly and efficiently.
The Volkswagen Touran 2016 Workshop Manual is a comprehensive guide to the repair and service of the Volkswagen Touran, and is an essential resource for anyone looking to keep their vehicle in top condition.

TABLE OF CONTENTS:

Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

Touran2016-4-cylinder_direct-injection_engine_(1_2 l_engine__4V__EA_211__turbocharger)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 1
00 – Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 7
1 Identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 7
1.1 Engine number, engine data…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 7
2 Safety instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 9
2.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 9
2.2 Safety precautions when working on vehicles with a start/stop system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 9
2.3 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 9
2.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 10
2.5 Safety precautions when working on ignition system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 10
3 Repair instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 11
3.1 Rules for cleanliness…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 11
3.2 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 11
3.3 General repair notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 12
3.4 Foreign objects in engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 12
3.5 Contact corrosion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 12
3.6 Routing and securing lines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 13
3.7 Installing coolers, condensers and radiators…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 13
3.8 Testing vacuum system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 13
10 – Removing and installing engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 14
1 Removing and installing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 14
1.1 Removing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 14
1.2 Separating engine and gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 25
1.3 Securing engine on engine and gearbox support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 27
1.4 Installing engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 28
2 Assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 32
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 32
2.2 Supporting engine in installation position………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 34
2.2.1 Supporting engine in installation position, Golf, Golf Estate, Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 34
2.2.2 Supporting engine in installation position, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 37
2.3 Removing and installing engine mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 41
2.4 Removing and installing gearbox mounting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 41
2.5 Removing and installing pendulum support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 43
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 44
2.7 Adjusting assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 44
13 – Crankshaft group……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 46
1 Cylinder block (pulley end)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 46
1.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 46
1.1.1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 46
1.1.2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 48
1.2 Removing and installing poly V-belt…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 50
1.2.1 Removing and installing poly V-belt, vehicles without air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 50
1.2.2 Removing and installing poly V-belt, vehicles with air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 51
1.3 Removing and installing tensioner for poly V-belt………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 53
1.3.1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 53
1.3.2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 53
1.4 Removing and installing vibration damper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 54
1.5 Removing and installing engine support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 55
1.6 Renewing crankshaft oil seal – belt pulley end…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 58
2 Cylinder block, gearbox end…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 61
2.1 Assembly overview – cylinder block, gearbox end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 61
2.2 Removing and installing flywheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 62
2.3 Removing and installing sealing flange on gearbox side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 63
3 Crankshaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 72
3.1 Crankshaft dimensions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 72
3.2 Measuring axial clearance of crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 72
3.3 Renewing needle bearing in crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 73
4 Pistons and conrods………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 76
4.1 Assembly overview – pistons and conrods…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 76
4.2 Separating new conrod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 78
4.3 Removing and installing pistons………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 78
4.4 Checking pistons and cylinder bores…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 79
4.5 Checking radial clearance of conrods……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 80
4.6 Removing and installing oil spray jets………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 81
15 – Cylinder head, valve gear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 83
1 Cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 83
1.1 Assembly overview – cylinder head………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 83
1.2 Assembly overview – camshaft housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 85
1.3 Removing and installing cylinder head…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 86
1.4 Removing and installing camshaft housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 90
1.5 Checking compression………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 93
2 Toothed belt drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 96
2.1 Assembly overview – toothed belt cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 96
2.2 Assembly overview – toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 97
2.3 Checking valve timing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 98
2.4 Detaching toothed belt from camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 104
2.5 Removing and installing toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 109
3 Valve gear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 116
3.1 Assembly overview – valve gear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 116
3.2 Measuring axial play of camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 118
3.3 Removing and installing camshaft adjuster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 119
3.4 Removing and installing toothed belt pulley……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 122
3.5 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 124
3.5.1 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 124
3.5.2 Removing and installing exhaust camshaft oil seal, pulley end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 126
3.5.3 Removing and installing exhaust camshaft oil seal, gearbox end……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 128
3.6 Removing and installing inlet camshaft control valve 1 -N205-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 130
3.7 Removing and installing valve stem seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 130
3.7.1 Removing and installing valve stem seals (cylinder head installed)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 130
3.7.2 Removing and installing valve stem seals (cylinder head removed)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 135
4 Inlet and exhaust valves……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 139
4.1 Checking valve guides…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 139
4.2 Checking valves………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 139
4.3 Valve dimensions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 140
17 – Lubrication………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 141
1 Sump, oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 141
1.1 Assembly overview – sump and oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 141
1.2 Engine oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 145
1.3 Removing and installing sump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 145
1.4 Removing and installing oil pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 149
1.5 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 152
2 Engine oil cooler………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 153
2.1 Assembly overview – engine oil cooler…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 153
2.2 Removing and installing engine oil cooler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 153
3 Crankcase breather…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 155
3.1 Assembly overview – crankcase breather system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 155
3.2 Removing and installing oil separator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 156
4 Oil filter, oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 158
4.1 Assembly overview – oil filter/oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 158
4.2 Removing and installing oil pressure switch for reduced oil pressure -F378-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 159
4.3 Checking oil pressure and oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 160
4.4 Removing and installing oil filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 161
19 – Cooling……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 163
1 Cooling system, coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 163
1.1 Coolant hose schematic diagram…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 163
1.2 Draining and filling coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 166
1.3 Checking cooling system for leaks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 171
2 Coolant pump, regulation of cooling system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 173
2.1 Assembly overview – coolant pump, thermostat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 173
2.2 Assembly overview – charge air cooling pump -V188-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 175
2.3 Assembly overview – coolant temperature sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 177
2.4 Removing and installing coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 178
2.5 Removing and installing toothed belt pulley for coolant pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 182
2.6 Removing and installing thermostat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 183
2.6.1 Removing and installing thermostat for large cooling circuit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 183
2.6.2 Removing and installing thermostat for small cooling circuit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 185
2.7 Removing and installing charge air cooling pump -V188-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 186
2.8 Removing and installing coolant temperature sender……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 187
2.8.1 Removing and installing coolant temperature sender -G62-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 187
2.8.2 Removing and installing coolant temperature sender at radiator outlet -G83-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 189
3 Coolant pipes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 191
3.1 Assembly overview – coolant pipes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 191
3.2 Removing and installing coolant pipes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 191
4 Radiator and radiator fan…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 195
4.1 Assembly overview – radiator and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 195
4.2 Assembly overview – radiator cowl and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 198
4.3 Removing and installing radiator……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 199
4.3.1 Removing and installing radiator, Golf, Golf Estate, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 199
4.3.2 Removing and installing radiator, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 202
4.4 Removing and installing radiator cowling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 206
4.5 Removing and installing radiator fan -V7-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 208
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 209
1 Turbocharger………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 209
1.1 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 209
1.2 Removing and installing turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 211
1.3 Removing and installing charge pressure positioner -V465-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 215
2 Charge air system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 217
2.1 Assembly overview – charge air system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 217
2.2 Removing and installing air pipe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 219
2.3 Removing and installing charge pressure sender -GX26-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 220
2.4 Removing and installing charge air cooler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 220
2.5 Checking charge air system for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 223
24 – Mixture preparation – injection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 225
1 Injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 225
1.1 Overview of fitting locations – injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 225
1.2 Releasing high pressure in fuel system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 228
2 Air filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 230
2.1 Assembly overview – air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 230
2.2 Removing and installing air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 231
2.3 Removing and installing resonator for intake air…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 232
3 Intake manifold……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 233
3.1 Assembly overview – intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 233
3.2 Removing and installing intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 234
3.3 Removing and installing throttle valve module -GX3-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 237
3.4 Cleaning throttle valve module -GX3-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 238
4 Injectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 240
4.1 Assembly overview – fuel rail with injectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 240
4.2 Removing and installing fuel rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 241
4.3 Removing and installing injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 242
4.3.1 Removing and installing injectors, Bosch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 242
4.3.2 Removing and installing injectors, Continental……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 248
4.4 Cleaning injectors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 252
5 Senders and sensors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 255
5.1 Removing and installing intake manifold sender -GX9-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 255
5.2 Removing and installing fuel pressure sender -G247-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 255
5.3 Checking fuel pressure sender -G247-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 256
6 High-pressure pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 260
6.1 Assembly overview – high-pressure pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 260
6.2 Removing and installing high-pressure pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 262
6.3 Removing and installing high-pressure pipe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 263
7 Lambda probe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 265
7.1 Assembly overview – Lambda probe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 265
7.2 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 266
8 Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 268
8.1 Removing and installing engine control unit -J623-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 268
8.1.1 Removing and installing engine control unit -J623- (with metal locking plate)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 268
8.1.2 Removing and installing engine control unit -J623- (with protective housing)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 270
26 – Exhaust system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 274
1 Exhaust pipes, silencers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 274
1.1 Assembly overview – silencers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 274
1.1.1 Assembly overview – silencers, Golf Saloon, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 274
1.1.2 Assembly overview – silencers, Golf estate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 276
1.1.3 Assembly overview – silencers, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 278
1.2 Separating exhaust pipes, silencers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 281
1.2.1 Separating exhaust pipes, silencers, Golf Saloon, Golf SV……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 281
1.2.2 Separating exhaust pipes/silencers, estate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 282
1.2.3 Separating exhaust pipes/silencers, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 283
1.3 Removing and installing silencer……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 284
1.3.1 Removing and installing front silencer, Golf, Golf Estate, Golf SV……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 284
1.3.2 Removing and installing front silencer, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 285
1.3.3 Removing and installing rear silencer, Golf, Golf Estate, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 286
1.3.4 Removing and installing rear silencer, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 287
1.4 Aligning exhaust system free of stress………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 288
1.5 Checking exhaust system for leaks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 289
2 Emission control…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 290
2.1 Assembly overview – emission control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 290
2.2 Removing and installing catalytic converter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 291
28 – Ignition system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 295
1 Ignition system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 295
1.1 Assembly overview – ignition system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 295
1.2 Test data, spark plugs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 296
1.3 Removing and installing ignition coils with output stage………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 296
1.4 Removing and installing knock sensor 1 -G61-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 298
1.5 Removing and installing Hall sender -G40-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 298
1.6 Removing and installing engine speed sender -G28-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 299
Touran2016-4-cylinder_injection_engine_(1_4_l_direct_injection_engine__turbocharger)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 301
00 – Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 307
1 Identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 307
1.1 Engine number, engine data…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 307
2 Safety instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 309
2.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 309
2.2 Safety precautions when working on vehicles with a Start/Stop system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 309
2.3 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 310
2.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 310
2.5 Safety precautions when working on ignition system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 310
3 Repair instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 311
3.1 Rules for cleanliness…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 311
3.2 Foreign objects in engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 311
3.3 Contact corrosion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 311
3.4 Routing and securing lines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 311
3.5 Installing coolers, condensers and radiators…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 312
10 – Removing and installing engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 313
1 Removing and installing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 313
1.1 Removing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 313
1.2 Separating engine and gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 324
1.3 Securing engine on engine and gearbox support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 325
1.4 Installing engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 327
2 Assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 330
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 330
2.2 Supporting engine in installation position………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 331
2.3 Removing and installing engine mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 334
2.4 Removing and installing gearbox mounting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 335
2.5 Removing and installing pendulum support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 337
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 338
2.7 Adjusting assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 338
13 – Crankshaft group……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 340
1 Cylinder block (pulley end)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 340
1.1 Assembly overview – poly V-belt drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 340
1.1.1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 340
1.1.2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 342
1.2 Assembly overview – sealing flange, belt pulley end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 344
1.3 Removing and installing poly V-belt…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 345
1.3.1 Removing and installing poly V-belt, vehicles without air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 345
1.3.2 Removing and installing poly V-belt, vehicles with air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 346
1.4 Removing and installing tensioner for poly V-belt………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 348
1.4.1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 348
1.4.2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 348
1.5 Removing and installing vibration damper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 349
1.6 Removing and installing engine support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 350
1.7 Renewing crankshaft oil seal – belt pulley end…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 353
1.8 Removing and installing sealing flange on pulley end……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 355
2 Cylinder block, gearbox end…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 358
2.1 Assembly overview – cylinder block, gearbox end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 358
2.2 Removing and installing flywheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 359
2.3 Removing and installing sealing flange on gearbox side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 360
3 Crankshaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 370
3.1 Renewing needle bearing in crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 370
3.2 Crankshaft dimensions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 371
3.3 Measuring axial clearance of crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 371
4 Pistons and conrods………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 373
4.1 Assembly overview – pistons and conrods…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 373
4.2 Removing and installing pistons………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 375
4.3 Removing and installing oil spray jets………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 376
4.4 Checking pistons and cylinder bores…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 377
4.5 Checking radial clearance of conrods……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 378
15 – Cylinder head, valve gear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 380
1 Toothed belt drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 380
1.1 Assembly overview – toothed belt cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 380
1.2 Assembly overview – toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 381
1.2.1 Assembly overview – toothed belt, engine codes CPTA, CHPA, CZEA, CZDA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 381
1.2.2 Assembly overview – toothed belt, engine codes CMBA, CPVA, CXSA, CZCA, CPVB……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 383
1.3 Checking valve timing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 384
1.3.1 Checking valve timing, engine codes CPTA, CZEA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 384
1.3.2 Checking valve timing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 390
1.4 Removing toothed belt from camshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 395
1.4.1 Removing toothed belt from camshafts, engine codes CPTA, CZEA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 395
1.4.2 Removing toothed belt from camshafts, engine code CHPA, CZDA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 407
1.4.3 Removing toothed belt from camshafts, engine codes CMBA, CPVA, CXSA, CZCA, CPVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 418
1.5 Removing and installing toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 429
1.5.1 Removing and installing toothed belt, engine codes CPTA, CZEA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 429
1.5.2 Removing and installing toothed belt, engine codes CHPA, CZDA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 442
1.5.3 Removing and installing toothed belt, engine codes CMBA, CPVA, CXSA, CZCA, CPVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 455
2 Cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 468
2.1 Assembly overview – cylinder head………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 468
2.2 Assembly overview – camshaft housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 470
2.2.1 Assembly overview – camshaft housing, engine codes CPTA, CZEA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 470
2.2.2 Assembly overview – camshaft housing, engine codes CHPA, CMBA, CPVA, CXSA, CZCA, CPVB, CZDA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 472
2.3 Removing and installing cylinder head…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 475
2.4 Removing and installing camshaft housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 480
2.5 Checking compression………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 484
3 Valve gear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 487
3.1 Assembly overview – valve gear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 487
3.1.1 Assembly overview – valves……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 487
3.2 Removing and installing camshaft control valve 1 -N205- and exhaust camshaft control valve 1 -N318-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 489
3.3 Removing and installing exhaust cam actuator for cylinder 2 -N587-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 489
3.4 Removing and installing exhaust cam actuator for cylinder 3 -N595-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 490
3.5 Removing and installing inlet cam actuator for cylinder 2 -N583-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 492
3.6 Removing and installing inlet cam actuator for cylinder 3 -N591-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 493
3.7 Removing and installing camshaft adjuster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 493
3.8 Measuring axial play of camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 495
3.9 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 496
3.9.1 Removing and installing inlet camshaft oil seal, pulley end, engine codes CPTA, CHPA, CZEA, CZDA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 496
3.9.2 Removing and installing inlet camshaft oil seal, pulley end, engine codes CMBA, CPVA, CXSA, CZCA, CPVB……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 498
3.9.3 Removing and installing exhaust camshaft oil seal, pulley end, engine codes CPTA, CHPA, CZEA, CZDA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 499
3.9.4 Removing and installing exhaust camshaft oil seal, pulley end, engine codes CMBA, CPVA, CXSA, CZCA, CPVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 501
3.9.5 Removing and installing exhaust camshaft oil seal, gearbox end, engine codes CPTA, CZEA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 503
3.9.6 Removing and installing exhaust camshaft oil seal, gearbox end, engine codes CHPA, CMBA, CPVA, CXSA, CZDA, CZCA, CPVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 505
3.10 Removing and installing valve stem seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 507
3.10.1 Removing and installing valve stem seals (cylinder head installed)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 507
3.10.2 Removing and installing valve stem seals (cylinder head removed)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 512
4 Inlet and exhaust valves……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 516
4.1 Checking valve guides…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 516
4.2 Checking valves………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 516
4.3 Valve dimensions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 517
17 – Lubrication………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 518
1 Sump, oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 518
1.1 Assembly overview – sump and oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 518
1.2 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 521
1.3 Removing and installing lower part of sump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 521
1.4 Removing and installing oil pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 523
1.5 Removing and installing upper part of sump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 524
1.6 Engine oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 527
2 Engine oil cooler………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 528
2.1 Assembly overview – engine oil cooler…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 528
2.2 Removing and installing engine oil cooler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 528
3 Crankcase breather…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 530
3.1 Assembly overview – crankcase breather system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 530
3.2 Removing and installing oil separator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 531
4 Oil filter, oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 533
4.1 Assembly overview – oil filter/oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 533
4.2 Removing and installing oil pressure switch -F1-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 534
4.3 Removing and installing oil pressure switch for reduced oil pressure -F378-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 535
4.4 Removing and installing oil pressure regulating valve -N428-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 536
4.5 Checking oil pressure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 537
19 – Cooling……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 540
1 Cooling system, coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 540
1.1 Coolant hose schematic diagram…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 540
1.2 Assembly overview – engine preheater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 542
1.2.1 Removing and installing engine preheater heater element -Z97-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 543
1.3 Draining and filling coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 544
1.4 Checking cooling system for leaks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 550
2 Coolant pump, regulation of cooling system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 552
2.1 Assembly overview – coolant pump, thermostat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 552
2.2 Assembly overview – electric coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 554
2.3 Assembly overview – coolant temperature sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 556
2.4 Removing and installing coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 557
2.5 Removing and installing toothed belt pulley for coolant pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 561
2.5.1 Removing and installing toothed belt pulley for coolant pump, engine codes CPTA, CZEA…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 561
2.5.2 Removing and installing toothed belt pulley for coolant pump, engine codes CHPA, CMBA, CPVA, CXSA, CZDA, CZCA, CPVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 564
2.6 Removing and installing thermostat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 565
2.6.1 Removing and installing thermostat for large cooling circuit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 565
2.6.2 Removing and installing thermostat for small cooling circuit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 567
2.7 Removing and installing electric coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 568
2.7.1 Removing and installing charge air cooling pump -V188-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 568
2.8 Removing and installing coolant temperature sender -G62-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 570
2.9 Removing and installing coolant temperature sender at radiator outlet -G83-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 571
3 Coolant pipes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 573
3.1 Assembly overview – coolant pipes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 573
3.2 Removing and installing coolant pipes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 573
4 Radiator and radiator fan…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 577
4.1 Assembly overview – radiator and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 577
4.2 Assembly overview – radiator cowl and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 579
4.3 Removing and installing radiator……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 579
4.3.1 Removing and installing radiator, Golf, Golf SV, Golf Estate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 579
4.3.2 Removing and installing radiator, Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 582
4.4 Removing and installing radiator cowling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 585
4.5 Removing and installing radiator fan -V7-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 586
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 587
1 Turbocharger………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 587
1.1 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 587
1.2 Removing and installing turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 589
1.3 Removing and installing charge pressure positioner -V465-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 594
2 Charge air system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 595
2.1 Assembly overview – charge air system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 595
2.2 Removing and installing charge pressure sender -GX26-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 597
2.3 Removing and installing charge air cooler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 597
2.4 Checking charge air system for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 600
24 – Mixture preparation – injection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 602
1 Injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 602
1.1 Overview of fitting locations – injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 602
1.2 Releasing high pressure in fuel system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 605
2 Air filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 607
2.1 Assembly overview – air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 607
2.2 Removing and installing air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 608
3 Intake manifold……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 609
3.1 Assembly overview – intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 609
3.2 Removing and installing intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 611
3.3 Removing and installing throttle valve module -GX3-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 613
3.4 Cleaning throttle valve module -GX3-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 615
4 Injectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 616
4.1 Assembly overview – fuel rail with injectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 616
4.2 Removing and installing fuel rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 617
4.3 Removing and installing injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 617
4.4 Cleaning injectors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 622
5 Senders and sensors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 624
5.1 Removing and installing intake manifold sender -GX9-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 624
5.2 Removing and installing fuel pressure sender -G247-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 624
5.3 Checking fuel pressure sender -G247-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 625
6 High-pressure pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 628
6.1 Assembly overview – high-pressure pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 628
6.2 Removing and installing high-pressure pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 629
6.3 Removing and installing high-pressure pipe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 630
7 Lambda probe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 632
7.1 Assembly overview – Lambda probe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 632
7.2 Removing and installing lambda probe 1 before catalytic converter -GX10-/lambda probe 1 after catalytic converter -GX7-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 633
8 Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 635
8.1 Removing and installing engine control unit -J623-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 635
8.1.1 Removing and installing engine control unit -J623- (with metal locking plate)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 635
8.1.2 Removing and installing engine control unit -J623- (with protective housing)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 637
26 – Exhaust system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 640
1 Exhaust pipes, silencers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 640
1.1 Assembly overview – silencers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 640
1.1.1 Golf, Golf estate, Sportsvan, (vehicles with torsion beam axle)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 640
1.1.2 Golf, Golf estate, Sportsvan, (vehicles with multi-link suspension)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 642
1.1.3 Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 643
1.1.4 Passat, all-wheel drive; Passat Estate, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 645
1.1.5 Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 646
1.2 Removing and installing silencer……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 647
1.2.1 Golf, Golf estate, Sportsvan, (vehicles with torsion beam axle)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 647
1.2.2 Golf, Golf estate, Sportsvan, (vehicles with multi-link suspension)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 648
1.2.3 Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 649
1.2.4 Passat, all-wheel drive; Passat Estate, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 650
1.2.5 Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 651
1.3 Separating exhaust pipes, silencers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 652
1.3.1 Golf, Golf estate, Sportsvan, (vehicles with torsion beam axle)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 652
1.3.2 Golf, Golf estate, Sportsvan, (vehicles with multi-link suspension)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 653
1.3.3 Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 654
1.3.4 Passat, all-wheel drive; Passat Estate, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 655
1.3.5 Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 657
1.4 Aligning exhaust system free of tension…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 657
1.5 Checking exhaust system for leaks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 658
2 Emission control…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 659
2.1 Assembly overview – emission control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 659
2.2 Removing and installing catalytic converter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 660
28 – Ignition system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 665
1 Ignition system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 665
1.1 Assembly overview – ignition system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 665
1.2 Test data, spark plugs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 666
1.3 Removing and installing ignition coils with output stage………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 666
1.4 Removing and installing knock sensor 1 -G61-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 668
1.5 Removing and installing Hall sender -G40-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 669
1.6 Removing and installing Hall sender 3 -G300-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 670
1.7 Removing and installing engine speed sender -G28-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 670
Touran2016-4-cylinder_injection_engine_(1_6_l_and_2_0_l__4V__direct_injection_engine__turbocharger)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 672
00 – Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 680
1 Safety instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 680
1.1 Safety precautions when working on fuel supply system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 680
1.2 Safety precautions when working on vehicles with a start/stop system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 681
1.3 Safety precautions during road tests in which test and measuring equipment is used…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 681
1.4 Safety precautions when working on cooling system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 681
1.5 Safety precautions when working on the SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 681
2 Identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 683
2.1 Engine number, engine data…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 683
3 Repair instructions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 688
3.1 Rules for cleanliness…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 688
3.2 Foreign objects in engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 688
3.3 Contact corrosion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 688
3.4 Routing and securing lines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 689
3.5 Installing coolers, condensers and radiators…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 689
3.6 Adapting learnt value for SCR system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 689
10 – Removing and installing engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 690
1 Removing and installing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 690
1.1 Removing engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 690
1.2 Separating engine and gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 701
1.2.1 Separating engine and gearbox, vehicles with manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 701
1.2.2 Separating engine and gearbox, vehicles with dual clutch gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 703
1.3 Securing engine on engine and gearbox support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 705
1.4 Installing engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 706
2 Assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 711
2.1 Assembly overview – assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 711
2.2 Supporting engine in installation position………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 712
2.2.1 Supporting engine in installation position, Golf, Golf Estate………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 712
2.2.2 Supporting engine in installation position, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 714
2.2.3 Supporting engine in installation position, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 716
2.3 Removing and installing engine mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 721
2.4 Removing and installing gearbox mounting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 722
2.5 Removing and installing pendulum support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 724
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 726
2.7 Adjusting assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 726
3 Engine cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 728
3.1 Removing and installing engine cover panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 728
13 – Crankshaft group……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 729
1 Cylinder block (pulley end)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 729
1.1 Assembly overview – cylinder block (pulley end)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 729
1.2 Removing and installing poly V-belt…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 731
1.3 Removing and installing tensioning device for poly V-belt…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 732
1.4 Removing and installing vibration damper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 732
1.5 Removing and installing engine support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 732
1.6 Removing and installing ancillary bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 733
1.7 Assembly overview – Sealing flange, belt pulley end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 735
1.8 Removing and installing sealing flange on pulley end……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 736
2 Cylinder block, gearbox end…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 739
2.1 Assembly overview – cylinder block, gearbox end………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 739
2.2 Removing and installing flywheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 740
2.3 Removing and installing sealing flange on gearbox side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 741
3 Crankshaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 750
3.1 Assembly overview – crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 750
3.2 Crankshaft dimensions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 751
3.3 Measuring axial clearance of crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 751
3.4 Renewing needle bearing in crankshaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 752
4 Pistons and conrods………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 755
4.1 Assembly overview – pistons and conrods…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 755
4.2 Removing and installing pistons………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 757
4.3 Measuring piston projection at TDC……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 759
4.4 Checking piston and cylinder bore………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 760
4.5 Checking radial clearance of conrods……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 761
15 – Cylinder head, valve gear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 763
1 Cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 763
1.1 Assembly overview – cylinder head………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 763
1.2 Assembly overview – cylinder head cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 765
1.3 Removing and installing cylinder head…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 767
1.4 Removing and installing cylinder head cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 775
1.5 Removing and installing injector seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 776
1.6 Removing and installing camshaft housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 777
1.7 Checking compression………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 782
2 Toothed belt drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 784
2.1 Exploded view – toothed belt cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 784
2.2 Assembly overview – toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 785
2.3 Removing and installing toothed belt guard………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 786
2.3.1 Removing and installing upper toothed belt guard……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 786
2.3.2 Removing and installing upper toothed belt guard, vehicles with SCR system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 788
2.3.3 Removing and installing lower toothed belt guard……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 790
2.4 Removing and installing toothed belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 792
2.5 Detaching toothed belt from camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 802
3 Valve gear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 807
3.1 Assembly overview – valve gear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 807
3.2 Measuring axial play of camshaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 810
3.3 Removing and installing camshaft oil seal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 811
3.4 Removing and installing camshaft adjuster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 813
3.5 Removing and installing inlet camshaft control valve 1 -N205-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 816
3.6 Checking hydraulic compensation elements………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 816
3.7 Removing and installing valve stem seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 817
3.7.1 Removing and installing valve stem oil seals (cylinder head installed)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 817
3.7.2 Removing and installing valve stem oil seals (cylinder head removed)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 820
3.8 Removing and installing control valve for the camshaft adjuster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 824
4 Inlet and exhaust valves……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 827
4.1 Checking valve guides…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 827
4.2 Checking valves………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 828
4.3 Valve dimensions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 828
17 – Lubrication………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 829
1 Sump, oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 829
1.1 Assembly overview – sump / oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 829
1.2 Engine oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 831
1.3 Removing and installing sump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 831
1.4 Removing and installing oil pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 835
1.5 Removing and installing oil level and oil temperature sender -G266-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 835
2 Engine oil cooler………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 837
3 Oil filter, oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 838
3.1 Assembly overview – oil filter housing, oil pressure switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 838
3.2 Removing and installing oil pressure switch -F1-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 839
3.3 Removing and installing oil pressure switch for reduced oil pressure -F378-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 840
3.4 Checking oil pressure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 840
3.5 Removing and installing oil filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 841
3.6 Removing and installing oil pressure regulating valve -N428-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 843
19 – Cooling……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 845
1 Cooling system, coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 845
1.1 Coolant hose schematic diagram…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 845
1.1.1 Coolant hose schematic diagram……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 845
1.1.2 Coolant hose schematic diagram, vehicles with gear oil cooler and auxiliary heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 847
1.1.3 Coolant hose schematic diagram, vehicles with exhaust gas recirculation control motor -V338-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 849
1.1.4 Coolant hose schematic diagram, vehicles with exhaust gas recirculation control motor -V338-, gear oil cooler and auxiliary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 851
1.1.5 Coolant hose schematic diagram, vehicles with SCR system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 853
1.2 Checking cooling system for leaks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 854
1.3 Draining and filling coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 856
2 Coolant pump, regulation of cooling system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 863
2.1 Assembly overview – coolant pump, thermostat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 863
2.2 Assembly overview – electric coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 865
2.2.1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 865
2.2.2 Assembly overview – charge air cooling pump -V188-, version 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 866
2.2.3 Assembly overview – auxiliary pump for heating -V488-, version 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 867
2.2.4 Assembly overview – charge air cooling pump -V188-, version 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 868
2.2.5 Assembly overview – auxiliary pump for heating -V488-, version 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 869
2.3 Assembly overview – coolant temperature sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 870
2.4 Removing and installing electric coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 870
2.4.1 Removing and installing charge air cooling pump -V188-, version 1 and 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 870
2.4.2 Removing and installing auxiliary pump for heating -V488-, version 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 872
2.4.3 Removing and installing charge air cooling pump -V188-, version 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 873
2.4.4 Removing and installing auxiliary pump for heating -V488-, version 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 876
2.4.5 Removing and installing auxiliary pump for heating -V488-, version 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 879
2.5 Removing and installing coolant pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 882
2.6 Removing and installing thermostat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 883
2.7 Checking thermostat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 884
2.8 Removing and installing coolant valve for cylinder head -N489-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 884
2.9 Removing and installing coolant temperature sender -G62-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 884
3 Coolant pipes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 887
3.1 Assembly overview – coolant pipes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 887
3.2 Removing and installing coolant pipes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 888
3.2.1 Removing and installing coolant pipes (top front)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 888
3.2.2 Removing and installing lower front coolant pipe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 889
3.2.3 Removing and installing coolant pipe (front left)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 891
3.2.4 Removing and installing front right coolant pipe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 893
3.2.5 Removing and installing left coolant pipes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 894
3.2.6 Removing and installing rear coolant pipe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 895
3.2.7 Removing and installing rear coolant pipe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 897
4 Radiator, radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 900
4.1 Assembly overview – radiator and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 900
4.1.1 Assembly overview – radiator, radiator fan, version 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 900
4.1.2 Assembly overview – radiator, radiator fan, version 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 902
4.1.3 Assembly overview – radiator, radiator fan, version 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 903
4.1.4 Plug-in connectors of coolant hoses……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 904
4.2 Assembly overview – radiator cowl and radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 905
4.2.1 Assembly overview – radiator cowl with one radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 905
4.2.2 Assembly overview – radiator cowl with two radiator fans…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 906
4.3 Assembly overview – radiator blind……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 907
4.3.1 Assembly overview – radiator blind………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 907
4.3.2 Assembly overview – components of radiator blind……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 908
4.4 Removing and installing radiator……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 909
4.4.1 Removing and installing radiator, variant 3 radiator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 909
4.4.2 Removing and installing radiator, variant 1 and 2 radiators………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 912
4.5 Removing and installing water radiator for charge air cooling circuit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 914
4.5.1 Removing and installing water radiator for charge air cooling circuit, versions 1 and 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 914
4.5.2 Removing and installing water radiator for charge air cooling circuit, version 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 917
4.6 Removing and installing radiator cowling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 917
4.7 Removing and installing radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 918
4.7.1 Removing and installing radiator fan -V7-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 918
4.7.2 Removing and installing radiator fan 2 -V177-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 919
4.7.3 Removing and installing radiator fan -V7-, vehicles with one radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 919
4.8 Removing and installing radiator blind………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 920
4.9 Removing and installing radiator blind control motor -V544-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 922
21 – Turbocharging/supercharging………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 926
1 Turbocharger………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 926
1.1 Assembly overview – turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 926
1.2 Removing and installing turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 928
1.2.1 Removing and installing turbocharger………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 928
1.2.2 Removing and installing turbocharger, engine code CRVA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 934
1.3 Renewing vacuum unit for turbocharger…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 938
1.3.1 Renewing vacuum unit for turbocharger, versions 1 and 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 938
1.3.2 Renewing vacuum unit for turbocharger, version 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 942
1.4 Removing and installing connecting piece………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 943
2 Charge air system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 945
2.1 Assembly overview – charge air system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 945
2.2 Removing and installing charge pressure sender -G31-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 947
2.3 Checking charge air system for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 947
23 – Mixture preparation – injection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 950
1 Injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 950
1.1 Schematic overview – fuel system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 950
1.1.1 Schematic overview – fuel system, version 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 950
1.1.2 Schematic overview – fuel system, version 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 952
1.2 Overview of fittings – injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 953
1.2.1 Overview of fitting locations – engine compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 953
1.2.2 Overview of fitting locations – front view of engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 955
1.2.3 Overview of fitting locations – rear view of engine, vehicles without SCR system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 957
1.2.4 Overview of fitting locations – rear view of engine, vehicles with SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 958
1.2.5 Overview of fitting locations – electrical connectors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 959
1.3 Filling, bleeding fuel system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 960
1.4 Checking fuel system for leaks…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 960
2 Vacuum system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 962
2.1 Schematic diagram – vacuum system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 962
2.2 Testing vacuum system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 962
3 Injectors and fuel rail…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 964
3.1 Assembly overview – injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 964
3.2 Assembly overview – fuel rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 966
3.3 Adapting correction values for injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 967
3.4 Testing injectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 967
3.5 Checking return flow rate of injectors with engine running………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 968
3.6 Checking return flow rate of injectors at starter speed…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 971
3.7 Testing jammed-open injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 973
3.8 Removing and installing injectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 975
3.9 Removing and installing high-pressure lines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 980
3.9.1 Removing high-pressure line between high-pressure reservoir (rail) and high-pressure pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 980
3.9.2 Installing high-pressure line…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 980
3.10 Removing and installing fuel rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 982
4 Air filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 986
4.1 Assembly overview – air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 986
4.2 Removing and installing air filter housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 987
5 Intake manifold……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 989
5.1 Assembly overview – intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 989
5.2 Removing and installing intake manifold…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………. 991
5.3 Removing and installing throttle valve module -J338-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 994
6 Senders and sensors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 997
6.1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Golf GTD…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 997
6.2 Removing and installing fuel pressure regulating valve -N276-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 999
6.2.1 Versions of fuel pressure regulating valve -N276-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 999
6.2.2 Removing and installing fuel pressure regulating valve, version 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….. 999
6.2.3 Removing and installing fuel pressure regulating valve -N276-, version 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1002
6.3 Checking fuel pressure regulating valve -N276-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1004
6.4 Removing and installing fuel pressure sender -G247-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1005
6.5 Removing and installing air mass meter -G70-/intake air temperature sender -G42-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1007
6.6 Removing and installing pressure differential sender -G505-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1008
6.7 Removing and installing charge air temperature sender before charge air cooler -G810-/charge air temperature sender after charge air cooler -G811-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1009
6.8 Removing and installing fuel temperature sender -G81-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1010
6.9 Removing and installing exhaust gas pressure sensor 1 -G450-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1011
7 Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1013
7.1 Removing and installing engine control unit -J623-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1013
7.2 Removing and installing engine control unit -J623- (with protective housing)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1014
7.2.1 Removing and installing engine control unit -J623- (with metal locking plate)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1014
7.2.2 Removing and installing engine control unit -J623- (with protective housing)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1017
8 High-pressure pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1019
8.1 Assembly overview – high-pressure pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1019
8.2 Removing and installing high-pressure pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1020
9 Lambda probe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1023
9.1 Assembly overview – Lambda probe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1023
9.1.1 Assembly overview – Lambda probe; vehicles without SCR system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1023
9.1.2 Assembly overview – Lambda probe; vehicles with SCR system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1024
9.2 Removing and installing Lambda probe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1025
9.2.1 Removing and installing Lambda probe 1 before catalytic converter -GX10-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1025
9.2.2 Removing and installing Lambda probe after catalytic converter -G130-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1026
9.3 Removing and installing NOx sender -G295- with control unit for NOx sender -J583-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1028
26 – Exhaust system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1032
1 Exhaust pipes, silencers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1032
1.1 Assembly overview – silencers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1032
1.1.1 Assembly overview – silencers, vehicles with front-wheel drive, Golf, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1032
1.1.2 Assembly overview – silencers, vehicles with four-wheel drive, Golf……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1035
1.1.3 Assembly overview – silencers, vehicles with Active Sound, Golf GTD……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1037
1.1.4 Assembly overview – silencers, vehicles with multi-link suspension, Golf Estate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1038
1.1.5 Assembly overview – silencers, vehicles with torsion beam rear suspension, Golf Estate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1040
1.1.6 Assembly overview – front exhaust pipe, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1041
1.1.7 Assembly overview – silencer, Touran with engine codes CRKB, DFEA and CRMB……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1043
1.1.8 Assembly overview – silencer, Touran with engine code CRVA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1044
1.2 Removing and installing front exhaust pipe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1046
1.3 Separating exhaust pipes, silencers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1047
1.3.1 Separating exhaust pipes/silencers, Golf……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1047
1.3.2 Separating exhaust pipes/silencers, Golf Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1048
1.3.3 Separating exhaust pipes/silencers, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1049
1.4 Removing and installing rear silencer……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1050
1.4.1 Removing and installing rear silencer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1050
1.5 Aligning exhaust system free of tension………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1051
1.6 Checking exhaust system for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1052
1.7 Removing and installing exhaust flap control unit -J883-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1052
1.8 Removing and installing silencer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1053
1.8.1 Removing and installing silencer, Touran with engine code CRKB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1053
1.8.2 Removing and installing silencer, Touran with engine code CRVA………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1054
1.8.3 Removing and installing silencer, Touran with engine code DFEA und CRMB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1055
1.9 Aligning tailpipes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1056
2 Emission control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1057
2.1 Assembly overview – emission control…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1057
2.1.1 Assembly overview – emission control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1057
2.1.2 Assembly overview – emission control, engine code CRVA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1059
2.2 Removing and installing catalytic converter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1060
2.3 Removing and installing particulate filter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1061
2.4 Removing and installing emission control module…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1062
3 SCR system (selective catalytic reduction)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1070
3.1 Assembly overview – tank for reducing agent………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1070
3.1.1 Assembly overview – tank for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1070
3.1.2 Assembly overview – tank for reducing agent from above……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1072
3.2 Assembly overview – reducing agent delivery line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1073
3.3 Assembly overview – delivery module for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1074
3.4 Removing and installing tank for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1074
3.5 Removing and installing reducing agent supply line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1077
3.5.1 Removing and installing front section of reducing agent supply line……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1077
3.5.2 Removing and installing rear section of reduction agent supply line……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1079
3.6 Removing and installing delivery module for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1080
3.7 Removing and installing injector for reducing agent -N474-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1082
3.8 Removing and installing control unit for reducing-agent heater -J891-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1084
3.9 Assembly overview – injector for reducing agent -N474-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1084
3.10 Emptying tank for reducing agent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1085
3.11 Removing and installing filler pipe for tank for reducing agent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1088
3.12 Disconnecting reducing agent supply line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1090
4 Exhaust gas temperature regulation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1092
4.1 Assembly overview – exhaust gas temperature regulation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1092
4.1.1 Assembly overview – exhaust gas temperature regulation, vehicles without SCR system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1092
4.1.2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1094
4.2 Removing and installing exhaust gas temperature sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1095
4.2.1 Removing and installing exhaust gas temperature sender 1 -G235-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1095
4.2.2 Removing and installing exhaust gas temperature sender 2 -G448-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1097
4.2.3 Removing and installing exhaust gas temperature sender 3 -G495-/exhaust gas temperature sender 4 -G648-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1098
4.2.4 Removing and installing exhaust gas temperature sender 2 -G448-, vehicles with SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1100
4.2.5 Removing and installing exhaust gas temperature sender 3 -G495-, vehicles with SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1103
4.2.6 Removing and installing exhaust gas temperature sender 4 -G648-, vehicles with SCR system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1105
5 Exhaust gas recirculation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1108
5.1 Assembly overview – exhaust gas recirculation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1108
5.1.1 Assembly overview – exhaust gas recirculation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1108
5.1.2 Assembly overview – exhaust gas recirculation, engine code CRVA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1110
5.2 Assembly overview – exhaust gas recirculation control motor -V338-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1112
5.3 Removing and installing exhaust gas recirculation cooler…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1113
5.3.1 Removing and installing exhaust gas recirculation cooler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1113
5.3.2 Removing and installing exhaust gas recirculation cooler, engine code CRVA……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1116
5.4 Checking exhaust gas recirculation cooler for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1118
5.5 Removing and installing exhaust gas recirculation control motor -V338-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1121
5.6 Removing and installing exhaust gas recirculation control motor 2 -V339-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1122
28 – Glow plug system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1124
1 Glow plug system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1124
1.1 Assembly overview – glow plug system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1124
1.2 Removing and installing glow plug……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1125
1.3 Removing and installing automatic glow period control unit -J179-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1127
1.4 Removing and installing Hall sender -G40-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1128
1.5 Removing and installing engine speed sender -G28-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1128
Touran2016-6-speed_dual_clutch_gearbox_0D9……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1130
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1134
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1134
1.1 General safety regulations……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1134
1.2 Safety precautions when working on vehicles with a Start/Stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1135
1.3 Notes on tow-starting/towing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1135
1.4 Safety precautions when using test and measuring equipment during a road test………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1135
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1137
2.1 Gearbox identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1137
2.1.1 Gearbox identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1137
2.1.2 Reading gearbox code letters………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1137
3 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1139
3.1 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1139
3.1.1 General notes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1139
3.2 Gaskets and seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1140
3.3 Nuts and bolts………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1140
4 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1141
4.1 Allocation gearbox – engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1141
4.1.1 Golf 2013 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1141
4.1.2 Golf Variant 2014 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1141
4.1.3 Golf SV 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1141
4.1.4 Passat 2015 ►, Passat Estate 2015 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1142
4.1.5 Touran 2016 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1142
4.2 Capacities……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1142
4.2.1 Capacities – dual clutch gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1142
4.2.2 Capacities – front differential lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1142
4.2.3 Bevel box……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1143
5 Electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1144
5.1 Overview of fitting locations – electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1144
5.1.1 Overview of fitting locations – gearbox control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1144
5.1.2 Overview of fitting locations – electrical components, front differential lock with Haldex coupling……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1145
30 – Clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1146
1 Clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1146
1.1 Assembly overview – dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1146
1.2 Removing and installing clutch end cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1148
1.3 Removing dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1152
1.4 Installing dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1153
34 – Controls, housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1159
1 Mechatronic unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1159
1.1 Assembly overview – mechatronic unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1159
1.2 Removing and installing sump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1161
1.3 Removing and installing mechatronic unit for dual clutch gearbox -J743-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1166
1.3.1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1166
1.3.2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1177
2 Bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1185
2.1 Assembly overview – bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1185
2.2 Removing bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1186
2.3 Installing bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1191
3 Selector mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1195
3.1 Assembly overview – selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1195
3.1.1 Assembly overview – selector mechanism, manufacturer ZF………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1195
3.1.2 Assembly overview – selector mechanism, manufacturer ECS……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1197
3.2 Emergency release from position P……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1198
3.2.1 Emergency release from P position, manufacturer ZF…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1198
3.2.2 Emergency release from P position, manufacturer ECS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1199
3.3 Removing and installing selector lever handle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1200
3.4 Moving pushbutton to installation position in the handle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1203
3.5 Removing and installing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1205
3.5.1 Removing and installing selector mechanism with selector lever cable…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1205
3.5.2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1207
3.5.3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1210
3.6 Removing and installing selector lever cable……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1212
3.6.1 Removing and installing selector lever cable, manufacturer ZF…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1212
3.6.2 Removing and installing selector lever cable, manufacturer ECS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1214
3.7 Checking selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1216
3.8 Checking and adjusting selector lever cable………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1217
3.9 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1219
4 Removing and installing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1222
4.1 Removing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1222
4.1.1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1222
4.1.2 Removing gearbox, Golf SV 2015 ►, vehicles with diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1229
4.1.3 Removing gearbox, Golf 2013 ►, vehicles with petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1236
4.1.4 Removing gearbox, Golf Estate 2014 ►, vehicles with diesel engine, all-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1246
4.1.5 Removing gearbox, Golf Estate 2014 ►, vehicles with petro engine, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1256
4.1.6 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with diesel engine, front-wheel drive, radiator version “1” or “3”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1266
4.1.7 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with diesel engine, front-wheel drive, radiator version “2”………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1275
4.1.8 Removing gearbox, Passat 2015 ►, vehicles with diesel engine, all-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1286
4.1.9 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with petrol engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1297
4.1.10 Removing gearbox, Passat 2015 ►, vehicles with petrol engine, all-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1306
4.1.11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1316
4.2 Installing gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1324
4.3 Specified torques for gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1328
5 Assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1330
5.1 Assembly overview – assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1330
6 Transporting gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1333
6.1 Transporting gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1333
6.2 Transporting front differential lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1333
7 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1334
7.1 Assembly overview – gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1334
8 Installing to engine and gearbox support ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1337
8.1 Installing gearbox to engine and gearbox support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1337
8.2 Installing front differential lock to engine and gearbox support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1338
9 Gear oil circuit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1340
9.1 Removing and installing gear oil cooler………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1340
9.2 Removing and installing cover for gear oil pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1342
9.3 Removing and installing gear oil pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1344
9.4 Removing and installing gear oil filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1345
10 Gear oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1347
10.1 Checking gear oil level……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1347
10.2 Draining and filling gear oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1350
11 Front differential lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1354
11.1 Assembly overview – front differential lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1354
11.2 Removing front differential lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1354
11.3 Installing front differential lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1357
11.4 Removing and installing differential lock control unit -J647-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1359
35 – Gears, shafts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1361
1 Currently, no repairs can be made to gears and shafts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1361
39 – Final drive – differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1362
1 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1362
1.1 Checking level of gear oil……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1362
1.1.1 Checking gear oil in bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1362
1.1.2 Filling gear oil in bevel box……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1362
2 High-performance oil for Haldex coupling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1365
2.1 Checking oil level in Haldex coupling……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1365
2.2 Draining and filling high performance oil for Haldex coupling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1366
3 Oil seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1370
3.1 Overview of fitting locations – seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1370
3.2 Renewing left oil seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1371
3.3 Renewing right oil seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1374
3.3.1 Renewing right oil seal, front wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1374
3.3.2 Renewing outer seal on right of bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1378
3.3.3 Renewing right seal on gearbox, between front differential lock and gearbox or between bevel box and gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1379
3.3.4 Renewing seal on bevel box between bevel box and gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1381
3.3.5 Renewing oil seal for propshaft drive flange at bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1382
4 Components of front differential lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1388
4.1 Assembly overview – components of front differential lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1388
4.2 Renewing seals for front differential lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1390
4.2.1 Renewing outer seal on right of front differential lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1390
4.2.2 Renewing seal between front differential lock and gearbox on front differential lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1394
4.2.3 Renewing seal for right flange shaft in front differential lock (Haldex coupling)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1395
4.3 Renewing ball bearing for flange shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1397
5 Haldex coupling…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1400
5.1 Checking function……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1400
5.2 Removing and installing Haldex coupling pump -V181-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1400
5.3 Removing and installing Haldex coupling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1401
6 Bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1402
6.1 Assembly overview – bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1402
6.2 Removing and installing right flange shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1403
6.3 Renewing needle bearing (polygon bearing) for right output shaft drive flange………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1405
6.4 Renewing output flange and redetermining thickness of shim, bevel box removed………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1407
Touran2016-6-speed_manual_gearbox_0AJ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1417
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1421
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1421
1.1 Safety precautions when working on vehicles with a start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1421
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1422
2.1 Gearbox identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1422
3 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1423
3.1 Allocation gearbox – engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1423
3.1.1 Allocation gearbox – engine, Golf SV……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1423
3.1.2 Allocation gearbox – engine, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1424
3.1.3 Allocation gearbox – engine, Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1424
3.1.4 Allocation gearbox – engine, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1425
3.2 Capacities……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1425
3.3 Calculation of gear ratios……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1425
4 Overview – power transmission………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1426
5 Electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1428
5.1 Overview of fitting locations – electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1428
5.1.1 Overview of fitting locations – electrical components, manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1428
5.1.2 Overview of fitting locations – electrical components, clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1429
6 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1430
6.1 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1430
30 – Clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1433
1 Clutch operation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1433
1.1 Overview of fitting locations – clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1433
1.2 Assembly overview – pedal cluster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1435
1.2.1 Assembly overview – pedal cluster, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1435
1.2.2 Assembly overview – pedal cluster, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1437
1.3 Assembly overview – clutch hydraulics……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1439
1.3.1 Assembly overview – clutch hydraulics, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1439
1.3.2 Assembly overview – clutch hydraulics, Scirocco, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1440
1.3.3 Assembly overview – clutch hydraulics, Scirocco, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1442
1.4 Assembly overview – clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1444
1.5 Removing and installing bearing bush…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1445
1.6 Checking clutch master cylinder and clutch slave cylinder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1445
1.7 Removing and installing clutch position sender -G476-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1446
1.7.1 Removing and installing clutch position sender -G476-, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1446
1.7.2 Removing and installing clutch position sender -G476-, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1446
1.8 Removing and installing return spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1449
1.9 Removing and installing over-centre spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1451
1.9.1 Removing and installing over-centre spring, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1451
1.9.2 Removing and installing over-centre spring, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1454
1.10 Removing and installing clutch pedal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1455
1.10.1 Removing and installing clutch pedal, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1455
1.10.2 Removing and installing clutch pedal, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1457
1.11 Removing and installing mounting bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1458
1.11.1 Removing and installing mounting bracket, Golf SV, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1458
1.11.2 Removing and installing mounting bracket, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1463
1.12 Removing and installing clutch master cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1467
1.12.1 Removing and installing clutch master cylinder, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1467
1.12.2 Removing and installing clutch master cylinder, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1467
1.13 Removing and installing clutch slave cylinder……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1469
1.14 Removing and installing lines for clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1472
1.15 Bleeding clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1474
1.16 Repairing clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1475
2 Clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1477
2.1 Assembly overview – clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1477
2.2 Removing and installing clutch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1478
34 – Controls, housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1482
1 Selector mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1482
1.1 Installation position – selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1482
1.2 Assembly overview – gear knob and cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1484
1.2.1 Assembly overview – gear knob and cover, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1484
1.2.2 Assembly overview – gear knob and cover, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1485
1.3 Assembly overview – selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1486
1.4 Removing and installing gear knob……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1488
1.4.1 Removing and installing gear knob, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1488
1.4.2 Removing and installing gear knob with gaiter and noise insulation, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1490
1.5 Removing and installing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1492
1.6 Repairing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1496
1.7 Adjusting selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1498
1.8 Checking selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1501
2 Removing and installing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1502
2.1 Distinguishing between different types of engines, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1502
2.2 Removing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1503
2.2.1 Removing gearbox, Scirocco, engine lifting eyes »at rear« of engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1503
2.2.2 Removing gearbox, Scirocco, engine lifting eyes »at front« of engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1512
2.2.3 Removing gearbox, Golf SV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1522
2.2.4 Removing gearbox, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1532
2.3 Installing gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1545
2.3.1 Installing gearbox, Scirocco, engine lifting eyes »at rear« of engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1545
2.3.2 Installing gearbox, Scirocco, engine lifting eyes »at front« of engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1550
2.3.3 Installing gearbox, Golf SV, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1556
2.4 Specified torques for gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1563
2.4.1 Specified torques for gearbox, Golf SV, Passat, Touran, Scirocco, engine lifting eyes »at front« of engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1563
2.4.2 Specified torques for gearbox, Scirocco, engine lifting eyes »at rear« of engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1564
3 Assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1566
3.1 Assembly overview – assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1566
4 Transporting gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1568
5 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1569
5.1 Checking gear oil level………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1569
6 Installing to engine and gearbox support ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1571
7 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1572
7.1 Schematic overview – gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1572
7.1.1 Assembly overview – gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1573
7.2 Assembly overview – cover for gearbox housing and 5th/6th gear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1574
7.3 Assembly overview – clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1576
7.4 Assembly overview – shafts, differential, selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1577
7.5 Assembly overview – selector unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1578
7.6 Assembly overview – selector forks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1580
7.7 Repairing selector forks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1581
7.8 Repairing selector unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1584
7.9 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1587
7.10 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1587
8 Gearbox housing, clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1604
8.1 Assembly overview – gearbox housing and clutch housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1604
8.2 Assembly overview – gearbox housing cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1606
8.3 Repairing gearbox housing cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1607
35 – Gears, shafts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1609
1 Input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1609
1.1 Assembly overview – input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1609
1.2 Dismantling and assembling input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1612
1.3 Renewing input shaft seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1620
2 Output shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1622
2.1 Assembly overview – output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1622
2.2 Dismantling and assembling output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1624
39 – Final drive – differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1630
1 Oil seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1630
1.1 Overview of fitting locations – seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1630
1.2 Renewing left oil seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1631
1.2.1 Renewing oil seal for left flange shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1631
1.3 Renewing right oil seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1633
1.3.1 Renewing oil seal for right flange shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1633
2 Differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1637
2.1 Assembly overview – differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1637
2.2 Dismantling and assembling differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1638
2.3 Adjusting differential…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1643
Touran2016-6-speed_manual_gearbox_02Q__0BB_and_0FB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1647
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1653
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1653
1.1 Safety precautions when working on vehicles with a start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1653
1.2 All-wheel drive – notes on performance test………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1653
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1654
2.1 Gearbox identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1654
2.1.1 Gearbox identification, front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1654
2.1.2 Gearbox identification, all-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1655
3 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1656
3.1 Allocation gearbox – engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1656
3.1.1 Allocation gearbox – engine, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1656
3.1.2 Allocation gearbox – engine, Golf SV……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1656
3.1.3 Allocation gearbox – engine, Scirocco, manual gearbox 02Q…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1657
3.1.4 Allocation gearbox – engine, Scirocco, manual gearbox 0FB…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1657
3.1.5 Allocation gearbox – engine, Passat, manual gearbox 02Q………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1658
3.1.6 Allocation gearbox – engine, Passat, manual gearbox 0FB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1659
3.1.7 Allocation gearbox – engine, Passat, all-wheel drive, manual gearbox 02Q……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1659
3.1.8 Allocation gearbox – engine, Passat, all-wheel drive, manual gearbox 0BB……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1659
3.2 Capacities……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1660
3.2.1 Capacity of manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1660
3.2.2 Capacity, bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1660
3.3 Calculation of gear ratios……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1660
4 Overview – power transmission………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1661
4.1 Overview – power transmission – front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1661
4.2 Overview – power transmission – all-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1663
5 Electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1665
5.1 Overview of fitting locations – electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1665
5.1.1 Overview of fitting locations – electrical components, manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1665
5.1.2 Overview of fitting locations – electrical components, clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1666
6 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1667
6.1 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1667
30 – Clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1670
1 Clutch operation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1670
1.1 Overview of fitting locations – clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1670
1.2 Assembly overview – pedal cluster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1672
1.2.1 Assembly overview – pedal cluster, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1672
1.2.2 Assembly overview – pedal cluster, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1674
1.3 Assembly overview – clutch hydraulics……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1676
1.3.1 Assembly overview – clutch hydraulics, Golf SV, Passat, Touran, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1676
1.3.2 Assembly overview – clutch hydraulics, Golf SV, Passat, Touran, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1678
1.3.3 Assembly overview – clutch hydraulics, Scirocco, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1679
1.3.4 Assembly overview – clutch hydraulics, Scirocco, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1681
1.4 Assembly overview – clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1683
1.5 Removing and installing bearing bush…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1684
1.6 Checking clutch master cylinder and clutch slave cylinder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1685
1.7 Removing and installing clutch position sender -G476-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1685
1.7.1 Removing and installing clutch position sender -G476-, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1685
1.7.2 Removing and installing clutch position sender -G476-, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1686
1.8 Removing and installing return spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1688
1.9 Removing and installing over-centre spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1691
1.9.1 Removing and installing over-centre spring, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1691
1.9.2 Removing and installing over-centre spring, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1693
1.10 Removing and installing clutch pedal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1695
1.10.1 Removing and installing clutch pedal, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1695
1.10.2 Removing and installing clutch pedal, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1696
1.11 Removing and installing mounting bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1698
1.11.1 Removing and installing mounting bracket, Golf SV, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1698
1.11.2 Removing and installing mounting bracket, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1703
1.12 Removing and installing clutch master cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1707
1.12.1 Removing and installing clutch master cylinder, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1707
1.12.2 Removing and installing clutch master cylinder, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1707
1.13 Removing and installing bleeder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1709
1.14 Removing and installing lines for clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1710
1.15 Removing and installing clutch slave cylinder together with release bearing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1713
1.16 Bleeding clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1714
1.17 Repairing clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1716
2 Clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1718
2.1 Determining make of clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1718
2.2 Assembly overview – clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1719
2.2.1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1719
2.2.2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1721
2.2.3 Assembly overview – clutch in connection with simple flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1722
2.3 Removing and installing clutch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1723
2.3.1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1723
2.3.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1727
2.3.3 Removing and installing clutch in connection with simple flywheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1731
34 – Controls, housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1736
1 Selector mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1736
1.1 Installation position – selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1736
1.2 Assembly overview – gear knob and cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1738
1.2.1 Assembly overview – gear knob and cover, Golf SV, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1738
1.2.2 Assembly overview – gear knob and cover, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1739
1.3 Assembly overview – selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1740
1.4 Removing and installing gear knob……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1742
1.4.1 Removing and installing gear knob, Golf SV, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1742
1.4.2 Removing and installing gear knob with gaiter and noise insulation, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1744
1.5 Removing and installing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1746
1.6 Repairing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1754
1.7 Adjusting selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1756
1.8 Checking selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1759
2 Removing and installing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1760
2.1 Removing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1760
2.1.1 Removing gearbox, Golf SV, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1760
2.1.2 Removing gearbox, Scirocco with petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1771
2.1.3 Removing gearbox, Scirocco with turbo diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1782
2.1.4 Removing gearbox, Passat, front-wheel drive, turbo diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1793
2.1.5 Removing gearbox, Passat, front-wheel drive, petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1805
2.1.6 Removing gearbox, Passat, all-wheel drive, turbo diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1819
2.1.7 Removing gearbox, Passat, all-wheel drive, petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1833
2.2 Installing gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1846
2.2.1 Installing gearbox, Golf SV, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1846
2.2.2 Installing gearbox, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1851
2.2.3 Installing gearbox, Passat, front-wheel drive, turbo diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1859
2.2.4 Installing gearbox, Passat, front-wheel drive, petrol engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1866
2.2.5 Installing gearbox, Passat, all-wheel drive, turbo diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1874
2.2.6 Installing gearbox, Passat, all-wheel drive, petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1880
2.3 Specified torques for gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1888
3 Assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1889
3.1 Assembly overview – assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1889
4 Bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1892
4.1 Assembly overview – bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1892
4.2 Removing bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1893
4.3 Installing bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1898
5 Transporting gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1903
6 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1904
6.1 Checking gear oil level………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1904
7 Installing to engine and gearbox support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1906
7.1 Installing manual gearbox to engine and gearbox support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1906
7.2 Installing bevel box to engine and gearbox support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1907
8 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1909
8.1 Schematic overview – gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1909
8.1.1 Schematic overview – gearbox, front-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1909
8.1.2 Schematic overview – gearbox, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1910
8.2 Assembly overview – gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1911
8.2.1 Assembly overview – gearbox, front-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1911
8.2.2 Assembly overview – gearbox, all-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1912
8.3 Assembly overview – gearbox housing and selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1913
8.4 Assembly overview – selector unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1915
8.5 Assembly overview – shafts, differential, selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1916
8.5.1 Assembly overview – shafts, differential, selector mechanism, front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1916
8.5.2 Assembly overview – shafts, differential, selector mechanism, all-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1918
8.6 Assembly overview – selector forks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1920
8.7 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1920
8.8 Dismantling and assembling gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1922
9 Gearbox housing, clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1937
9.1 Assembly overview – gearbox housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1937
9.2 Assembly overview – clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1939
9.3 Repairing gearbox housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1940
9.4 Repairing clutch housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1947
35 – Gears, shafts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1950
1 Input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1950
1.1 Assembly overview – input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1950
1.2 Dismantling and assembling input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1951
1.3 Renewing input shaft seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1955
2 Output shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1957
2.1 Assembly overview – output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1957
2.1.1 Assembly overview – output shaft for 1st to 4th gears………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1957
2.1.2 Assembly overview – output shaft for 5th, 6th and reverse gears……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1961
2.2 Dismantling and assembling output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1964
2.2.1 Dismantling and assembling output shaft for 1st through 4th gears……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1964
2.2.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1976
2.3 Adjusting output shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1986
2.3.1 Adjusting output shaft for 1st through 4th gears…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1986
2.3.2 Adjusting output shaft for 5th, 6th and reverse gears………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..1991
39 – Final drive – differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1997
1 Oil seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1997
1.1 Overview of fitting locations – seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1997
1.2 Renewing left oil seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………1998
1.2.1 Renewing oil seal for left flange shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….1998
1.3 Renewing right oil seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2001
1.3.1 Renewing oil seal for right flange shaft, front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2001
1.3.2 Renewing oil seal for right flange shaft, four-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2003
1.3.3 Renew right seal on the manual gearbox, between gearbox and bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2007
2 Differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2009
2.1 Assembly overview – differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2009
2.1.1 Assembly overview – differential, front-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2009
2.1.2 Assembly overview – differential, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2012
2.2 Dismantling and assembling differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2014
2.2.1 Dismantling and assembling differential, front-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2014
2.2.2 Dismantling and assembling differential, all-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2019
2.3 Adjusting differential…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2025
3 Adjustment overview…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2030
4 Components of bevel box……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2031
4.1 Assembly overview – components of bevel box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2031
4.2 Renewing bevel box seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2033
4.2.1 Renewing seal between gearbox and bevel box with bevel box removed…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2033
4.2.2 Renewing bevel box output flange oil seal (bevel box removed)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2034
4.3 Renewing output flange and redetermining thickness of shim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2043
4.4 Renewing needle bearing (polygon bearing) and oil seal for right flange shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2044
5 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2050
5.1 Checking level of gear oil……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2050
5.1.1 Checking gear oil level in bevel box……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2050
5.1.2 Topping up gear oil in bevel box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2051
Touran2016-6-speed_manual_gearbox_02S………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2055
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2059
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2059
1.1 Safety precautions when working on vehicles with a Start/Stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2059
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2060
2.1 Gearbox identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2060
3 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2061
3.1 Allocation gearbox – engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2061
3.1.1 Allocation gearbox – engine, Golf SV……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2061
3.1.2 Allocation gearbox – engine, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2061
3.1.3 Allocation gearbox – engine, Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2062
3.1.4 Allocation gearbox – engine, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2063
3.2 Capacities……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2063
3.3 Calculation of gear ratios……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2064
4 Overview – power transmission………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2065
5 Electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2067
5.1 Overview of fitting locations – electrical components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2067
5.1.1 Overview of fitting locations – electrical components, manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2067
5.1.2 Overview of fitting locations – electrical components, clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2068
6 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2069
6.1 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2069
30 – Clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2072
1 Clutch operation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2072
1.1 Overview of fitting locations – clutch mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2072
1.2 Assembly overview – pedal cluster……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2074
1.2.1 Assembly overview – pedal cluster, Golf Sportsvan, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2074
1.2.2 Assembly overview – pedal cluster, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2076
1.3 Assembly overview – clutch hydraulics……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2078
1.3.1 Assembly overview – clutch hydraulics, Golf Sportsvan, Passat, Touran, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2078
1.3.2 Assembly overview – clutch hydraulics, Golf Sportsvan, Passat, Touran, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2079
1.3.3 Assembly overview – clutch hydraulics, Scirocco, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2080
1.3.4 Assembly overview – clutch hydraulics, Scirocco, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2082
1.4 Assembly overview – clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2084
1.5 Removing and installing bearing bush…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2085
1.6 Checking clutch master cylinder and clutch slave cylinder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2085
1.7 Removing and installing clutch position sender -G476-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2086
1.7.1 Removing and installing clutch position sender -G476-, Golf Sportsvan, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2086
1.7.2 Removing and installing clutch position sender -G476-, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2086
1.8 Removing and installing return spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2089
1.9 Removing and installing over-centre spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2091
1.9.1 Removing and installing over-centre spring, Golf Sportsvan, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2091
1.9.2 Removing and installing over-centre spring, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2094
1.10 Removing and installing clutch pedal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2095
1.10.1 Removing and installing clutch pedal, Golf Sportsvan, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2095
1.10.2 Removing and installing clutch pedal, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2097
1.11 Removing and installing mounting bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2098
1.11.1 Removing and installing mounting bracket, Golf Sportsvan, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2098
1.11.2 Removing and installing mounting bracket, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2103
1.12 Removing and installing clutch master cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2107
1.12.1 Removing and installing clutch master cylinder, Golf Sportsvan, Passat, Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2107
1.12.2 Removing and installing clutch master cylinder, Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2107
1.13 Removing and installing clutch slave cylinder……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2109
1.14 Removing and installing lines for clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2112
1.15 Bleeding clutch mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2115
1.16 Repairing clutch release mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2117
2 Clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2118
2.1 Assembly overview – clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2118
2.1.1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2118
2.1.2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2119
2.1.3 Assembly overview – clutch in connection with simple flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2120
2.2 Removing and installing clutch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2121
2.2.1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2121
2.2.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2124
2.2.3 Removing and installing clutch in connection with simple flywheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2129
34 – Controls, housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2133
1 Selector mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2133
1.1 Installation position – selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2133
1.2 Assembly overview – gear knob and cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2135
1.2.1 Assembly overview – gear knob and cover, Golf Sportsvan, Passat, Touran………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2135
1.2.2 Assembly overview – gear knob and cover, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2136
1.3 Assembly overview – Selector lever and selector housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2137
1.4 Assembly overview – selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2138
1.5 Removing and installing gear knob……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2140
1.5.1 Removing and installing gear knob, Golf Sportsvan, Passat, Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2140
1.5.2 Removing and installing gear knob with gaiter and noise insulation, Scirocco……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2142
1.6 Removing and installing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2144
1.7 Repairing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2148
1.8 Adjusting selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2150
1.9 Checking selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2154
2 Removing and installing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2155
2.1 Removing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2155
2.1.1 Removing gearbox, Golf Sportsvan, Touran, with petrol engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2155
2.1.2 Removing gearbox, Golf Sportsvan, Touran, with turbo diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2167
2.1.3 Removing gearbox, Passat with petrol engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2180
2.1.4 Removing gearbox, Passat with turbo diesel engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2192
2.1.5 Removing gearbox, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2203
2.2 Installing gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2212
2.2.1 Installing gearbox, Golf Sportsvan, Touran, with petrol engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2212
2.2.2 Installing gearbox, Golf Sportsvan, Touran, with turbo diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2219
2.2.3 Installing gearbox, Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2226
2.2.4 Installing gearbox, Scirocco………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2234
2.3 Specified torques for gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2241
3 Assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2243
3.1 Assembly overview – assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2243
4 Transporting gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2245
5 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2246
5.1 Checking gear oil level………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2246
5.2 Draining and filling gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2246
6 Installing to engine and gearbox support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2249
7 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2250
7.1 Schematic overview – gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2250
7.2 Assembly overview – gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2252
7.3 Assembly overview – cover for gearbox housing and 5th/6th gear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2253
7.4 Assembly overview – gearbox housing and selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2255
7.5 Assembly overview – selector unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2257
7.6 Assembly overview – shafts, differential, selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2258
7.7 Assembly overview – selector forks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2259
7.8 Repairing selector unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2262
7.9 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2263
7.10 Repairing selector forks………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2264
7.11 Removing cover for gearbox housing and 5th and 6th gears………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2267
7.12 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2273
7.13 Installing cover for gearbox housing and 5th and 6th gears………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2288
8 Gearbox housing, clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2293
8.1 Assembly overview – gearbox housing and clutch housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2293
8.2 Assembly overview – gearbox housing cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2295
8.3 Repairing gearbox housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2296
8.4 Repairing clutch housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2297
8.5 Repairing gearbox housing cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2299
35 – Gears, shafts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2302
1 Input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2302
1.1 Assembly overview – input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2302
1.2 Dismantling and assembling input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2304
1.3 Adjusting input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2309
1.4 Renewing input shaft seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2313
2 Output shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2315
2.1 Assembly overview – output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2315
2.2 Dismantling and assembling output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2318
2.3 Adjusting output shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2327
3 Reverse shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2332
3.1 Assembly overview – reverse shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2332
3.2 Dismantling and assembling reverse shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2335
39 – Final drive – differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2338
1 Oil seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2338
1.1 Overview of fitting locations – seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2338
1.2 Renewing left oil seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2339
1.2.1 Renewing oil seal for left flange shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2339
1.3 Renewing right oil seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2341
1.3.1 Renewing oil seal for right flange shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2341
2 Differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2345
2.1 Assembly overview – differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2345
2.2 Dismantling and assembling differential………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2347
2.3 Adjusting differential…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2352
3 Adjustment overview…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2355
Touran2016-7-speed_dual_clutch_gearbox_0CW……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2356
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2360
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2360
1.1 General safety regulations……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2360
1.2 Safety precautions when working on vehicles with a Start/Stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2360
1.3 Safety precautions when using test and measuring equipment during a road test………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2361
1.4 Notes on tow-starting/towing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2361
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2362
2.1 Gearbox identification…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2362
3 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2363
3.1 General notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2363
3.2 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2364
3.3 Gaskets, seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2365
3.4 Nuts and bolts………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2365
4 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2366
4.1 Allocation gearbox – engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2366
4.1.1 Golf 2013 ►, Golf Estate 2014 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2366
4.1.2 Golf SV 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2366
4.1.3 Polo 2014 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2366
4.1.4 Passat 2015 ►, Passat Estate 2015 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2367
4.1.5 Touran 2016 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2367
4.2 Capacities……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2368
5 Overview – power transmission………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2369
5.1 Overview – power transmission – front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2369
30 – Clutch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2370
1 Clutch operation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2370
1.1 Assembly overview – clutch engagement……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2370
1.2 Removing and installing clutch engagement………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2371
1.3 Adjusting clutch engagement…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2374
2 Clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2386
2.1 Assembly overview – dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2386
2.2 Removing dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2387
2.3 Installing dual clutch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2391
2.4 Renewing input shaft seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2395
2.5 Renewing oil seal for inner input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2397
34 – Controls, housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2400
1 Mechatronic unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2400
1.1 Exploded view – mechatronic unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2400
1.2 Removing and installing mechatronic unit for dual clutch gearbox -J743-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2401
1.3 Moving mechatronic unit for dual clutch gearbox -J743- into removal position by hand………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2414
2 Selector mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2417
2.1 Assembly overview – selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2417
2.1.1 Assembly overview – selector mechanism, manufacturer ZF………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2417
2.1.2 Assembly overview – selector mechanism, manufacturer ECS……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2419
2.2 Emergency release from position P……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2420
2.2.1 Emergency release from position P, Golf 2013 ►, Golf Estate 2014 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2420
2.2.2 Emergency release from position P, Polo 2014 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2420
2.2.3 Emergency release from position P, Golf SV 2015 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2421
2.2.4 Emergency release from position P, Passat 2015 ►, Passat Estate 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2422
2.2.5 Emergency release from position P, Touran 2016 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2423
2.3 Removing and installing selector lever handle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2424
2.3.1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Passat 2015 ►, Passat Estate 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2424
2.3.2 Removing and installing selector lever handle, Polo 2014 ►, Golf SV 2015 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2426
2.3.3 Removing and installing selector lever handle, Touran 2016 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2429
2.4 Moving push button to installation position in the handle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2431
2.5 Removing and installing selector mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2433
2.5.1 Removing and installing selector mechanism with selector lever cable…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2433
2.5.2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2436
2.5.3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2439
2.6 Removing and installing selector lever cable……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2441
2.6.1 Removing and installing selector lever cable, manufacturer ZF…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2441
2.6.2 Removing and installing selector lever cable, manufacturer ECS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2443
2.7 Checking selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2445
2.8 Checking and adjusting selector lever cable………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2446
2.9 Renewing oil seal for selector shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2448
3 Removing and installing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2449
3.1 Removing gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2449
3.1.1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2449
3.1.2 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2457
3.1.3 Removing gearbox, Golf SV 2015 ►, vehicles with diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2465
3.1.4 Removing gearbox, Polo 2014 ►, vehicles with 1.0, 1.2 l and 1.4 l petrol engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2471
3.1.5 Removing gearbox, Polo 2014 ►, vehicles with diesel engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2477
3.1.6 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with diesel engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2483
3.1.7 Removing gearbox, Polo 2014 ►, vehicles with 1.8 l petrol engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2491
3.1.8 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with 1.4 l petrol engines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2497
3.1.9 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, vehicles with 1.8 l petrol engines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2505
3.1.10 Removing gearbox, Touran 2016 ►, vehicles with 1.4 l petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2514
3.1.11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2520
3.2 Installing gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2527
3.3 Specified torques for gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2531
4 Assembly mountings………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2533
4.1 Assembly overview – assembly mountings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2533
4.1.1 Assembly overview – assembly mountings, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, Passat 2015 ►, Passat Estate 205 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2533
4.1.2 Assembly overview – assembly mountings, Polo 2014 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2535
5 Transporting gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2537
6 Dismantling and assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2540
6.1 Schematic overview – gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2540
6.2 Dismantling and assembling gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2541
6.2.1 Dismantling gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2541
6.2.2 Assembling gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2548
7 Gearbox housing, clutch housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2559
7.1 Repairing gearbox housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2559
7.2 Repairing clutch housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2562
8 Installing to engine and gearbox support………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2566
9 Gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2568
9.1 Draining and filling gear oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2568
35 – Gears, shafts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2571
1 Input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2571
1.1 Dismantling and assembling input shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2571
1.1.1 Dismantling and assembling outer input shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2571
2 Output shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2575
2.1 Assembly overview – output shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2575
2.1.1 Assembly overview – output shaft 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2575
2.1.2 Assembly overview – output shaft 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2577
2.1.3 Assembly overview – output shaft 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2578
2.2 Dismantling and assembling output shaft 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2579
2.2.1 Dismantling output shaft 1 partially……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2579
2.2.2 Dismantling output shaft 1 completely………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2580
2.2.3 Assembling output shaft 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2582
2.2.4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2588
2.3 Dismantling and assembling output shaft 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2588
2.3.1 Dismantling output shaft 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2588
2.3.2 Assembling output shaft 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2590
2.3.3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2594
2.4 Dismantling and assembling output shaft 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2594
2.4.1 Dismantling output shaft 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2594
2.4.2 Assembling output shaft 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2596
2.4.3 Dismantling and assembling locking collar and synchro-hub of output shaft 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2598
2.5 Determining shims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2598
2.5.1 Notes on gearbox adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2598
2.5.2 Calculating shims for clutch housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2599
2.5.3 Calculating shims for gearbox housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2612
3 Parking lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2633
3.1 Removing and installing cover for parking lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2633
3.2 Removing and installing parking lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2634
39 – Final drive – differential……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2636
1 Oil seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2636
1.1 Overview of fitting locations – seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2636
1.2 Renewing left oil seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2636
1.3 Renewing right oil seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2639
1.3.1 Renewing right oil seal, gearboxes with flange shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2639
1.3.2 Renewing right oil seal, gearboxes with stub shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2643
Touran2016-Auxiliary_heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2645
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2649
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2649
1.1 Safety precautions for working on vehicles with auxiliary/supplementary heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2649
1.2 Safety measures for when working on vehicles with a start/stop system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2650
1.3 Safety precautions when working on the fuel system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2650
1.4 Safety precautions when working on cooling system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2651
1.5 Safety precautions when using testers and measuring instruments during a road test……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2651
1.6 Safety precautions when working on high-voltage system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2651
1.7 Safety precautions when working in vicinity of high-voltage components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2652
2 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2653
2.1 Starting conditions for auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2653
2.1.1 Starting conditions for auxiliary/supplementary heater, auxiliary heater mode…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2653
2.1.2 Starting conditions for auxiliary/supplementary heater, supplementary heater mode……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2653
2.2 Notes for vehicles with a start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2654
2.3 Rules for cleanliness for working on the auxilary/supplementary heater and the fuel system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2654
2.4 Identification plates………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2654
3 Repair notes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2656
3.1 General repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2656
82 – Supplementary heating………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2657
1 Fittings location overview – auxiliary/supplementary heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2657
1.1 Fittings location overview – auxiliary/supplementary heater components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2657
2 Auxiliary/supplementary heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2659
2.1 Fittings location overview – auxiliary/supplementary heater………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2659
2.2 Assembly overview – auxiliary/supplementary heater attachments……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2661
2.3 Assembly overview – auxiliary/supplementary heater, internal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2662
2.4 Removing and installing auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2663
2.5 Dismantling and assembling auxilary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2668
2.6 Removing and installing air intake silencer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2670
2.7 Removing and installing circulation pump -V55-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2670
2.8 Removing and installing exhaust system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2673
2.9 Removing and installing auxiliary/supplementary heater bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2673
2.10 Removing and installing covers for auxiliary heater control unit -J364-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2674
2.11 Removing and installing glow plug with flame monitoring -Q8-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2675
2.12 Removing and installing temperature sensor -G18- and overheating sensor -G189-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2675
2.13 Connector pin assignment for supplementary heater………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2676
2.14 Dismantling and assembling burner unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2676
2.15 Removing and installing auxiliary heater control unit -J364- with combustion air blower -V6-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2677
3 Coolant circuit with auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2679
3.1 Schematic diagram – coolant hoses……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2679
3.2 Bleeding coolant circuit of auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2680
3.3 Removing and installing coolant pipes for auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2682
3.3.1 Removing and installing coolant pipes for auxiliary/supplementary heater, vehicles with petrol engines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2682
3.3.2 Removing and installing coolant pipes for auxiliary/supplementary heater, vehicles with diesel engines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2684
4 Fuel supply………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2687
4.1 Fittings location overview – fuel supply…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2687
4.2 Testing quantity of fuel delivered………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2688
4.3 Removing and installing metering pump -V54-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2689
5 Regulation of auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2691
5.1 Functional description…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2691
5.2 Supplementary heating mode……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2692
5.3 Auxiliary heater mode………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2692
5.4 Switching off auxiliary/supplementary heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2692
6 Other control components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2694
6.1 Removing and installing ambient temperature sensor -G17-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2694
6.2 Removing and installing remote control receiver for auxiliary coolant heater -R149-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2694
6.3 Functional description of remote control for auxiliary/supplementary heater………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2695
Touran2016-Body_Repairs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2698
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2704
1 Vehicle identification data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2704
1.1 Vehicle identification number…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2704
1.2 Identification plate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2706
1.3 Vehicle data sticker…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2707
2 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2708
3 Moulded foam elements……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2709
4 Galvanized body parts, high- and higher-strength and hot-formed body panels……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2711
5 Laser welding………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2714
6 Gaps/shut lines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2715
6.1 Body – front………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2715
6.2 Body – centre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2717
6.3 Body – rear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2720
7 Body dimensions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2722
7.1 Body – front………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2722
7.2 Body – centre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2723
7.3 Body – rear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2728
7.4 Floor group – front……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2729
7.5 Floor group – centre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2730
7.6 Floor group – rear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2731
8 Alignment bracket set……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2732
8.1 Setup overview of complete body…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2732
9 Portal gauge……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2734
9.1 Setup overview of complete body…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2734
50 – Body – front………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2736
1 Renewing right bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2736
1.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2736
1.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2736
1.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2738
1.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2738
1.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2740
2 Repairing threads for securing subframe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2741
2.1 Contents of thread repair kit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2743
2.2 Repairing threads……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2743
2.2.1 Drilling thread………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2743
2.2.2 Cutting thread…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2744
2.2.3 Inserting thread insert…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2745
3 Renewing retaining bracket for subframe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2747
3.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2748
3.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2748
3.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2749
3.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2749
3.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2750
4 Renewing front bumper bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2752
4.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2753
4.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2753
4.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2754
4.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2754
4.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2756
5 Replacing upper wheel housing longitudinal member………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2757
5.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2758
5.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2758
5.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2759
5.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2760
5.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2761
6 Renewing upper inner wheel housing longitudinal member………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2763
6.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2764
6.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2764
6.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2765
6.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2765
6.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2766
7 Renewing front wheel housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2768
7.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2769
7.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2769
7.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2771
7.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2771
7.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2772
8 Renewing front longitudinal member……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2775
8.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2776
8.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2776
8.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2777
8.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2777
8.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2778
9 Renewing front longitudinal member (left part section)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2780
9.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2781
9.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2781
9.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2782
9.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2783
9.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2784
9.3.3 Renewing studs…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2787
10 Renewing front longitudinal member (right part section)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2788
10.1 Tools……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2789
10.2 Removing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2789
10.3 Installing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2790
10.3.1 Preparing new part………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2790
10.3.2 Welding in……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2792
51 – Body – centre……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2795
1 Renewing roof – vehicles with no panorama tilting sunroof……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2795
1.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2796
1.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2796
1.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2798
1.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2799
1.3.2 Adjusting roof depth……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2800
1.3.3 Bonding roof…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2801
1.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2807
2 Renewing roof – vehicles with panorama tilting sunroof………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2809
2.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2810
2.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2810
2.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2812
2.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2813
2.3.2 Adjusting roof depth……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2814
2.3.3 Bonding roof…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2815
2.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2821
3 Renewing side member cover plate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2822
3.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2823
3.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2823
3.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2824
3.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2824
3.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2825
4 Renewing A-pillar…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2827
4.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2828
4.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2829
4.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2830
4.3.1 Authorised parting cuts on complete side panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2831
4.3.2 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2831
4.3.3 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2832
4.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2833
5 Renewing A-pillar reinforcement (part section)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2835
5.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2836
5.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2836
5.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2837
5.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2838
5.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2839
6 Renewing B-pillar…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2841
6.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2842
6.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2843
6.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2844
6.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2845
6.3.2 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2845
6.3.3 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2846
7 Renewing B-pillar reinforcement………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2848
7.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2849
7.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2849
7.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2851
7.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2852
7.3.2 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2852
7.3.3 Marking areas where no welding work may be carried out……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2853
7.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2854
8 Renewing B-pillar reinforcement (part section)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2856
8.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2857
8.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2857
8.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2861
8.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2861
8.3.2 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2863
8.3.3 Marking areas where no welding work may be carried out……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2864
8.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2864
9 Renewing outer side member…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2869
9.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2870
9.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2870
9.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2872
9.3.1 Other approved parting cuts on outer side member (sill)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2872
9.3.2 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2873
9.3.3 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2874
9.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2875
53 – Body – rear…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2877
1 Renewing rear apron…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2877
1.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2878
1.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2879
1.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2883
1.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2884
1.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2885
2 Renewing lower corner part…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2889
2.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2890
2.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2890
2.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2891
2.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2891
2.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2892
3 Renewing cross panel member………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2895
3.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2896
3.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2896
3.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2897
3.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2898
3.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2899
4 Renewing luggage compartment floor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2901
4.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2902
4.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2902
4.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2903
4.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2904
4.3.2 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2905
4.3.3 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2905
5 Renewing rear longitudinal member (part section)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2908
5.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2909
5.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2909
5.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2911
5.3.1 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2911
5.3.2 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2913
6 Renewing side panel (part section)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2915
6.1 Tools………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2916
6.2 Removing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2916
6.3 Installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2918
6.3.1 Authorised parting cuts on complete side panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2919
6.3.2 Preparing new part……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2919
6.3.3 Moulded foam inserts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2920
6.3.4 Welding in………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2921
Touran2016-Brake_system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2924
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2928
1 Notes on safety…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2928
1.1 Safety precautions during a road test using test and measuring equipment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2928
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2929
2.1 Allocation of PR number – brakes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2929
2.1.1 Front brakes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2929
2.1.2 Rear brakes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2929
3 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2930
3.1 Technical data for brakes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2930
3.1.1 Brake master cylinder and brake servo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2930
4 Brake test…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2932
4.1 General information……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2932
4.2 Checking vehicles with front-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2932
4.3 Checking parking brake…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2932
4.3.1 Checking electromechanical parking brake, vehicles with front-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2932
45 – Anti-lock brake system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2934
1 General information…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2934
1.1 Repair instructions for repair work on ABS……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2934
2 Overview of fitting locations………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2937
2.1 Overview of fitting locations – ABS/ESP………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2937
3 Control unit and hydraulic unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2939
3.1 Assembly overview – control unit and hydraulic unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2939
3.1.1 Assembly overview – control unit and hydraulic unit, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2939
3.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2941
3.2.1 Removing and installing control unit and hydraulic unit, LHD vehicles, petrol engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2941
3.2.2 Removing and installing control unit and hydraulic unit, LHD vehicles, diesel engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2945
3.3 Separating control unit from hydraulic unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2950
3.4 Fitting control unit to hydraulic unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2951
3.5 Connecting brake lines to hydraulic unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2952
3.5.1 Connecting brake lines to hydraulic unit, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2952
4 Sensors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2954
4.1 Assembly overview – speed sensor on front axle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2954
4.2 Assembly overview – speed sensor on rear axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2955
4.2.1 Assembly overview – speed sensor on rear axle, front-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2955
4.2.2 Assembly overview – speed sensor on rear axle, all-wheel drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2956
4.3 Removing and installing speed sensors on front axle -G45-/-G47-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2956
4.4 Removing and installing speed sensor on rear axle -G44-/-G46-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2957
4.4.1 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with front-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2957
4.4.2 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with four-wheel drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2958
4.5 Checking ABS sensor ring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2958
4.6 Removing and installing ESP sensor unit -G419-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2959
46 – Brakes – mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2960
1 Front brakes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2960
1.1 Assembly overview – front brakes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2960
1.1.1 Assembly overview – front brake PC57……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2960
1.2 Removing and installing brake pads or linings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2962
1.2.1 Removing and installing brake pads, front brake PC57…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2962
1.3 Removing and installing brake caliper……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2964
1.3.1 Removing and installing brake pads, front brake PC57…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2964
2 Rear brakes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2967
2.1 Assembly overview – rear brakes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2967
2.2 Removing and installing brake pads or linings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2969
2.3 Removing and installing brake caliper……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2973
3 Handbrake………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2978
3.1 Overview of fitting locations – parking brake…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2978
3.2 Removing and installing control unit for electromechanical parking brake -J540-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2979
3.3 Removing and installing parking brake motor -V282-/-V283-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2979
4 Brake pedal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2982
4.1 Assembly overview – brake pedal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2982
4.1.1 Assembly overview – brake pedal, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2982
4.2 Removing and installing mounting bracket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2984
4.2.1 Removing and installing mounting bracket, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2984
4.3 Separating brake pedal from brake servo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2986
4.4 Connecting brake pedal to brake servo……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2987
4.5 Removing and installing brake pedal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2987
4.5.1 Removing and installing brake pedal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2987
47 – Brakes – hydraulics………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2989
1 Front brake caliper…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2989
1.1 Assembly overview – front brake caliper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2989
1.1.1 Assembly overview – brake caliper (PC57 brakes)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2989
1.2 Removing and installing brake caliper piston……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2990
1.2.1 Removing and installing brake caliper PC57………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2990
2 Rear brake caliper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2993
2.1 Assembly overview – rear brake caliper…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2993
2.2 Removing and installing protective cap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2993
3 Brake servo and brake master cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2997
3.1 Assembly overview – brake servo/brake master cylinder……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2997
3.1.1 Assembly overview – brake servo/brake master cylinder, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………2997
3.2 Removing and installing brake light switch……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….2999
3.2.1 Removing and installing brake light switch, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..2999
3.3 Removing and installing brake servo……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3000
3.3.1 Removing and installing brake servo, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3000
3.4 Removing and installing brake master cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3005
3.4.1 Removing and installing brake master cylinder, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3005
4 Vacuum system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3009
4.1 Assembly overview – vacuum pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3009
4.1.1 Vacuum pump for brake servo, diesel vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3009
4.2 Checking non-return valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3009
4.3 Removing and installing vacuum sender -G608-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3009
4.4 Checking vacuum system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3010
4.4.1 Instructions for checking…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3010
4.4.2 Connecting vacuum gauge for brake servo -VAS 6721-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3011
4.4.3 Checking vacuum generation………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3012
4.4.4 Checking for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3012
5 Brake lines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3015
5.1 Repairing brake lines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3015
5.1.1 Assembly overview – flanging tool………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3015
5.1.2 Instructions for use of flanging tool………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3016
6 Hydraulic system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3019
6.1 General notes on brake fluid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3019
6.1.1 General notes on brake fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3019
6.1.2 Changing brake fluid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3019
6.2 Bleeding hydraulic system following standard procedure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3019
6.3 Subsequent bleeding of hydraulic system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3020
6.4 Testing for leaks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3021
Touran2016-Communication……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3023
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3027
1 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3027
1.1 General repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3027
1.2 Routing and securing wiring…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3027
1.3 Notes on repair of CAN bus wiring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3027
1.4 General notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3027
1.4.1 Transmitting power and aerial fitting locations……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3027
91 – Communication……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3029
1 Infotainment system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3030
1.1 Overview – infotainment system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3030
1.2 Overview of fitting locations – infotainment system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3035
1.3 Removing and installing infotainment system display……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3036
1.4 Removing and installing information electronics control unit 1 -J794-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3037
2 Sound system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3039
2.1 Overview – sound system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3039
2.2 Overview of fitting locations – sound system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3039
2.3 Removing and installing rear treble loudspeakers -R14-/-R16-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3040
2.4 Removing and installing front treble loudspeakers -R20-/-R22-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3041
2.5 Removing and installing rear bass loudspeakers -R15-/-R17-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3041
2.6 Removing and installing front bass loudspeakers -R21-/-R23-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3043
3 Aerial systems……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3045
3.1 Overview of fitting locations – aerial systems……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3045
3.2 Removing and installing aerial amplifiers -R24-/-R84-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3046
3.3 Removing and installing amplitude modulation (AM) frequency filter -R177-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3047
3.4 Removing and installing frequency modulation (FM) frequency filter R178/R179…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3048
3.5 Removing and installing roof aerial……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3049
3.6 Removing and installing aerial module……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3050
3.6.1 Removing and installing vehicle location system aerial 2 -R260-/GSM aerial 2 -R267-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3050
4 Radio……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3052
4.1 Overview – radio………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3052
4.1.1 Overview – radio, Composition Touch and Composition Colour version…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3052
4.1.2 Overview – radio, Composition Media and Discover Media version………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3052
4.1.3 Overview – radio, Discover Pro version……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3052
4.2 Removing and installing radio…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3052
4.2.1 Removing and installing radio, Composition Touch and Composition Colour version…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3052
4.2.2 Removing and installing radio, Composition Media and Discover Media or Discover Pro……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3054
5 Telephone system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3055
5.1 Mobile telephone preparation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3055
5.1.1 Mobile telephone preparation, Bluetooth hands-free system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3055
5.1.2 Mobile telephone preparation, Bluetooth car phone online……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3055
5.1.3 Notes on Bluetooth technology……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3056
5.2 Overview of fitting locations – telephone system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3056
5.3 Removing and installing telephone microphone -R38-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3057
5.4 Removing and installing aerial amplifier for mobile telephone -R86-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3058
5.5 Removing and installing aerial for Bluetooth……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3059
5.5.1 Coupling aerial for Bluetooth mobile phone -R309-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3059
6 Navigation system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3060
6.1 Components of navigation system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3060
6.1.1 Overview – navigation system, Discover Pro version…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3060
6.1.2 Overview – navigation system, Discover Pro version…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3060
6.2 Overview of fitting locations – navigation system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3060
6.3 Removing and installing navigation system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3061
7 TV system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3062
7.1 Overview of fitting locations – TV system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3062
7.2 Removing and installing TV tuner………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3062
8 Reversing camera system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3064
8.1 Overview – reversing camera system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3064
8.2 Overview of fitting locations – reversing camera system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3064
8.3 Removing and installing reversing camera -R189-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3065
8.4 Calibrating reversing camera system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3065
8.4.1 Assembling and setting-up calibration unit -VAS 6350-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3065
8.4.2 Calibrating reversing camera -R189-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3068
9 Multifunction steering wheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3071
9.1 Components of multifunction steering wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3071
9.2 Assembly overview – multifunction steering wheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3071
9.3 Removing and installing steering wheel multifunction buttons -E441-/-E440-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3073
9.4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3075
10 Connection for external multimedia devices……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3077
10.1 Connectors, connection for external multimedia devices……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3077
10.1.1 Removing and installing USB connection of storage compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3077
10.1.2 Removing and installing USB connection in rear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3077
10.1.3 Removing and installing USB hub -R293-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3078
10.2 Removing and installing connection for external audio sources -R199-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3078
11 Mobile online services……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3080
11.1 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3080
11.2 Overview of fitting locations – mobile online services……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3080
11.2.1 Overview of fitting locations – mobile online services, left-hand drive vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3080
11.2.2 Overview of fitting locations – mobile online services, right-hand drive vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3082
11.3 Removing and installing emergency call module control unit and communication unit -J949-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3083
11.3.1 Removing and installing emergency call module control unit and communication unit -J949-, left-hand drive vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3083
11.3.2 Removing and installing emergency call module control unit and communication unit -J949-, right-hand drive vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3083
Touran2016-Electrical_system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3085
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3093
1 Notes on safety…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3093
1.1 Safety precautions when working on vehicles with Start/Stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3093
1.2 Safety precautions when using testing and measuring instruments during a road test……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3093
1.3 Operation and safety notes for gas discharge bulbs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3094
2 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3096
2.1 Contact corrosion……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3096
2.2 Routing and securing wiring…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3096
3 Battery……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3097
3.1 Battery – general notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3097
3.2 Types of battery………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3097
27 – Starter, current supply, CCS………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3098
1 Battery……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3098
1.1 Assembly overview – battery…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3098
1.2 Removing and installing battery…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3099
1.3 Disconnecting and reconnecting battery…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3102
1.4 Removing and installing battery tray…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3103
1.5 Checking battery………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3104
1.6 Charging battery………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3104
1.7 Removing and installing earth wire with battery monitor control unit -J367-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3104
1.8 Adapting battery monitor control unit -J367-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3105
2 Alternator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3106
2.1 Assembly overview – alternator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3106
2.1.1 Assembly overview – alternator with sliding bushes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3106
2.1.2 Assembly overview – alternator without sliding bushes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3107
2.2 Removing and installing alternator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3107
2.2.1 Removing and installing alternator, vehicles with TSI engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3107
2.2.2 Removing and installing alternator, vehicles with 1.8 l TSI engine…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3109
2.2.3 Removing and installing alternator, vehicles with TDI engine………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3111
2.3 Checking alternator……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3113
2.4 Removing and installing poly V-belt pulley……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3114
2.4.1 Removing and installing poly V-belt pulley without freewheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3114
2.4.2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3115
2.4.3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3117
2.4.4 Removing and installing decoupler pulley with freewheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3119
2.5 Removing and installing voltage regulator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3121
2.5.1 Removing and installing voltage regulator, manufacturer: Bosch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3121
2.5.2 Removing and installing voltage regulator, manufacturer: Valeo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3122
3 Starter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3124
3.1 Assembly overview – starter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3124
3.1.1 Assembly overview – starter, vehicles with manual gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3124
3.1.2 Assembly overview – starter, vehicles with dual clutch gearbox (DQ200–7F)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3125
3.1.3 Assembly overview – starter, vehicles with dual clutch gearbox (DQ250-6F)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3126
3.2 Removing and installing starter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3126
3.2.1 Removing and installing starter, vehicle with manual gearbox………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3126
3.2.2 Removing and installing starter, vehicles with double clutch gearbox (DQ200–7F)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3129
3.2.3 Removing and installing starter, vehicles with dual clutch gearbox (DQ250-6F)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3130
4 Cruise control system (CCS)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3133
5 Start/Stop system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3134
5.1 General description – Start/Stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3134
5.2 Overview of fitting locations – Start/Stop system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3134
6 Adaptive cruise control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3135
6.1 Overview of fitting locations – adaptive cruise control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3135
6.2 Removing and installing automatic distance control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3136
6.2.1 Removing and installing control unit for adaptive cruise control, with retaining plate and adapter frame…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3136
6.2.2 Removing control unit for adaptive cruise control from and installing to adapter frame…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3137
6.3 Calibrating adaptive cruise control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3137
90 – Gauges, instruments………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3138
1 Dash panel insert…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3138
1.1 Assembly overview – dash panel insert……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3138
1.2 Removing and installing dash panel insert -KX2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3138
2 Horn………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3141
2.1 Assembly overview – horn……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3141
2.2 Removing and installing treble horn -H2- / bass horn -H7-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3142
2.2.1 Removing and installing treble horn -H2- / bass horn -H7-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3142
2.2.2 Removing and installing bracket for treble horn -H2-/bass horn -H7-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3142
92 – Windscreen wash/wipe system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3144
1 Windscreen wiper system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3144
1.1 Assembly overview – windscreen wiper system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3144
1.1.1 Assembly overview – windscreen wiper system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3144
1.1.2 Assembly overview – windscreen wiper motor and wiper frame……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3146
1.2 Moving wipers to service position……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3146
1.3 Removing and installing wiper blade……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3147
1.4 Removing and installing wiper arms………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3147
1.5 Adjusting wiper arms…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3149
1.6 Removing and installing wiper motor -V-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3150
1.7 Renewing wiper motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3151
1.8 Deactivating APP function of wiper motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3153
1.9 Removing and installing rain and light sensor -G397-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3154
1.9.1 Removing and installing rain and light sensor -G397-, vehicles with front camera for driver assist systems…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3154
1.9.2 Removing and installing rain and light sensor -G397-, vehicles without front camera for driver assist systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3157
1.10 Repairing rain and light sensor -G397-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3159
1.10.1 Repairing rain and light sensor -G397-, TRW………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3159
1.10.2 Repairing rain and light sensor -G397-, Valeo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3160
2 Windscreen washer system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3162
2.1 Assembly overview – windscreen washer system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3162
2.1.1 Assembly overview – windscreen washer system, with headlight washer system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3162
2.1.2 Assembly overview – windscreen washer system, without headlight washer system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3163
2.2 Removing and installing washer fluid reservoir……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3164
2.3 Removing and installing windscreen washer fluid level sender -G33-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3165
2.4 Removing and installing windscreen washer pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3165
2.5 Removing and installing washer jets……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3166
2.6 Adjusting spray jets…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3167
3 Rear window wiper system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3168
3.1 Assembly overview – rear window wiper system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3168
3.2 Removing and installing wiper blade……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3169
3.3 Removing and installing wiper arm……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3169
3.4 Adjusting wiper arm……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3170
3.5 Removing and installing rear window wiper motor -V12-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3171
4 Rear window washer system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3173
4.1 Assembly overview – rear window washer system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3173
4.2 Removing and installing washer fluid reservoir……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3174
4.3 Removing and installing rear window washer pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3174
4.4 Removing and installing washer jet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3174
4.5 Adjusting spray jet……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3175
5 Headlight washer system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3176
5.1 Assembly overview – headlight washer system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3176
5.2 Removing and installing washer fluid reservoir……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3177
5.3 Removing and installing headlight washer system pump -V11-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3177
5.4 Removing and installing pop-up cylinder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3178
5.5 Removing and installing washer jets……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3180
5.6 Adjusting spray jets…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3180
6 Washer fluid lines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3181
6.1 Repairing washer fluid lines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3181
94 – Lights, bulbs, switches – exterior…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3182
1 Headlight………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3182
1.1 Assembly overview – headlight…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3182
1.1.1 Assembly overview – dual halogen headlight………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3182
1.1.2 Assembly overview – LED headlights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3184
1.1.3 Assembly overview – LED headlights with variable light distribution……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3184
1.2 Removing and installing headlight……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3184
1.3 Adjusting headlights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3186
1.3.1 Adjusting headlights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3186
1.3.2 Adjusting fog lights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3186
1.4 Adjusting headlight installation position………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3186
1.5 Removing and installing front turn signal bulb -M5-/-M7-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3187
1.6 Installing repair kit for headlight housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3188
1.7 Converting headlights from driving on right to driving on left……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3189
1.7.1 Changing headlights over from driving on right to driving on left (dual halogen headlights)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3189
1.7.2 Converting headlights from driving on right to driving on left, LED headlights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3189
1.8 Converting headlights from driving on left to driving on right……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3189
1.8.1 Changing headlights over from driving on left to driving on right (dual halogen headlights)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3189
1.8.2 Converting headlights from driving on left to driving on right, LED headlights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3190
1.9 Removing and installing headlight range control motor -V48-/-V49-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3190
1.10 Removing and installing dipped beam bulb………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3192
1.10.1 Removing and installing headlight dipped beam bulb, halogen headlights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3192
1.10.2 Removing and installing headlight dipped beam bulb (LED)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3192
1.10.3 Removing and installing headlight dipped beam bulb, LED headlights with variable light distribution………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3194
1.11 Removing and installing headlight main beam bulb -M30-/-M32-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3195
1.11.1 Removing and installing headlight main beam bulb -M30-/-M32-, halogen headlights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3195
1.11.2 Removing and installing headlight main beam bulb -M30-/-M32- (LED)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3196
1.11.3 Removing and installing headlight main beam bulb -M30-/-M32-, LED headlights with variable light distribution……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3197
1.12 Removing and installing side light bulb -M1-/-M3-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3199
1.13 Removing and installing daytime running light bulb -L174-/-L175-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3199
1.14 Removing and installing LED modules for daytime running light and side light -L176-/-L177-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3199
1.15 Removing and installing output module for headlight -J667-/-J668-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3200
1.16 Removing and installing output module 1 for left LED headlight -A27-/-A31-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3201
1.17 Removing and installing control motor sender for VARILIS headlight -G695-/-G696-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3202
1.18 Removing and installing control motor for VARILIS headlight -V446-/-V447-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3202
1.19 Removing and installing swivel module position sensor -G474-/-G475-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3203
1.20 Removing and installing dynamic cornering light control motor -V318-/-V319-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3203
2 Fog lights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3204
2.1 Assembly overview – fog lights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3204
2.2 Removing and installing fog light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3204
2.3 Removing and installing fog light bulb -L22-/-L23-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3205
3 Lights in exterior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3207
3.1 Assembly overview – lights in exterior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3207
3.2 Removing and installing turn signal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3208
3.3 Removing and installing entry light in exterior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3210
4 Tail lights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3211
4.1 Assembly overview – tail lights in body………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3211
4.1.1 Assembly overview – tail lights in body…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3211
4.1.2 Assembly overview – tail lights in vehicle body (LEDs)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3213
4.2 Assembly overview – tail lights in rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3214
4.2.1 Assembly overview – tail lights in rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3214
4.2.2 Assembly overview – tail lights in rear lid (LEDs)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3215
4.3 Removing and installing tail light in rear lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3215
4.4 Adjusting installation position of tail light…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3216
4.5 Removing and installing tail light………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3217
4.6 Removing and installing tail light bulb -M2-/-M4-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3218
4.6.1 Removing and installing tail light bulb -M2-/-M4-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3218
4.6.2 Removing and installing tail light bulb -M2-/-M4-, LED……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3219
4.7 Removing and installing rear fog light bulb -L46-/-L47-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3219
4.7.1 Removing and installing rear fog light bulb -L46-/-L47-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3219
4.7.2 Removing and installing rear fog light bulb -L46-/-L47-, LED………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3220
4.8 Removing and installing brake and tail light bulb -M21-/-M22-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3221
4.8.1 Removing and installing brake and tail light bulb -M21-/-M22-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3221
4.8.2 Removing and installing brake and tail light bulb -M21-/-M22-, LED…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3222
4.9 Removing and installing reversing light bulb -M16-/-M17-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3222
4.9.1 Removing and installing reversing light bulb -M16-/-M17-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3222
4.9.2 Removing and installing reversing light bulb -M16-/-M17-, LED…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3223
4.10 Removing and installing rear turn signal bulb -M6-/-M8-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3223
4.10.1 Removing and installing rear turn signal bulb -M6-/-M8-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3223
4.10.2 Removing and installing rear turn signal bulb -M6-/-M8-, body tail light cluster with LED……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3224
5 High-level brake light………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3226
5.1 Assembly overview – high-level brake light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3226
5.2 Removing and installing high-level brake light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3226
6 Number plate light………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3229
6.1 Assembly overview – number plate lights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3229
6.2 Removing and installing number plate light -X4-/-X5-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3229
6.3 Removing and installing bulb for number plate light -X4-/-X5-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3230
7 Entry and start authorisation system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3231
7.1 Overview of fitting locations – entry and start authorisation system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3231
7.1.1 Fitting locations overview – entry and start authorisation system, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3231
7.1.2 Fitting locations overview – entry and start authorisation system, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3233
7.2 Fitting locations overview – keyless entry system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3234
7.2.1 Fitting locations overview – front keyless entry system, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3234
7.2.2 Fitting locations overview – front keyless entry system, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3235
7.2.3 Fitting locations overview – rear keyless entry system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3236
7.3 Removing and installing interface for entry and start system -J965-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3236
7.4 Removing and installing door exterior handle contact sensor -G415-/-G416-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3238
7.5 Removing and installing contact sensor for rear exterior door handle -G417-/-G418-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3238
7.6 Removing and installing interior aerial 1 for entry and start authorisation -R138-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3238
7.7 Removing and installing interior aerial 2 for entry and start authorisation -R139-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3239
7.8 Removing and installing driver side aerial for entry and start system -R134-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3240
7.9 Removing and installing front passenger side aerial for entry and start system -R135-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3240
7.10 Removing and installing rear bumper aerial for entry and start system -R136-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3240
7.11 Removing and installing rear entry and start authorisation aerial -R165-/-R166-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3241
7.12 Removing and installing rear lid power opening control unit -J938-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3241
7.13 Removing and installing rear lid power opening sender -G750-/-G760-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3242
8 Steering column switch module………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3243
8.1 Assembly overview – steering column switch module…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3243
8.2 Removing and installing steering column switch module……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3244
8.3 Removing and installing steering column electronics control unit -J527-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3246
8.4 Removing and installing turn signal switch -E2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3250
8.5 Removing and installing intermittent wiper switch -E22-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3251
8.6 Removing and installing immobiliser reader coil -D2-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3251
8.7 Removing and installing base for steering column combination switch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3251
9 Parking aid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3253
9.1 Assembly overview – parking aid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3253
9.1.1 Assembly overview – front parking aid, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3253
9.1.2 Assembly overview – rear parking aid, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3255
9.1.3 Assembly overview – front parking aid, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3256
9.1.4 Assembly overview – rear parking aid, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3257
9.2 Removing and installing parking aid control unit -J446-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3257
9.2.1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3257
9.2.2 Removing and installing parking aid control unit -J446-, RHD vehicle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3258
9.3 Removing and installing front parking aid warning buzzer -H22-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3259
9.3.1 Removing and installing front parking aid warning buzzer -H22-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3259
9.3.2 Removing and installing front parking aid warning buzzer -H22-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3259
9.4 Removing and installing rear parking aid warning buzzer -H15-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3260
9.5 Removing and installing front parking aid senders…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3260
9.6 Removing and installing rear parking aid senders………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3261
10 Park assist steering……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3262
10.1 Assembly overview – park assist steering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3262
10.1.1 Assembly overview – park assist steering, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3262
10.1.2 Assembly overview – park assist steering, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3263
10.2 Removing and installing park assist steering control unit -J791-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3263
10.3 Removing and installing front senders…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3263
10.4 Removing and installing rear senders……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3264
11 Automatic headlight range control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3265
11.1 Assembly overview – automatic headlight range control…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3265
11.1.1 Assembly overview – automatic headlight range control, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3265
11.1.2 Assembly overview – automatic headlight range control, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3266
11.2 Removing and installing control unit for headlight range control -J431-/cornering light and headlight range control unit -J745-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3267
11.2.1 Removing and installing headlight range control unit -J431-/control unit for cornering light and headlight range control -J745-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3267
11.2.2 Removing and installing headlight range control unit -J431-/control unit for cornering light and headlight range control -J745-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3268
12 Towing bracket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3270
12.1 Assembly overview – towing bracket socket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3270
12.2 Trailer socket -U10-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3270
12.3 Removing and installing trailer detector control unit -J345-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3271
96 – Lights, bulbs, switches – interior…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3272
1 Lights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3273
1.1 Overview of fitting locations – lights in dash panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3274
1.2 Fitting locations overview – lights in front doors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3275
1.3 Fitting locations overview – lights in rear doors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3276
1.4 Overview of fitting locations – lights in centre console…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3277
1.5 Overview of fitting locations – lights in luggage compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3278
1.6 Overview of fitting locations – lights in roof trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3279
1.6.1 Overview of fitting locations – lights in roof trim, without panorama tilting sunroof……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3279
1.6.2 Overview of fitting locations – lights in roof trim, with panorama tilting sunroof………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3280
1.7 Removing and installing glove compartment light -W6-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3280
1.8 Replacing bulb for glove compartment light -W6-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3281
1.9 Removing and installing footwell light -W9-/-W10-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3281
1.9.1 Removing and installing footwell light -W9-, driver side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3281
1.9.2 Removing and installing footwell light -W10-, front passenger side…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3282
1.10 Removing and installing front footwell illumination bulb -L151-/-L152-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3282
1.11 Removing and installing central locking SAFELOCK function warning lamp -K133-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3282
1.12 Removing and installing light 2 for front door background lighting -L203-/-L204-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3283
1.13 Removing and installing front entry light -W31-/-W32-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3283
1.14 Removing and installing door warning lamp -W30-/-W36-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3285
1.15 Removing and installing rear entry light -W33-/-W34-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3285
1.16 Removing and installing rear door warning lamp -W37-/-W38-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3285
1.17 Removing and installing light 1 for front door background lighting -L199-/-L200-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3285
1.18 Removing and installing interior door handle illumination bulb -L146-/-L147-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3285
1.19 Removing and installing selector lever position display -Y26-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3286
1.20 Removing and installing luggage compartment light -W3-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3286
1.21 Removing and installing illuminated vanity mirror -W20-/-W14-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3287
1.22 Removing and installing bulb for front interior light -W1-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3287
1.23 Removing and installing bulb for rear interior light -W43-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3288
1.24 Removing and installing bulb for rear reading light -W11-/-W12-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3288
1.25 Removing and installing bulb for rear interior light -W47-/-W48-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3289
2 Controls…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3292
2.1 Overview of fitting locations – controls in dash panel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3293
2.2 Overview of fitting locations – controls in front doors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3295
2.3 Overview of fitting locations – controls in rear doors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3296
2.4 Overview of fitting locations – controls in centre console…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3297
2.5 Overview of fitting locations – controls in luggage compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3298
2.6 Overview of fitting locations – controls in roof trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3299
2.6.1 Overview of fitting locations – controls in roof trim, without panorama tilting sunroof………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3299
2.6.2 Overview of fitting locations – control elements in roof trim, with panoramic roof………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3300
2.7 Removing and installing rotary light switch -EX1-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3301
2.8 Removing and installing headlight range control adjuster -E102-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3302
2.9 Removing and installing button for Charisma -E735-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3302
2.10 Removing and installing Start/Stop operation button -E693-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3302
2.11 Removing and installing TCS and ESP button -E256-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3303
2.12 Removing and installing parking aid button -E266-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3303
2.13 Removing and installing park assist steering button -E581-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3303
2.14 Removing and installing switch module 1 in centre console -EX23-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3303
2.15 Removing and installing hazard warning light switch -EX3-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3304
2.16 Removing and installing buttons for seat heating -E653-/-E654-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3304
2.17 Removing and installing glove compartment light switch -E26-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3305
2.18 Removing and installing exterior mirror adjuster -EX11-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3305
2.19 Removing and installing operating unit for window regulator in driver door -E512-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3306
2.20 Removing and installing front passenger side window regulator button -E716-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3307
2.21 Removing and installing driver side interior locking button for central locking system -E308-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3307
2.22 Removing and installing rear lid remote release button -E233-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3308
2.23 Removing and installing button for deactivating interior monitoring and vehicle inclination sensor -E616-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3308
2.24 Removing and installing door contact switch -F2-/-F3-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3309
2.25 Removing and installing rear window regulator button -E711-/-E713-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3309
2.26 Removing and installing rear door contact switches -F10-/-F11-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3310
2.27 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3310
2.28 Removing and installing the starter button -E378-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3311
2.29 Removing and installing rear lid warning buzzer -H32-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3311
2.30 Removing and installing rear lid contact switch………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3312
2.31 Removing and installing rear lid closure button -E574-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3312
2.32 Removing and installing electric hinged tow coupling attachment button -E474-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3313
2.33 Removing and installing vanity mirror contact switch -F147-/-F148-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3314
2.34 Removing and installing sunroof button -E325-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3314
2.35 Removing and installing front interior light -WX1-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3315
2.36 Removing and installing rear interior light -WX2-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3316
2.37 Removing and installing front right reading light button -E634-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3317
2.38 Removing and installing front passenger side airbag deactivated warning lamp -K145-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3318
3 Anti-theft alarm system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3319
3.1 Assembly overview – interior monitor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3319
3.1.1 Assembly overview – interior monitoring, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3319
3.1.2 Assembly overview – interior monitoring, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3320
3.2 Removing and installing alarm horn -H12-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3320
3.3 Removing and installing anti-theft alarm sensor -G578-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3321
4 Lane change assist………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3323
4.1 Overview – lane change assist…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3323
4.2 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3324
4.3 Removing and installing lane change assist control unit -J769-/-J770-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3324
4.4 Calibrating lane change assist………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3325
4.4.1 Measurement location……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3325
4.4.2 Preparatory measures for calibration……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3326
4.4.3 Calibrating lane change assist control unit -J769-/-J770-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3330
5 Front camera for assist systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3332
5.1 Removing and installing front camera for driver assist systems……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3332
6 Cigarette lighter, socket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3333
6.1 Assembly overview – DC/AC converter with socket, 12 V – 230 V………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3333
6.2 Removing and installing cigarette lighter -U1-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3334
6.3 Removing and installing socket illumination bulb -L42-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3334
6.4 Removing and installing rear cigarette lighter illumination bulb -L32-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3334
6.5 Removing and installing electric socket -U-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3334
6.6 Removing and installing AC/DC converter with socket, 12 V – 230 V -U13-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3334
97 – Wiring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3337
1 Relay carriers, fuse holders, electronics boxes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3337
1.1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3337
1.1.1 Relay carriers, fuse carriers, electronics box (engine compartment)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3337
1.1.2 Relay carrier, fuse carrier in dash panel/A-pillar, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3339
1.1.3 Relay carrier, fuse carrier in dash panel/A-pillar, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3340
1.2 Removing and installing electronics box………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3340
1.3 Removing and installing relay and fuse holder in electronics box……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3342
1.3.1 Removing and installing fuse holder B -SB-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3342
1.3.2 Removing and installing fuse holder A -SA-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3343
1.4 Removing and installing relay and fuse carrier behind dash panel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3344
1.4.1 Removing and installing relay and fuse carrier behind dash panel, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3344
1.4.2 Removing and installing relay and fuse carrier behind dash panel, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3345
2 Control units………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3347
2.1 Overview of fitting locations – control units…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3347
2.1.1 Fitting locations overview – control units, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3347
2.1.2 Fitting locations overview – control units, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3349
2.2 Overview of fitting locations – control units…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3350
2.2.1 Fitting locations overview – control units, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3350
2.2.2 Fitting locations overview – control units, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3351
2.3 Assembly overview – data bus diagnostic interface…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3352
2.3.1 Assembly overview – data bus diagnostic interface, left-hand drive vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3352
2.3.2 Assembly overview – data bus diagnostic interface, right-hand drive vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3353
2.4 Removing and installing onboard supply control unit -J519-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3353
2.4.1 Removing and installing onboard supply control unit -J519-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3353
2.4.2 Removing and installing onboard supply control unit -J519-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3355
2.5 Removing and installing data bus diagnostic interface -J533-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3357
2.5.1 Removing and installing (left-hand drive models) data bus diagnostic interface -J533-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3357
2.5.2 Removing and installing data bus diagnostic interface -J533-, right-hand drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3357
2.6 Removing and installing bracket for onboard supply control unit -J519-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3358
2.6.1 Removing and installing bracket for onboard supply control unit -J519-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3358
2.6.2 Removing and installing bracket for onboard supply control unit -J519-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3359
2.7 Renewing bracket for onboard supply control unit -J519-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3360
2.7.1 Renewing bracket for onboard supply control unit -J519-, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3360
2.7.2 Renewing bracket for onboard supply control unit -J519-, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3360
2.8 Removing and installing parking aid control unit -J446-/park assist steering control unit -J791-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3360
2.9 Removing and installing rear lid control unit -J605-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3361
2.10 Removing and installing bracket for rear lid control unit -J605-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3361
3 Connectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3363
3.1 Repairing electrical wiring harnesses and electrical connectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3363
3.1.1 Repairs to wiring harnesses and connectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3363
3.1.2 Repairing connector housings and electrical connectors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3363
4 Releasing and dismantling connector housings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3364
5 Repairing aerial cables……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3365
6 Optical fibre conductor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3366
7 Vehicle diagnostic, testing and information systems…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3367
Touran2016-Emission_test_VW…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3368
AKP 6N Polo; manual gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3368
AKP 6N Polo; automatic gearbox…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3369
AVQ 1T Touran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3370
AXA 7F Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3371
AXB 7H Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3372
AXC 7H Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3373
AXE 7J Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3374
BDL 7H Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3375
BDL 7H Multivan …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3376
BJJ 2E Diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3377
BJJ 2F Diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3378
BPC 7J Transporter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3379
BSE 521 Golf Plus; ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3380
BSE 52 Golf Plus; ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3381
BSF 521 Golf Plus;……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3382
BSF 52 Golf Plus;………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3383
BSX 2C Caddy…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3384
BWS 362,365 Passat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3385
BWS 36 Passat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3386
BYD 1K Golf……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3387
BZB 35 Passat CC; injection and ignition system: Motronic MED 17.5…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3388
CAAA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3389
CAAA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3390
CAAA SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3391
CAAB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3392
CAAB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3393
CAAB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3394
CAAB 7F Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3395
CAAB 7F Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3396
CAAB SG T6 – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3397
CAAB SG T6 – 0GZ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3398
CAAB SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3399
CAAB SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3400
CAAB SF T6 (SF) – 0GZ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3401
CAAB SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3402
CAAC SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3403
CAAC SG T6 – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3404
CAAC SG T6 – 0GZ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3405
CAAC SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3406
CAAC SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3407
CAAC SF T6 (SF) – 0GZ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3408
CAAD 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3409
CAAD 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3410
CAAD 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3411
CAAE 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3412
CAAE 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3413
CAAE 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3414
CASA 7P Touareg; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3415
CAVD 517 Golf Cabrio; MED 17.5.10………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3416
CAVD 358 CC……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3417
CAWB 13 Scirocco; injection and ignition system: Motronic MED 17.5…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3418
CAWB 35 Passat CC; injection and ignition system: Motronic MED 17.5……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3419
CAXA 362,365 Passat; MED 9………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3420
CAXA 5N Tiguan; MED 9…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3421
CAXA 517 Golf Cabrio; MED 9.5.10…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3422
CAXA 16 Jetta; MED 17.05.20……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3423
CAYB AJ Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3424
CAYB 1T Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3425
CAYB 52 Golf Plus………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3426
CAYC 1K Jetta……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3427
CAYC AJ Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3428
CAYC 1T Touran…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3429
CAYC 3C,362,365 Passat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3430
CAYC 517 Golf convertible…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3431
CAYC 36 Passat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3432
CAYC 51 Golf convertible………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3433
CAYC 52 Golf Plus………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3434
CAYC 5C Beetle Cabriolet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3435
CAYC 16 Jetta……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3436
CAYC 52 Golf Plus………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3437
CAYD 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3438
CAYD 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3439
CAYD 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3440
CAYD 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3441
CAYD SA Caddy4 – 7MJ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3442
CAYD SA Caddy4 – 7MG……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3443
CAYD SA Caddy4 – 0GZ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3444
CAYD SA Caddy4 – 7MQ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3445
CAYE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3446
CAYE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3447
CAYE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3448
CAYE SA Caddy4 – 7MJ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3449
CBAC 357 CC; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3450
CBAC 3C Passat; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3451
CBDA 52 Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3452
CBDB 5K Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3453
CBDB 5M Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3454
CBDB 1K Golf Variant; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3455
CBDB 52 Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3456
CBDC 3C Passat; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3457
CBDC 5M Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3458
CBDC 52 Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3459
CBRA 1K Golf; Motronic ME 7.1.1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3460
CBZA AJ Golf Estate; Simos 10……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3461
CBZA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3462
CBZA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3463
CBZA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3464
CBZB 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3465
CBZB 517 Golf Cabrio; Simos 10…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3466
CBZB AJ5 Golf Estate; Simos 10…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3467
CBZB 1T Touran; Simos 10………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3468
CBZB 16 Jetta; Simos 10…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3469
CBZB 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3470
CBZB 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3471
CBZC 6R Polo; Simos 10……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3472
CCHB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3473
CCSA 5M,521 Golf Plus; …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3474
CCSA 52 Golf Plus; ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3475
CCZA 7N1 Sharan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3476
CCZA 7N Sharan…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3477
CCZA 35 CC………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3478
CCZA 16 Jetta……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3479
CCZB 357 CC……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3480
CCZB 362,365 Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3481
CCZB 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3482
CCZB 36 Passat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3483
CCZB 5N Tiguan;………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3484
CCZB 35 CC………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3485
CCZB 51 Golf convertible………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3486
CCZD 5N Tiguan;………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3487
CDAA 362,365 Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3488
CDAA 35 CC………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3489
CDAA 36 Passat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3490
CDAB 362,365 Passat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3491
CDAB 35 CC………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3492
CDAB 36 Passat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3493
CDBA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3494
CDCA 2H Diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3495
CDCA 2H Diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3496
CDCA 2H Diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3497
CDGA 362, 365 Passat; MED nutural gas………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3498
CDLA 13 Scirocco R……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3499
CDLC 13 Scirocco R……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3500
CDLC 5K Golf R…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3501
CDLF 5K Golf R…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3502
CDLG 5K Golf ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3503
CFCA 7E Transporter; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3504
CFCA SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3505
CFCA SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3506
CFFA 5K Golf; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3507
CFFA 5N Tiguan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3508
CFFA 1F Eos; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3509
CFFA 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3510
CFFA 36 Passat; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3511
CFFA 7N Sharan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3512
CFFB 5K Golf; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3513
CFFB 5N Tiguan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3514
CFFB 1F Eos; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3515
CFFB 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3516
CFFB 36 Passat; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3517
CFFB 7N Sharan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3518
CFFB 5C Beetle Cabriolet; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3519
CFFD 5N Tiguan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3520
CFFE 7N Sharan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3521
CFGB 7N Sharan; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3522
CFGC 13 Scirocco; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3523
CFGC 35 CC; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3524
CFGC 36 Passat Estate; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3525
CFGC 5N Tiguan; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3526
CFGC 7N Sharan; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3527
CFHB 5K Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3528
CFHB 5M Golf Plus; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3529
CFHB AJ Golf Variant; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3530
CFHB 13 Scirocco; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3531
CFHC 5K Golf Plus; Diesel-Direkteinspritzanlage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3532
CFHC AJ Golf Variant; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3533
CFHC 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3534
CFHC 13 Scirocco; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3535
CFHC 1T Touran; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3536
CFHC 51 Golf Cabriolet; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3537
CFHC 5M,52 Golf Plus; diesel direct injection system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3538
CFHC 52 Golf Plus; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3539
CFHC 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3540
CFHC 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3541
CFHC SA Caddy4 – 7MJ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3542
CFHE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3543
CFHE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3544
CFHE 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3545
CFHF 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3546
CFHF 1T Touran; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3547
CFHF 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3548
CFHF 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3549
CFHF SA Caddy4 – 7MJ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3550
CFJA 1T Touran; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3551
CFJA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3552
CFJA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3553
CFJB 1T Touran; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3554
CFPA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3555
CFPA S1 AMAROK…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3556
CFPA S1 AMAROK…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3557
CFWA 60 Polo KH IN……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3558
CFWA 6R Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3559
CGEA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3560
CGEA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3561
CGFA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3562
CGFA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3563
CGNA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3564
CGNA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3565
CGRA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3566
CGRA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3567
CGYA 35 Passat CC; CC…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3568
CHGA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3569
CHGA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3570
CHHA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3571
CHHB 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3572
CHPA 5G Golf; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3573
CHPA AU Golf; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3574
CHPA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3575
CHYA 121 up!…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3576
CHYA 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3577
CHYB 121 up!…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3578
CHYB 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3579
CHZB 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3580
CHZC 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3581
CHZG SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3582
CJGD 7P Touareg; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3583
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3584
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3585
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3586
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3587
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3588
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3589
CJKA 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3590
CJKA SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3591
CJKA SG T6 – 7GR…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3592
CJKA SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3593
CJKA SG T6 – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3594
CJKA SG T6 – 0GV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3595
CJKA SG T6 – 7MT…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3596
CJKB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3597
CJKB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3598
CJKB 7E Transporter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3599
CJKB SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3600
CJKB SG T6 – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3601
CJKB SG T6 – 7MT…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3602
CJKB SG T6 – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3603
CJKB SG T6 – 0GV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3604
CJKB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3605
CJKB SF T6 (SF) – 7MJ…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3606
CJKB SF T6 (SF) – 7MT…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3607
CJKB SF T6 (SF) – 0GG…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3608
CJKB SF T6 (SF) – 0GV…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3609
CJLA 60 Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3610
CJMA 7P Touareg; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3611
CJTA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3612
CJTA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3613
CJXC 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3614
CJZA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3615
CJZB BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3616
CJZC 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3617
CJZD 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3618
CKDA 7P Touareg; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3619
CKFC 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3620
CKFC 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3621
CKFC BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3622
CKMA 362,365 Passat; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3623
CKMA 357 Passat CC; MED 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3624
CKMA 358 CC……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3625
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3626
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3627
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3628
CKTB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3629
CKTC 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3630
CKTC 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3631
CKTC 2F Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3632
CKTC 2F Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3633
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3634
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3635
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3636
CKUB 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3637
CKUC 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3638
CLCA 2C Caddy……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3639
CLCA 1T Touran; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3640
CLHA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3641
CLHA 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3642
CLHA BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3643
CLHB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3644
CLHB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3645
CLHB BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3646
CLJA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3647
CLJA 5N Tiguan; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3648
CLLA 35 CC; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3649
CLLA 36 Passat; diesel direct injection system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3650
CLNA 60 Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3651
CLPA 64 Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3652
CMBA 5G Golf; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3653
CMKA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3654
CMKA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3655
CMKB 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3656
CMKB 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3657
CMSB 137 Scirocco; MED 9.5.10……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3658
CMSB 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3659
CMTA 7P5 Touareg…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3660
CMTA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3661
CMVA 3D Phaeton………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3662
CMXA 521 Golf Plus……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3663
CMXA 5K Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3664
CMXA 52 Golf Plus………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3665
CNEA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3666
CNEA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3667
CNEA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3668
CNEA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3669
CNEA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3670
CNFA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3671
CNFA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3672
CNFA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3673
CNFA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3674
CPGA 12 up!……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3675
CPTA 5G Golf; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3676
CPTA 6R Polo; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3677
CPVA 5G Golf; ME 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3678
CPVB 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3679
CPVB AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3680
CPVB BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3681
CPWA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3682
CPWA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3683
CPWA SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3684
CRBC 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3685
CRBC 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3686
CRBC BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3687
CRCA 7P Touareg; diesel direct injection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3688
CRGA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3689
CRKB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3690
CRKB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3691
CRKB BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3692
CRKB AM Golf Sportsvan; Diesel, Common Rail…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3693
CRLB 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3694
CRLB 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3695
CRLB BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3696
CRLB 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3697
CSCA 5K XL1; Diesel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3698
CSCA 6Z XL1; Diesel check according to sticker value…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3699
CSHA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3700
CSHA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3701
CSHA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3702
CSHA 2H Amarok…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3703
CSLB 2F Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3704
CSNA 2E Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3705
CSNA 2F Crafter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3706
CTHA 1F Eos; MED 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3707
CTHA 5N Tiguan; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3708
CTHA 7N Sharan; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3709
CTHB 1T Touran; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3710
CTHC 1T Touran; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3711
CTHD 1F Eos; MED 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3712
CTHD 358 CC; MED 17………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3713
CTHD 36 Passat; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3714
CTHD 52 Golf Plus; MED 17…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3715
CTHD 5K Golf; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3716
CTHD 5N Tiguan; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3717
CTHE 6R Polo; MED 17……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3718
CTKA 51 Golf convertible………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3719
CTKA 52 Golf Plus………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3720
CTKA 5K Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3721
CTKA 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3722
CUAA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3723
CUKB 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3724
CULA 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3725
CULC 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3726
CUNA 5K Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3727
CUNA 5G Golf; Diesel, Common Rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3728
CUNA BA Golf Estate; Diesel, Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3729
CUPA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3730
CUSA 6C Polo; Diesel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3731
CUSB 6C Polo; Diesel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3732
CUTA 6C Polo; Diesel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3733
CUUA 517 Golf Cabriolet; Diesel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3734
CUUB 517 Golf Cabriolet; Diesel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3735
CUUB 138 Scirocco; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3736
CUUB SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3737
CUUD SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3738
CUUE SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3739
CUUF SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3740
CUVA 7N2 Sharan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3741
CUVC 5N2 Tiguan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3742
CUVC 358 CC; Diesel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3743
CUVC 7N2 Sharan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3744
CUVE 5N2 Tiguan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3745
CUWA 5N2 Tiguan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3746
CUWA 7N2 Sharan; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3747
CUWA 358 CC; Diesel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3748
CUWA 138 Scirocco; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3749
CUXA 138 Scirocco; Diesel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3750
CWVA 5G Golf ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3751
CWVA AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3752
CWVA BA Golf Variant …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3753
CWVA 61 Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3754
CWVB 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3755
CXEB SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3756
CXEB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3757
CXFA SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3758
CXGA SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3759
CXGA SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3760
CXGB SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3761
CXGB SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3762
CXHA SG T6 – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3763
CXHA SF T6 (SF) – 7MM…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3764
CXSA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3765
CYJA 7P Touareg………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3766
CYVA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3767
CYVA AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3768
CYVA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3769
CYVB 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3770
CYVB AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3771
CYVB BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3772
CYVC SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3773
CYVD 517 Golf convertible…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3774
CZCA 13 Scirocco…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3775
CZCA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3776
CZCA AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3777
CZCA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3778
CZCA 3G Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3779
CZCA 517 Golf convertible…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3780
CZCA SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3781
CZCB SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3782
CZDA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3783
CZDA AM Golf SV………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3784
CZDA BA Golf Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3785
CZDA 5N2 Tiguan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3786
CZDA 358 CC……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3787
CZDA 517 Golf convertible…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3788
CZDA 7N2 Sharan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3789
CZDB 5N2 Tiguan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3790
CZEA 5G Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3791
CZEA 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3792
CZEA 3G Passat, Passat Estate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3793
DAJA 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3794
DAJB 6C Polo…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3795
DCXA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3796
DDAA 3G Passat; Common Rail……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3797
DFSC SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3798
DFSD SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3799
DFSE SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3800
DFSF SA Caddy4 – 7MM……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3801
Touran2016-Fuel_supply_system_-_Diesel_engines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3802
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3806
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3806
1.1 Safety precautions when working on fuel supply system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3806
1.2 Safety precautions when working on vehicles with a start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3807
1.3 Safety precautions during road tests in which test and measuring equipment is used……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3807
1.4 Safety precautions when working on the SCR system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3807
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3809
2.1 Engine number, engine data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3809
3 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3810
3.1 Cleanliness specifications for working on the auxiliary heater and fuel system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3810
4 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3811
4.1 Routing and securing lines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3811
4.2 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3811
20 – Fuel supply system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3812
1 Procedure when filling with incorrect fuel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3812
1.1 Step 1, engine was started with incorrect fuel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3812
1.2 Step 2, engine was not started with incorrect fuel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3814
1.3 Step 3, there are metal particles in fuel delivery unit and fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3816
1.4 Step 4, there are no metal particles in fuel delivery unit or fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3817
1.5 Step 5, there are metal particles in high-pressure pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3818
1.6 Step 6, there are no metal particles in high-pressure pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3818
2 Fuel tank………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3820
2.1 Assembly overview – fuel tank…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3820
2.1.1 Assembly overview – fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3820
2.2 Removing and installing fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3821
2.3 Emptying fuel tank…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3828
2.3.1 Emptying fuel tank when fuel pump is intact…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3828
2.3.2 Emptying fuel tank if it is more than 3/4 full………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3830
2.3.3 Emptying fuel tank if it is less than 3/4 full………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3831
2.4 Removing and installing misfuelling prevention device……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3833
2.4.1 Removing and installing misfuelling prevention device, plastic cap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3833
2.4.2 Removing and installing misfuelling prevention device, metal cap………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3836
2.5 Deactivating misfuelling prevention device……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3837
2.5.1 Deactivating the misfuelling prevention device, plastic cap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3837
2.5.2 Deactivating the misfuelling prevention device, metal cap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3837
3 Fuel delivery unit/fuel gauge sender………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3838
3.1 Assembly overview – fuel delivery unit/fuel gauge sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3838
3.1.1 Assembly overview – fuel delivery unit/fuel gauge sender……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3838
3.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3840
3.2 Removing and installing fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3840
3.2.1 Removing and installing fuel delivery unit, fuel gauge sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3840
3.2.2 Removing and installing fuel line for auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3845
4 Plug-in connectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3847
4.1 Separating plug-in connectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3847
5 Fuel filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3851
5.1 Assembly overview – fuel filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3851
5.1.1 Assembly overview – fuel filter, version 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3851
5.1.2 Assembly overview – fuel filter, version 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3853
5.2 Removing and installing fuel filter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3854
5.3 Fuel hoses in the engine compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3857
6 Accelerator mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3858
6.1 Assembly overview – accelerator pedal module……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3858
6.2 Removing and installing accelerator pedal module -GX2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3859
7 Fuel pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3860
7.1 Checking fuel system pressurisation pump -G6-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3860
7.1.1 Checking fuel pressure……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3860
7.1.2 Checking fuel delivery rate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3866
7.2 Removing and installing fuel pump control unit -J538-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3873
8 Senders and sensors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3875
8.1 Removing and installing fuel gauge sender -G-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3875
Touran2016-Fuel_supply_system_-_petrol_engines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3876
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3880
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3880
1.1 Safety precautions when working on fuel supply system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3880
1.2 Safety precautions during road tests in which test and measuring equipment is used……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3880
1.3 Safety precautions when working on vehicles with a start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3881
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3882
2.1 Engine number, engine data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3882
3 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3883
3.1 Cleanliness specifications for working on the auxiliary heater and fuel system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3883
4 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3884
4.1 Routing and securing lines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3884
4.2 General repair notes…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3884
20 – Fuel supply system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3885
1 Fuel tank………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3885
1.1 Assembly overview – fuel tank…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3885
1.1.1 Assembly overview – fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3885
1.2 Removing and installing fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3886
1.2.1 Removing and installing fuel tank………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3886
1.3 Emptying fuel tank…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3894
1.3.1 Emptying fuel tank when fuel pump is intact…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3894
1.3.2 Emptying fuel tank if it is more than 3/4 full………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3897
1.3.3 Emptying fuel tank if it is less than 3/4 full………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3899
2 Fuel delivery unit/fuel gauge sender………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3902
2.1 Assembly overview – fuel delivery unit/fuel gauge sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3902
2.1.1 Assembly overview – fuel delivery unit/fuel gauge sender……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3902
2.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3904
2.2 Removing and installing fuel delivery unit, fuel gauge sender………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3904
2.2.1 Removing and installing fuel delivery unit, fuel gauge sender…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3904
2.2.2 Removing and installing fuel line for auxiliary/supplementary heater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3908
3 Plug-in connectors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3911
3.1 Separating plug-in connectors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3911
4 Fuel filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3915
5 Activated charcoal filter system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3916
5.1 Assembly overview – activated charcoal filter system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3916
5.2 Removing and installing activated charcoal filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3917
5.3 Checking fuel tank breather…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3918
6 Accelerator mechanism……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3924
6.1 Assembly overview – accelerator pedal module……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3924
6.2 Removing and installing accelerator pedal module -GX2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3925
7 Fuel pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3926
7.1 Checking fuel system pressurisation pump -G6-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3926
7.1.1 Checking operation and power supply of fuel pump…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3926
7.1.2 Checking fuel pressure……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3930
7.1.3 Checking holding pressure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3933
7.1.4 Checking fuel delivery rate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3937
7.2 Removing and installing fuel pump control unit -J538-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3943
8 Senders and sensors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3945
8.1 Removing and installing fuel gauge sender -G-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3945
Touran2016-General_body_repairs__exterior………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3946
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3954
1 Safety information………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3954
1.1 Safety measures when working on vehicles with a start-stop system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3954
1.2 Safety measures when working with pyrotechnic components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3954
1.3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3956
1.4 Safety regulations for crash sensors (pressure sensors)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3956
1.5 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3957
1.6 Checking airbag securing parts after an accident………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3957
1.7 Accident without airbag triggering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3958
50 – Body – front………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3959
1 Lock carrier……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3959
1.1 Assembly overview – lock carrier………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3959
1.2 Removing and installing lock carrier…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3960
1.3 Moving to and back from service position…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3962
1.4 Repairing lock carrier…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3966
1.4.1 Left headlight mounting…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3966
1.4.2 Right headlight mounting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3968
2 Wing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3969
2.1 Assembly overview – wing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3969
2.2 Removing and installing wing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3969
3 Plenum chamber bulkhead……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3974
3.1 Assembly overview – plenum chamber bulkhead………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3974
3.1.1 Assembly overview – bulkhead, left-hand drive vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3974
3.1.2 Assembly overview – bulkhead, right-hand drive vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3975
3.2 Assembly overview – plenum chamber cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3976
3.3 Removing and installing plenum chamber bulkhead…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3976
3.3.1 Removing and installing bulkhead, left-hand drive vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3976
3.3.2 Removing and installing bulkhead, right-hand drive vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3978
3.4 Removing and installing plenum chamber cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3979
3.4.1 Removing and installing plenum chamber cover, left-hand drive vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3979
3.4.2 Removing and installing plenum chamber cover, right-hand drive vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3982
55 – Bonnet, rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3985
1 Bonnet…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3985
1.1 Assembly overview – bonnet……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3985
1.1.1 Assembly overview – bonnet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3985
1.1.2 Assembly overview – active bonnet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3987
1.2 Assembly overview – Bowden cable………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3988
1.3 Assembly overview – gas strut…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..3989
1.4 Removing and installing bonnet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3989
1.5 Adjusting bonnet………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3992
1.6 Removing and installing rear lid lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………3999
1.6.1 Removing and installing bonnet lock, LHD vehicle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….3999
1.6.2 Removing and installing bonnet lock, RHD vehicle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4001
1.7 Removing and installing bonnet release lever……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4004
1.8 Removing and installing striker pin……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4005
1.9 Removing and installing hinges………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4007
1.9.1 Removing and installing hinge……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4007
1.9.2 Removing and installing active hinge……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4009
1.9.3 Removing and installing trigger unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4012
1.10 Removing and installing insulation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4015
1.11 Removing and installing gas strut………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4017
1.12 Releasing gas from gas strut…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4018
1.13 Removing and installing Bowden cable……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4018
2 Rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4022
2.1 Assembly overview – rear lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4022
2.2 Removing and installing rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4023
2.3 Adjusting rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4025
2.4 Removing and installing rear lid lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4032
2.4.1 Removing and installing rear lid lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4032
2.4.2 Removing and installing rear lid lock with power latching system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4034
2.4.3 Installing new rear lid lock with power latching system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4039
2.4.4 Removing and installing power latching system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4040
2.4.5 Installing new power latching system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4043
2.5 Removing and installing operating mechanism………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4044
2.6 Removing and installing hinges………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4045
2.7 Removing and installing striker pin……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4048
2.8 Removing and installing rear lid seal……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4049
2.9 Removing and installing gas strut……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4051
2.10 Releasing gas from gas strut…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4053
2.11 Removing and installing drive unit for rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4053
2.11.1 Removing and installing drive for rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4053
2.11.2 Removing and installing pinch protection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4055
3 Tank flap unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4058
3.1 Assembly overview – tank flap unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4058
3.2 Removing and installing tank flap unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4058
3.3 Removing and installing fuel tank flap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4061
3.4 Removing and installing actuator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4064
57 – Front doors, door components, central locking…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4065
1 Door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4065
1.1 Assembly overview – door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4065
1.2 Removing and installing door inner seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4067
1.3 Removing and installing door outer seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4069
1.4 Removing and installing door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4071
1.5 Adjusting door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4074
1.6 Adjusting striker pin………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4077
1.7 Removing and installing door arrester……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4079
2 Door components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4082
2.1 Assembly overview – door components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4082
2.2 Assembly overview – window regulator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4085
2.3 Assembly overview – door handle and door lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4086
2.4 Removing and installing window regulator motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4087
2.5 Removing and installing window regulator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4089
2.6 Removing and installing inner door cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4092
2.7 Removing and installing striker pin……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4094
2.8 Removing and installing cover cap, for lock cylinder………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4096
2.9 Removing and installing cover cap, without lock cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4097
2.10 Removing and installing lock cylinder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4101
2.11 Removing and installing door handle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4104
2.12 Removing and installing mounting bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4106
2.13 Removing and installing door lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4108
2.14 Removing and installing window channel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4113
2.15 Removing and installing window slot outer seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4116
2.16 Removing and installing window slot inner seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4118
3 Central locking…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4119
3.1 Overview of fitting locations – central locking…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4119
3.2 Removing and installing ignition key battery……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4121
3.3 Removing and installing cap on ignition key………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4123
58 – Rear doors, door components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4124
1 Door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4124
1.1 Assembly overview – door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4124
1.2 Removing and installing door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4126
1.3 Adjusting door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4128
1.4 Adjusting striker pin………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4130
1.5 Removing and installing door arrester……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4133
1.6 Removing and installing door inner seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4135
1.7 Removing and installing door outer seal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4137
2 Door components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4140
2.1 Assembly overview – door components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4140
2.2 Assembly overview – window regulator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4142
2.3 Assembly overview – door handle and door lock…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4143
2.4 Removing and installing window regulator motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4143
2.5 Removing and installing window regulator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4146
2.6 Removing and installing inner door cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4149
2.7 Removing and installing striker pin……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4151
2.8 Removing and installing cap…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4153
2.9 Removing and installing door handle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4157
2.10 Removing and installing mounting bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4159
2.11 Removing and installing door lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4162
2.12 Removing and installing door padding……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4166
2.13 Removing and installing window channel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4168
2.14 Removing and installing window slot outer seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4171
2.15 Removing and installing window slot inner seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4172
60 – Sunroof…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4174
1 Sliding sunroof…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4174
1.1 Assembly overview – sliding sunroof……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4174
1.2 Assembly overview – sunroof roller blind…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4176
1.3 Assembly overview – wind deflector………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4177
1.4 Removing and installing sliding sunroof cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4177
1.5 Removing and installing rear sliding sunroof cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4181
1.6 Adjusting sliding sunroof cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4185
1.6.1 Checking height adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4185
1.6.2 Adjusting front sliding sunroof cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4187
1.6.3 Adjusting rear sliding sunroof cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4188
1.7 Removing and installing sliding sunroof frame…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4189
1.8 Removing and installing wind deflector…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4192
1.9 Removing and installing -J245-sliding sunroof adjustment control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4196
1.10 Removing and installing sunroof roller blind motor -V260-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4198
1.11 Removing and installing roller blind adjustment control unit -J394-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4200
1.12 Operating without current……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4201
1.12.1 Operating without current – sliding roof panel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4201
1.12.2 Operating without current – sunroof roller blind……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4203
1.13 Removing and installing sliding sunroof seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4204
1.13.1 Removing and installing seal for sliding sunroof frame………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4204
1.13.2 Removing and installing glass panel seal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4206
1.14 Removing and installing sunroof roller blind…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4207
1.15 Programming sliding sunroof adjustment control unit -J245-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4212
1.16 Adapting sunroof roller blind control unit -J394-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4213
2 Water drain hoses…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4214
2.1 Assembly overview – water drainage hoses…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4214
2.2 Cleaning water drain hoses……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4214
2.3 Removing and installing water drain hoses………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4216
63 – Bumpers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4218
1 Front bumper……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4218
1.1 Assembly overview – bumper cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4218
1.1.1 Assembly overview – bumper cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4218
1.1.2 Assembly overview – bumper cover with components for pedestrian protection system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4220
1.2 Assembly overview – add-on parts………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4221
1.3 Assembly overview – impact bar………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4222
1.4 Removing and installing bumper cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4222
1.5 Repairing bumper cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4226
1.6 Installing brackets for parking aid system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4226
2 Rear bumper………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4232
2.1 Assembly overview – bumper cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4232
2.2 Assembly overview – guides for bumper cover………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4233
2.3 Assembly overview – add-on parts………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4234
2.4 Assembly overview – impact bar………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4235
2.5 Removing and installing bumper cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4235
2.6 Removing and installing impact bar………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4238
2.7 Repairing bumper cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4239
2.8 Installing brackets for parking aid system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4239
64 – Glazing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4246
1 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4246
1.1 Minimum curing periods for bonded windows………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4246
1.2 Window repair…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4246
1.3 Installation instructions for bonded windows……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4247
1.3.1 Installation instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4247
1.3.2 Materials……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4247
1.4 Preparing old undamaged windows for fitting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4248
1.5 Preparing new windows for installing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4248
1.6 Preparing body flange for fitting……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4250
1.7 Cleaning off excess adhesive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4251
2 Windscreen…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4252
2.1 Assembly overview – windscreen………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4252
2.2 Removing and installing windscreen………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4253
2.2.1 Removing and installing windscreen…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4253
2.2.2 Removing broken windscreen………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4259
3 Rear window………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4260
3.1 Assembly overview – rear window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4260
3.2 Removing and installing rear window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4261
3.2.1 Removing and installing rear window………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4261
3.2.2 Removing broken rear window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4264
4 Side windows……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4265
4.1 Assembly overview – front side window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4265
4.2 Assembly overview – rear side windows……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4266
4.3 Removing and installing front side window………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4266
4.3.1 Removing and installing front side window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4266
4.3.2 Removing broken front side window………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4269
4.4 Removing and installing rear side window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4270
4.4.1 Removing and installing rear side window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4270
4.4.2 Removing broken rear side window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4274
5 Door windows……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4275
5.1 Assembly overview – front door window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4275
5.2 Assembly overview – rear door window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4276
5.3 Removing and installing front door window………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4276
5.4 Removing and installing rear door window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4280
5.5 Removing and installing fixed rear door window……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4284
66 – Exterior equipment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4286
1 Radiator grille and front trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4286
1.1 Assembly overview – radiator grille……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4286
1.2 Removing and installing radiator grille………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4286
2 Spoiler……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4289
2.1 Assembly overview – side spoiler………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4289
2.2 Removing and installing side spoiler…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4289
3 Mouldings, trims, extensions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4293
3.1 Assembly overview – water deflector……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4293
3.2 Assembly overview – heat shield…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4294
3.3 Removing and installing water deflector………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4295
3.4 Removing and installing B-pillar trim on front door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4296
3.5 Removing and installing B-pillar trim on rear door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4297
3.6 Removing and installing trim strip………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4298
3.6.1 Removing and installing window channel trim strip of front door……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4298
3.6.2 Removing and installing window channel trim strip of rear door………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4299
3.7 Removing and installing entry moulding…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4299
3.7.1 Fitting notes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4299
3.7.2 Removing and installing outer sill panel trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4300
3.8 Removing and installing underbody heat shield…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4302
3.8.1 Removing and installing underbody heat shield……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4302
3.8.2 Removing and installing heat shield for centre exhaust system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4303
3.8.3 Removing and installing heat shield for rear silencer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4304
4 Noise insulation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4306
4.1 Assembly overview – noise insulation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4306
4.1.1 Assembly overview – short noise insulation………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4306
4.1.2 Assembly overview – long noise insulation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4307
4.1.3 Assembly overview – skid plate…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4308
5 Underbody cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4309
5.1 Assembly overview – underbody cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4309
5.2 Removing and installing underbody panels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4310
5.2.1 Removing and installing underbody panel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4310
5.2.2 Removing and installing centre underbody covers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4312
5.2.3 Removing and installing short centre underbody cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4312
5.2.4 Removing and installing rear underbody panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4314
5.3 Removing and installing tunnel cross-piece……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4315
6 Roof moulding and roof railing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4318
6.1 Assembly overview – roof railing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4318
6.2 Removing and installing roof railing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4319
7 Exterior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4320
7.1 Assembly overview – exterior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4320
7.2 Removing and installing exterior mirror………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4321
7.2.1 Removing and installing exterior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4321
7.2.2 Preparing exterior mirror for painting……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4323
7.3 Removing and installing mirror glass…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4323
7.4 Removing and installing mirror adjustment unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4325
7.5 Removing and installing mirror cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4327
7.6 Removing and installing mirror trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4328
8 Wheel housing liner…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4330
8.1 Assembly overview – front wheel housing liner…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4330
8.2 Assembly overview – rear wheel housing liner……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4331
8.3 Removing and installing front wheel housing liner…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4332
8.4 Removing and installing rear wheel housing liner………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4334
9 Lettering and emblems……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4336
9.1 Dimensions – lettering and emblems on rear lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4336
9.1.1 Removing and installing bonded lettering……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4336
9.1.2 Dimensions – lettering on rear lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4337
9.2 Dimensions – lettering and emblems on wing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4338
9.3 Removing and installing emblems at vehicle front………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4339
9.4 Renewing lettering and emblems for rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4340
10 Towing bracket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4342
10.1 Assembly overview – towing bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4342
10.2 Removing and installing towing bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4342
10.3 Removing and installing trigger unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4345
Touran2016-General_body_repairs__interior………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4347
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4355
1 Safety information………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4355
1.1 Safety measures when working on vehicles with a start-stop system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4356
1.2 Safety measures when working with pyrotechnic components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4357
1.3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4358
1.4 Additional safety regulations for side airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4359
1.5 Additional safety instructions for curtain airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4359
1.6 Safety regulations for crash sensors (pressure sensors) for front side airbags……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4360
1.7 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4360
1.8 Checking airbag securing parts after an accident………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4362
1.9 Accident without airbag triggering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4363
1.10 Checking seat belts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4363
1.11 Checking belt webbing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4363
1.12 Checking inertia reel (locking mechanism)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4364
1.13 Visually inspecting belt buckle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4365
1.14 Checking operation of belt buckle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4365
1.15 Checking belt guide fittings and latch plates……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4365
1.16 Checking securing parts and anchorage points after an accident…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4366
1.17 Checking seat belt restraint function for holding additional child seats (not for driver’s seat belt) – country-specific…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4366
1.18 Checking child seat anchors after an accident……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4366
2 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4368
2.1 Contact corrosion……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4368
2.2 Routing and securing wires……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4368
68 – Interior equipment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4369
1 Compartments/covers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4369
1.1 Assembly overview – storage compartment in headliner………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4369
1.2 Removing and installing upper steering column trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4370
1.3 Removing and installing lower steering column trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4371
1.4 Removing and installing dash panel cover on driver’s side………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4373
1.5 Removing and installing glove compartment opener………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4375
1.6 Service position for glove compartment lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4377
1.7 Removing and installing damper element for glove compartment lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4377
1.8 Removing and installing glove compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4378
1.9 Removing and installing glove compartment lid…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4380
1.10 Removing and installing headliner storage compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4380
2 Equipment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4382
2.1 Assembly overview – sun visors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4382
2.2 Removing and installing retainers for net partition……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4383
2.3 Removing and installing sun visor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4383
2.4 Removing and installing sun visor centre mount……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4385
2.5 Removing and installing roof grab handle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4386
2.6 Removing and installing bracket for roof grab handle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4388
3 Centre console……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4390
3.1 Removing and installing centre console trim in footwell……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4390
3.2 Removing and installing trim for operating and display unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4391
3.3 Removing and installing centre console…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4393
3.4 Removing and installing centre console bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4401
3.4.1 Centre console bracket, removing and installing mounting bracket and insulation for selector mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4401
3.5 Removing and installing rear centre console trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4403
3.6 Removing and installing centre console insert…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4405
4 Front centre armrest………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4408
4.1 Removing and installing front centre armrest……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4408
5 Interior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4411
5.1 Assembly overview – interior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4411
5.1.1 Assembly overview – manually operated anti-dazzle interior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4411
5.1.2 Assembly overview – automatic anti-dazzle interior mirror, without front camera for driver assist systems -R242-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4412
5.1.3 Assembly overview – automatic anti-dazzle interior mirror, with front camera for driver assist systems -R242-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4413
5.2 Removing and installing interior mirror………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4413
5.2.1 Removing and installing manually operated anti-dazzle interior mirror………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4413
5.2.2 Removing and installing automatic anti-dazzle interior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4415
5.2.3 Bonding retaining plate for manually operated anti-dazzle interior mirror………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4417
5.2.4 Bonding retaining plate for automatic anti-dazzle interior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4419
69 – Passenger protection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4421
1 Seat belts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4421
1.1 Overview of fitting locations – seat belts and anchorage points…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4421
1.2 Assembly overview – front three-point seat belt…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4424
1.3 Assembly overview – rear outer three-point seat belt, 2nd row………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4425
1.4 Assembly overview – rear outer three-point seat belt, 3rd row………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4426
1.5 Assembly overview – rear three-point seat belt, roof cross member…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4427
1.6 Assembly overview – front belt buckle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4428
1.7 Assembly overview – rear belt buckle, 2nd row…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4429
1.8 Assembly overview – rear belt buckle, 3rd row…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4430
1.9 Removing and installing front three-point seat belt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4430
1.10 Removing and installing rear three-point seat belt, 2nd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4433
1.11 Removing and installing rear three-point seat belt, 3rd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4435
1.12 Removing and installing rear centre three-point seat belt, roof cross member………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4436
1.13 Removing and installing front belt guide………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4437
1.14 Removing and installing front belt end fitting…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4437
1.15 Removing and installing rear outer belt end fitting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4438
1.16 Removing and installing belt height adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4438
1.17 Removing and installing front belt buckle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4440
1.18 Removing and installing rear belt buckles, 2nd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4441
1.19 Removing and installing rear belt buckles, 3rd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4441
2 Child seat anchors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4442
2.1 Assembly overview – rear child seat anchors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4442
2.2 Removing and installing guide for ISOFIX child seat anchor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4443
2.3 Removing and installing cover for Top Tether child seat anchor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4443
3 Airbag system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4444
3.1 Airbag system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4444
4 Airbag control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4446
4.1 Assembly overview – airbag control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4446
4.2 Removing and installing airbag control unit -J234-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4446
5 Battery isolator igniter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4450
5.1 Assembly overview – battery isolator igniter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4450
5.2 Removing and installing battery isolator igniter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4450
6 Driver’s airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4453
6.1 Assembly overview – driver side airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4453
6.2 Removing and installing airbag unit with igniter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4454
6.3 Renewing connector on airbag……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4459
7 Front passenger side airbag………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4461
7.1 Assembly overview – front passenger side airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4461
7.2 Removing and installing front passenger side airbag unit with igniter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4462
7.3 Removing and installing key-operated switch to deactivate front passenger airbag……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4464
7.4 Removing and installing front passenger side airbag deactivated warning lamp -K145-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4465
8 Side airbags……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4466
8.1 Assembly overview – front side airbag……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4466
8.2 Assembly overview – rear side airbag…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4467
8.3 Removing and installing front side airbag with igniter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4467
8.4 Removing and installing rear side airbag with igniter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4469
9 Curtain airbags…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4472
9.1 Assembly overview – curtain airbag………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4472
9.2 Removing and installing curtain airbag with igniter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4472
10 Knee airbags………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4477
10.1 Assembly overview – knee airbag………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4477
10.2 Removing and installing knee airbag with igniter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4478
11 Airbag crash sensors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4481
11.1 Installation location overview – airbag crash sensors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4481
11.2 Removing and installing front airbag crash sensor, driver side -G190-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4482
11.3 Removing and installing front side airbag crash sensor -G179-/-G180-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4484
11.4 Removing and installing rear side airbag crash sensor -G256-/-G257-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4487
12 Seat belt verification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4490
12.1 Removing and installing seat occupied sensor, front passenger side -G128-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4490
13 Pedestrian protection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4492
13.1 Assembly overview – pedestrian protection……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4492
13.2 Removing and installing centre crash sensor for pedestrian protection -G693-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4493
13.3 Removing and installing driver side crash sensor 2 for pedestrian protection -G851-/front passenger side crash sensor 2 for pedestrian protection -G852-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4494
13.4 Removing and installing trigger for pedestrian protection -G598-/-G599-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4496
70 – Trim, insulation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4499
1 Front door trims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4499
1.1 Assembly overview – front door trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4499
1.2 Removing and installing door trim at front……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4500
1.3 Removing and installing mirror cover trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4505
1.4 Removing and installing inner door handle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4505
1.5 Removing and installing trim panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4507
2 Rear door trims…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4510
2.1 Assembly overview – rear door trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4510
2.2 Assembly overview – sun blind for door window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4511
2.3 Removing and installing rear door trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4511
2.4 Removing and installing inner door handle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4515
2.5 Removing and installing trim panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4517
2.6 Removing and installing sun blind for door window…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4519
2.7 Removing and installing eyelet for sun blind……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4520
3 Dash panel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4521
3.1 Removing and installing dash panel side cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4521
3.2 Removing and installing light switch trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4521
3.3 Removing and installing radio/navigation system blanking plate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4522
3.4 Removing and installing dash panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4523
3.5 Removing and installing dash panel trim panel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4533
3.6 Removing and installing dash panel vents…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4539
4 Dash panel central tube……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4541
4.1 Assembly overview – dash panel central tube………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4541
4.2 Removing and installing crash bar……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4542
4.3 Removing and installing dash panel central tube…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4543
5 Interior trims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4549
5.1 Overview of fitting locations – interior trims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4549
5.2 Assembly overview – sill panel moulding………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4551
5.3 Assembly overview – A-pillar trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4552
5.3.1 Assembly overview – A-pillar trim, upper A-pillar trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4552
5.3.2 Assembly overview – A-pillar trim, lower A-pillar trim, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4553
5.3.3 Assembly overview – A-pillar trim, lower A-pillar trim, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4554
5.4 Assembly overview – B-pillar trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4555
5.5 Assembly overview – C-pillar trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4556
5.6 Assembly overview – D-pillar trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4557
5.7 Assembly overview – foot rest and floor covering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4558
5.7.1 Assembly overview – foot rest and floor covering, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4558
5.7.2 Assembly overview – foot rest and floor covering, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4559
5.8 Removing and installing sill panel strip…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4559
5.9 Removing and installing A-pillar gap cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4561
5.10 Removing and installing A-pillar trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4562
5.10.1 Removing and installing A-pillar trim, upper A-pillar trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4562
5.10.2 Removing and installing A-pillar trim, lower A-pillar trim, driver side, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4564
5.10.3 Removing and installing A-pillar trim, lower A-pillar trim, driver side, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4566
5.10.4 Removing and installing A-pillar trim, lower A-pillar trim, front passenger side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4568
5.11 Removing and installing B-pillar trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4569
5.12 Removing and installing C-pillar trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4573
5.13 Removing and installing D-pillar trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4575
5.14 Removing and installing foot rest………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4576
5.14.1 Removing and installing foot rest, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4576
5.14.2 Removing and installing foot rest, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4577
5.15 Removing and installing floor covering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4578
6 Luggage compartment trims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4580
6.1 Overview of fitting locations – luggage compartment trims………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4580
6.1.1 Overview of fitting locations – luggage compartment trim, 5-seater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4580
6.1.2 Overview of fitting locations – luggage compartment trim, 7-seater…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4582
6.2 Assembly overview – luggage compartment side trim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4583
6.3 Assembly overview – luggage compartment floor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4584
6.3.1 Assembly overview – luggage compartment floor, 5-seater………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4584
6.3.2 Assembly overview – luggage compartment floor, 5-seater Vario…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4585
6.3.3 Assembly overview – luggage compartment floor, 7-seater………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4586
6.4 Assembly overview – lower rear lid trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4587
6.5 Assembly overview – upper rear lid trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4588
6.6 Removing and installing lower rear lid trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4588
6.7 Removing and installing upper trim on rear lid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4590
6.8 Removing and installing luggage compartment side trim panel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4592
6.9 Removing and installing luggage compartment cover…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4594
6.10 Removing and installing lock carrier trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4594
6.11 Removing and installing fastening rings…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4595
6.12 Removing and installing support for luggage compartment floor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4596
6.13 Removing and installing retaining rail………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4597
7 Roof trims…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4599
7.1 Assembly overview – moulded headliner……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4599
7.2 Removing and installing roof end strip…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4600
7.3 Removing and installing moulded headliner………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4601
7.4 Mounting roof reinforcement on body……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4603
7.4.1 Installing roof reinforcement to body, without sliding sunroof………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4603
7.4.2 Installing roof reinforcement to body, with sliding sunroof…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4606
72 – Seat frames…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4609
1 Overview of seat variants……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4609
1.1 Overview of fitting locations – seat variants…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4609
1.2 Mounting front seat on seat repair stand…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4610
2 Front seats………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4612
2.1 Overview of fitting locations – electrical and electronic components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4613
2.1.1 Overview of fitting locations – electrical and electronic components, standard seat, seat of type “ergo Aktiv”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4613
2.1.2 Overview of fitting locations – electrical and electronic components, electrically adjustable seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4614
2.2 Assembly overview – front seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4616
2.2.1 Assembly overview – front seat, standard seat, seat of type “ergo Aktiv”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4616
2.2.2 Assembly overview – front seat, electrically adjustable seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4618
2.3 Assembly overview – front backrest………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4620
2.3.1 Assembly overview – front backrest, standard seat of type “ergo Aktiv”…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4620
2.3.2 Assembly overview – front backrest, electrically adjustable lumbar support……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4621
2.4 Assembly overview – seat pan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4622
2.4.1 Assembly overview – seat pan, standard seat, seat of type “ergo Aktiv”…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4622
2.4.2 Assembly overview – seat pan, electrically adjustable seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4624
2.4.3 Assembly overview – seat pan, torsion rod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4625
2.5 Assembly overview – seat height adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4626
2.6 Assembly overview – seat rake adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4627
2.6.1 Assembly overview – seat rake adjustment, standard seat, seat of type “ergo Aktiv”………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4627
2.6.2 Assembly overview – seat rake adjustment, electrically adjustable seat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4628
2.7 Assembly overview – folding tray table…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4629
2.8 Assembly overview – fire extinguisher……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4630
2.9 Removing and installing front seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4630
2.10 Removing front seat if seat longitudinal adjustment motor -V28-/-V31- is defective…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4634
2.11 Connecting and disconnecting airbag adapter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4638
2.12 Removing and installing seat trim on tunnel side…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4639
2.13 Removing and installing seat trim on sill side…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4640
2.13.1 Removing and installing seat trim on sill side, standard seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4640
2.13.2 Removing and installing seat trim on sill side, seat of type “ergo Aktiv”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4642
2.13.3 Removing and installing seat trim on sill side, electrically adjustable seat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4643
2.14 Removing and installing bracket for seat trim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4645
2.14.1 Removing and installing bracket for seat trim, standard seat of type “ergo Aktiv”………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4645
2.14.2 Removing and installing bracket for seat trim, electrically adjustable seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4646
2.15 Removing and installing front backrest………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4647
2.16 Removing and installing manually adjustable lumbar support frame…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4649
2.17 Removing and installing seat rake adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4652
2.17.1 Removing and installing seat rake adjustment, standard seat, seat of type “ergo Aktiv”………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4652
2.17.2 Removing and installing seat rake adjustment, electrically adjustable seat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4653
2.18 Removing and installing handle for seat height adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4655
2.19 Removing and installing seat height…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4655
2.19.1 Removing and installing seat height adjustment, standard seat, seat of type “ergo Aktiv”………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4655
2.19.2 Removing and installing seat height adjustment, electrically adjustable seat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4657
2.20 Removing and installing lower seat pan frame with seat longitudinal adjustment motor -V28-/-V31-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4659
2.21 Removing and installing backrest adjustment mechanism…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4660
2.21.1 Removing and installing backrest adjustment, standard seat with through-loading function………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4660
2.21.2 Removing and installing backrest adjustment, standard seat without through-loading function, ergo Aktiv seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4661
2.21.3 Removing and installing backrest adjustment, electrically adjustable seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4662
2.22 Removing and installing lumbar support adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4662
2.23 Removing and installing head restraint………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4663
2.24 Removing and installing head restraint guide…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4664
2.25 Removing and installing storage compartment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4665
2.26 Removing and installing fire extinguisher holder on seat frame…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4666
2.27 Removing and installing fire extinguisher holder…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4667
2.28 Removing and installing lumbar support adjustment switch -E176-/-E177-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4667
2.29 Removing and installing lumbar support adjustment motor -V125-/-V126-/-V129-/-V130-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4668
2.30 Removing and installing seat adjustment operating unit -E470-/-E471-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4669
2.31 Removing and installing massage control unit -J740-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4670
2.32 Removing and installing seat and steering column adjustment control unit with memory -J136-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4670
3 Seats, 2nd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4671
3.1 Assembly overview – bench seat / individual seats…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4671
3.1.1 Assembly overview – individual seat, outer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4671
3.1.2 Assembly overview – individual seat, centre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4672
3.2 Removing and installing seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4672
3.3 Removing and installing front trim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4675
3.4 Removing and installing head restraint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4675
3.5 Removing and installing head restraint guide……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4676
3.6 Removing and installing backrest cover panel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4677
3.7 Removing and installing locking mechanism for rear seat backrest……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4677
4 Seats, 3rd row……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4679
4.1 Assembly overview – bench seat / individual seats…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4679
4.2 Removing and installing seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4680
4.3 Removing and installing head restraint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4682
4.4 Removing and installing head restraint guide……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4682
4.5 Removing and installing backrest cover panel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4683
4.6 Removing and installing locking mechanism for rear seat backrest……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4684
4.7 Removing and installing backrest release loop…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4685
74 – Seat – padding, covers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4686
1 Front seat covers and padding………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4686
1.1 Assembly overview – cover and padding for seat pan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4686
1.1.1 Assembly overview – cover and padding for seat pan…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4686
1.1.2 Assembly overview – cover and padding for seat pan, seat depth adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4688
1.2 Assembly overview – cover and padding for backrest………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4689
1.3 Assembly overview – seat heater element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4690
1.4 Assembly overview – backrest heater element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4691
1.5 Removing and installing seat cover and seat cushion for seat pan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4691
1.6 Removing and installing backrest cover and cushion………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4694
1.7 Separating seat pan cover from seat pan padding…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4698
1.8 Separating backrest cover from backrest padding…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4701
1.9 Removing and installing seat heating element -Z6-/-Z8-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4705
1.10 Removing and installing backrest heating element -Z7-/-Z9-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4706
2 Second row seat covers and padding……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4707
2.1 Assembly overview – cover and padding for bench seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4707
2.2 Assembly overview – rear seat backrest cover and padding…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4708
2.3 Assembly overview – seat heater element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4709
2.4 Removing and installing bench seat cover and padding………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4709
2.5 Removing and installing rear seat backrest cover and padding……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4712
2.6 Removing and installing seat heater element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4715
2.7 Removing and installing backrest heater element…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4716
Touran2016-Guide_for_using_trailers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4717
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4725
1 Preface……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4725
1.1 Legal requirements outside Germany………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4725
2 Technical prerequisites……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4726
2.1 Factory fitted towing attachment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4726
2.2 Retrofitted towing attachment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4726
2.3 Ball head…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4726
2.4 Trailer socket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4726
2.4.1 »7-pin« trailer socket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4726
2.4.2 »13-pin« trailer socket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4727
2.5 Trailer detector control unit -J345-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4727
2.5.1 Retrofitting trailer detector control unit -J345-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4727
2.5.2 Coding trailer detector control unit -J345-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4728
2.6 Engine cooling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4728
2.7 Exterior mirrors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4729
2.8 Uprated shock absorbers and coil springs…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4729
3 Notes on operation and driving……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4730
4 General……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4731
4.1 Towing attachment type plate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4731
4.2 Weight of vehicle and trailer combination………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4731
4.3 Tachograph……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4731
5 Drawbar load details………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4732
6 Legal requirements………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4733
7 Beetle 2012 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4734
8 Bora 1999 ►, Bora Variant 1999 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4735
9 Eos 2006 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4737
10 Fox 2004 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4738
11 Golf 1992 ►, Golf Variant 1994 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4739
12 Golf Cabriolet 1994 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4741
13 Golf 1998 ►, Golf Variant 1999 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4742
13.1 Golf R32…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4743
13.2 Celebration GTI………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4743
13.3 Golf Bi Fuel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4744
14 Golf 2004 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4745
15 Golf Plus 2005 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4747
16 Golf Variant 2007 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4749
17 Golf 2009 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4750
18 Golf Plus 2009 ►, CrossGolf 2009 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4752
18.1 Golf Plus……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4752
18.2 Cross Golf…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4753
19 Golf Variant 2010 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4754
20 Golf Cabriolet 2012 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4755
21 Golf 2013 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4757
22 Golf Variant 2014 ►, Golf Alltrack 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4760
22.1 Golf Variant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4760
22.2 Golf Alltrack………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4761
23 e Golf 2014 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4763
24 Golf SV 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4764
25 Jetta 2005 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4766
26 Jetta 2011 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4768
27 Jetta 2015 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4770
28 Lupo 3L, Lupo FSI, Lupo GTI 1999 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4772
29 Lupo 1999 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4773
30 New Beetle 1999 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4774
31 New Beetle RSi…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4776
32 New Beetle Cabriolet 2003 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4777
33 Passat saloon, estate 1994 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4778
33.1 Passat Syncro………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4779
33.1.1 Increase in trailer load…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4780
34 Passat saloon, estate 1997 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4781
35 Passat saloon, estate 2001 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4782
36 Passat W8 2002 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4783
37 Passat saloon 2006 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4784
38 Passat Variant 2006 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4786
39 Passat CC 2009 ►; CC 2010 ►; CC 2012 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4788
40 Passat saloon 2011 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4791
41 Passat Estate 2011 ►, Passat Alltrack 2012 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4793
41.1 Passat Variant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4793
41.2 Passat Alltrack………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4795
42 Passat saloon 2015 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4796
43 Passat Estate 2015 ►, Passat Alltrack 2016 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4798
43.1 Passat Variant 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4798
43.2 Passat Alltrack 2016 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4800
44 Phaeton 2003 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4801
45 Polo 1995 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4802
46 Polo Classic 1996 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4803
47 Polo Variant 1998 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4804
48 Polo 2002 ►, Polo Fun 2004 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4805
48.1 Polo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4805
48.2 Polo Fun…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4806
48.2.1 Retrofitting a towing attachment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4807
49 Polo saloon 2004 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4808
50 Polo 2010 ►, CrossPolo 2010 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4809
50.1 Polo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4809
50.2 CrossPolo……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4810
51 Polo 2014 ►, CrossPolo 2014 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4811
51.1 Polo………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4811
51.2 CrossPolo……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4812
52 Scirocco 2009 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4814
53 Scirocco 2015 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4815
54 Sharan 1996 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4816
54.1 Retrofitting towing attachment on Sharan BlueMotion………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4817
55 Sharan 2011 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4818
56 Sharan 2016 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4819
57 Tiguan 2008 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4820
57.1 Tiguan Trend & Fun/Sport & Style……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4820
57.2 Tiguan Track & Field………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4821
58 Touran 2003 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4824
59 CrossTouran……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4826
60 Touran 2016 ►……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4828
61 Touareg 2003 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4829
62 Touareg 2010 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4830
63 Touareg 2015 ►…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4831
64 up! 2012 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4832
65 e-up! 2014 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4833
66 Vento 1992 ►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4834
Touran2016-Heating__air_conditioning…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4835
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4841
1 Safety instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4841
1.1 Safety precautions when working on air conditioning systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4841
1.2 Safety precautions for working on vehicles with start-stop system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4841
1.3 Safety precautions when working on the cooling system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4841
2 Identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4843
2.1 Identification of heater and air conditioning unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4843
2.1.1 Identification of Valeo heater and air conditioning unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4843
2.1.2 Identification of Denso heater and air conditioning unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4843
3 General notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4844
3.1 Notes concerning odours in air conditioned vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4844
3.2 Notes for vehicles with start-stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4844
3.3 Identification plates………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4845
4 Repair notes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4846
4.1 Working on refrigerant circuit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4846
4.2 Refrigerant circuit seals………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4846
5 Technical data……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4847
5.1 Capacities for refrigerant R134a………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4847
5.2 Refrigerant oil……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4847
5.3 Oil distribution………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4847
80 – Heating…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4848
1 Overview of fitting locations – heating……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4848
1.1 Overview of fitting locations – components not located in passenger compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4848
1.2 Overview of fitting locations – components located in front section of passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4849
2 Control motors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4850
2.1 Overview of fitting locations – front control motors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4850
2.1.1 Overview of fitting locations – front control motors, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4850
2.1.2 Overview of fitting locations – front control motors, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4851
2.2 Removing and installing temperature flap control motor -V68- with potentiometer -G92-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4851
2.2.1 Removing and installing temperature flap control motor -V68- with potentiometer -G92-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4851
2.2.2 Removing and installing temperature flap control motor -V68- with potentiometer -G92-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4852
2.3 Removing and installing air recirculation flap control motor -V113-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4852
2.3.1 Removing and installing air recirculation flap control motor -V113- (LHD)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4852
2.3.2 Removing and installing air recirculation flap control motor -V113- (RHD)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4852
2.4 Removing and installing air distribution flap control motor -V428- with potentiometer -G645-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4852
2.4.1 Removing and installing air distribution flap control motor -V428- with potentiometer -G645-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4852
2.4.2 Removing and installing air distribution flap control motor -V428- with potentiometer -G645-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4852
3 Heater unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4853
3.1 Assembly overview – heater unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4853
3.2 Removing and installing fresh air blower -V2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4857
3.3 Removing and installing fresh air blower control unit -J126-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4857
3.4 Removing and installing dust and pollen filter……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4857
3.5 Removing and installing heater unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4857
3.6 Dismantling and assembling heater unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4857
3.7 Checking auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4858
3.8 Removing and installing auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4858
3.9 Removing and installing heat exchanger…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4858
3.10 Removing and installing baffle plate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4858
4 Air duct…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4859
4.1 Assembly overview – air duct and air distribution in passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4859
4.2 Removing and installing driver side footwell vents………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4859
4.3 Removing and installing front passenger side footwell vents………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4859
4.4 Removing and installing rear footwell vent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4859
4.5 Removing and installing fresh air intake…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4859
4.6 Removing and installing cover for fresh air intake………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4859
4.7 Removing and installing air intake duct………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4860
4.8 Checking exhaust ventilation for passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4860
4.9 Removing and installing exhaust ventilation for passenger compartment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4860
4.10 Removing and installing air duct for defroster vent………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4860
4.11 Removing and installing air duct for centre dash panel vent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4860
5 Operating and display unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4861
5.1 Overview of operating and display unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4861
5.2 Removing and installing operating and display unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4862
6 Other controlling and regulating components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4863
6.1 Removing and installing ambient temperature sensor -G17-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4863
87 – Air conditioning system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4864
1 Overview of fitting locations – air conditioning system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4864
1.1 Overview of fitting locations – components not located in passenger compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4864
1.2 Overview of fitting locations – components located in front section of passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4865
2 Refrigerant circuit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4868
2.1 System overview – refrigerant circuit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4868
2.2 Assembly overview – condenser…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4870
2.3 Removing and installing refrigerant circuit pressure sender -G805-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4871
2.4 Removing and installing expansion valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4873
2.5 Removing and installing condenser……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4875
2.6 Removing and installing desiccant bag or cartridge………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4877
2.6.1 Removing and installing desiccant bag or cartridge, Denso condenser……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4877
2.6.2 Removing and installing desiccant bag or cartridge, Modine condenser…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4878
2.6.3 Removing and installing desiccant bag or cartridge, Keihin condenser…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4882
2.7 Removing and installing refrigerant line with internal heat exchanger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4885
2.8 Removing and installing damper weight for refrigerant line, low-pressure side………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4887
2.9 Removing and installing evacuating and charging valves on low and high-pressure side………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4888
2.10 Removing and installing refrigerant line between condenser and evaporator…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4890
2.11 Removing and installing refrigerant line between condenser and air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4892
2.12 Removing and installing refrigerant line between air conditioner compressor and evaporator……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4894
3 Air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4896
3.1 Assembly overview – drive unit of air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4896
3.2 Assembly overview – belt pulley…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4897
3.2.1 Assembly overview – belt pulley, Denso air conditioner compressor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4897
3.2.2 Assembly overview – belt pulley, Sanden air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4898
3.3 Removing and installing air conditioning compressor from and to bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4899
3.4 Removing and installing air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4900
3.5 Checking high-pressure safety valve on air conditioner compressor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4905
3.6 Removing and installing belt pulley……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4905
3.6.1 Removing and installing belt pulley, Denso air conditioner compressor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4905
4 Control motors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4907
4.1 Overview of fitting locations – front control motors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4907
4.1.1 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4907
4.1.2 Overview of fitting locations – front control motors, air conditioning system with electric/manual controls, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4909
4.1.3 Overview of fitting locations – front control motors, Climatronic, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4910
4.1.4 Overview of fitting locations – front control motors, Climatronic, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4911
4.2 Removing and installing temperature flap control motor -V68- with potentiometer -G92-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4912
4.2.1 Removing and installing temperature flap control motor -V68-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4912
4.2.2 Removing and installing temperature flap control motor -V68- (RHD)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4913
4.3 Removing and installing defroster flap control motor -V107- with potentiometer -G135-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4915
4.3.1 Removing and installing defroster flap control motor -V107- with potentiometer -G135-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4915
4.3.2 Removing and installing defroster flap control motor -V107- with potentiometer -G135-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4917
4.4 Removing and installing air recirculation flap control motor -V113-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4919
4.4.1 Removing and installing air recirculation flap control motor -V113- (LHD)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4919
4.4.2 Removing and installing air recirculation flap control motor -V113- (RHD)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4920
4.5 Removing and installing left temperature flap control motor -V158- with potentiometer -G220-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4923
4.5.1 Removing and installing left temperature flap control motor -V158-, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4923
4.5.2 Removing and installing left temperature flap control motor -V158-, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4924
4.6 Removing and installing right temperature flap control motor -V159- with potentiometer -G221-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4927
4.6.1 Removing and installing right temperature flap control motor -V159-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4927
4.6.2 Removing and installing right temperature flap control motor -V159-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4928
4.7 Removing and installing rear temperature flap control motor -V137-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4930
4.8 Removing and installing fresh air/recirculated air, air flow flap control motor -V425- with potentiometer -G644-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4931
4.8.1 Removing and installing fresh air/recirculated air, air flow flap control motor -V425-, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4931
4.8.2 Removing and installing fresh air/recirculated air, air flow flap control motor -V425-, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4933
4.9 Removing and installing front air distribution flap control motor -V426- with potentiometer for front air distribution flap control motor -G642-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4936
4.9.1 Removing and installing front air distribution flap control motor -V426-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4936
4.9.2 Removing and installing front air distribution flap control motor -V426-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4938
4.10 Removing and installing air distribution flap control motor -V428- with potentiometer -G645-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4941
4.10.1 Removing and installing air distribution flap control motor -V428-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4941
4.10.2 Removing and installing air distribution flap control motor -V428-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4942
4.11 Removing and installing air distribution flap actuation unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4945
4.11.1 Removing and installing front air distribution flap actuator, electric/manual air conditioning system, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4945
4.11.2 Removing and installing front air distribution flap actuator, electric/manual air conditioning system, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4946
4.11.3 Removing and installing front air distribution flap actuation unit, Climatronic………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4947
4.11.4 Removing and installing front air distribution flap actuation unit, Climatronic, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4949
5 Front heater and air conditioning unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4951
5.1 Assembly overview – heater and air conditioning unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4951
5.1.1 Assembly overview – heater and air conditioning unit, Climatronic……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4951
5.2 Assembly overview – add-on parts of heater and air conditioning unit and of air intake box…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4955
5.3 Assembly overview – evaporator housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4957
5.4 Assembly overview – flaps and partitions in air distribution housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4958
5.5 Removing and installing heater and air conditioning unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4961
5.6 Dismantling and assembling heater and air conditioning unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4966
5.7 Removing and installing air distribution housing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4967
5.8 Removing and installing holder for heater and air conditioning unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4968
5.9 Removing and installing evaporator………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4969
5.10 Removing and installing fresh air blower control unit -J126-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4970
5.10.1 Removing and installing fresh air blower control unit -J126-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4970
5.10.2 Removing and installing fresh air blower control unit -J126-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4971
5.11 Removing and installing dust and pollen filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4971
5.12 Removing and installing fresh air blower -V2-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4973
5.12.1 Removing and installing fresh air blower -V2-, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4973
5.12.2 Removing and installing fresh air blower -V2- (RHD)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4974
5.13 Checking auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4975
5.13.1 Checking auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4975
5.13.2 Checking auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4976
5.14 Removing and installing auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4977
5.14.1 Removing and installing auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4977
5.14.2 Removing and installing auxiliary air heater element -Z35- with auxiliary air heater control unit -J604-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4977
5.15 Removing and installing heat exchanger………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4979
5.15.1 Removing and installing Valeo heat exchanger, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4979
5.15.2 Removing and installing Valeo heat exchanger, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4983
5.15.3 Removing and installing Denso heat exchanger, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4988
5.15.4 Removing and installing Denso heat exchanger, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4993
5.16 Removing and installing coolant pipes on heat exchanger…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..4997
5.16.1 Removing and installing coolant pipes at heat exchanger (Valeo)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4997
5.16.2 Removing and installing coolant pipes at heat exchanger (Denso)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4998
5.17 Removing and installing evaporator temperature sensor -G308-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………4999
5.17.1 Removing and installing evaporator temperature sensor -G308-, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….4999
5.17.2 Removing and installing evaporator temperature sensor -G308-, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5000
5.18 Checking condensation drainage…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5001
5.19 Removing and installing condensation drainage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5002
5.19.1 Removing and installing condensation drainage (LHD)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5002
5.19.2 Removing and installing condensation drain (RHD)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5004
5.20 Removing and installing baffle plate……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5006
5.20.1 Removing and installing baffle plate, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5006
5.20.2 Removing and installing baffle plate, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5006
6 Air duct…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5008
6.1 Assembly overview – air duct and air distribution in passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5008
6.2 Removing and installing fresh air intake…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5009
6.2.1 Removing and installing fresh air intake duct, LHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5009
6.2.2 Removing and installing fresh air intake duct, RHD vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5010
6.3 Removing and installing cover for fresh air intake………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5011
6.4 Removing and installing air intake duct………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5012
6.5 Removing and installing driver side footwell vents………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5013
6.5.1 Removing and installing driver side footwell vents, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5013
6.5.2 Removing and installing driver side footwell vents, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5013
6.6 Removing and installing front passenger side footwell vents………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5014
6.6.1 Removing and installing front passenger side footwell vents, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5014
6.6.2 Removing and installing front passenger side footwell vents, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5014
6.7 Removing and installing rear footwell vent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5015
6.8 Removing and installing rear centre console vent duct……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5016
6.9 Removing and installing air duct for rear vent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5017
6.10 Checking forced ventilation for passenger compartment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5018
6.11 Removing and installing exhaust ventilation for passenger compartment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5018
6.12 Removing and installing air duct for defroster vent………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5019
6.13 Removing and installing air duct for centre dash panel vent……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5019
7 Operating and display unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5021
7.1 Overview of operating and display unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5021
7.1.1 Overview – control and display unit, air conditioning system with electric/manual controls……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5021
7.1.2 Overview of operating and display unit, Climatronic………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5023
7.1.3 Overview of operating and display unit, rear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5026
7.2 Removing and installing operating and display unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5026
7.2.1 Removing and installing operating and display unit, front…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5026
7.2.2 Removing and installing rear operating and display unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5027
8 Other controlling and regulating components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5029
8.1 Removing and installing sunlight penetration photosensor -G107-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5029
8.2 Removing and installing air quality sensor -G238-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5030
8.2.1 Removing and installing air quality sensor -G238-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5030
8.2.2 Removing and installing air quality sensor -G238-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5031
8.3 Removing and installing ambient temperature sensor -G17-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5031
8.4 Removing and installing humidity sender for air conditioning system -G260-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5032
8.5 Removing and installing left vent temperature sender -G150-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5032
8.5.1 Removing and installing left vent temperature sender -G150-, LHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5032
8.5.2 Removing and installing left vent temperature sender -G150-, RHD vehicles………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5033
8.6 Removing and installing right vent temperature sender -G151-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5034
8.6.1 Removing and installing right vent temperature sender -G151-, LHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5034
8.6.2 Removing and installing right vent temperature sender -G151-, RHD vehicles……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5035
8.7 Removing and installing rear vent temperature sender -G174-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5036
8.8 Removing and installing footwell vent temperature sender -G192-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5037
Touran2016-Maintenance……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5039
1 Engine list……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5043
2 Service work…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5044
2.1 Information reference flexible or fixed service………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5044
2.1.1 Service identification……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5044
2.1.2 Flexible service…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5044
2.1.3 Fixed service……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5045
2.1.4 Service interval display……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5045
2.2 Service tables for market group A…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5046
2.2.1 Service tables for market group A……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5047
2.3 Service tables for market group B and C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5050
2.3.1 Delivery inspection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5050
2.3.2 Scopes of service……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5052
2.3.3 Time or mileage dependent additional work as of model year 2016►………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5055
3 General……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5057
3.1 Raising vehicle with lifting platform or trolley jack…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5057
3.1.1 Safety notes:……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5057
3.1.2 Lifting points for lifting platform and trolley jack…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5057
3.2 Sticker………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5058
3.3 Entries in service schedule………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5058
3.4 Vehicle diagnosis, testing and information system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5059
3.4.1 Connecting vehicle diagnostic tester…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5059
3.5 Vehicle identification number………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5060
3.5.2 Vehicle identification number on extension of longitudinal member…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5061
3.5.3 Significance of vehicle identification number…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5061
3.6 Vehicle data sticker………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5061
3.7 Severe operating conditions………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5062
3.8 Allocation of countries to market groups…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5062
3.9 Engine code and engine number………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5064
3.10 Type plate………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5064
4 Descriptions of work……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5066
4.1 Swivel joints and suspension link mountings: visual check……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5067
4.2 Automatic headlight control and static cornering light: performing functional check………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5068
4.3 Front passenger front airbag: checking key switch and “ON/OFF function”…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5069
4.4 12 V battery: checking battery terminal clamp for firm seating…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5070
4.5 12-V battery: checking with battery tester (always refer to workshop manual)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5072
4.6 12 V battery: Reading status and sending diagnosis protocol via online connection………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5072
4.7 Checking tyres: condition, wear pattern, tyre pressure and tread depth………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5072
4.7.1 Checking condition of tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5073
4.7.2 Checking wear pattern………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5073
4.7.4 General notes……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5074
4.7.5 Touran tyre pressures………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5075
4.8 Brake and clutch system: changing brake fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5077
4.9 Brake system and shock absorbers: performing visual check for leaks and damage…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5082
4.10 Checking thickness of brake pads/linings and condition of brake discs, front and rear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5082
4.10.1 Front brake pads:…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5083
4.10.2 Rear brake pads:……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5083
4.10.3 Condition of brake discs: checking……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5084
4.11 Brake fluid level: checking……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5084
4.12 Checking diesel particulate filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5085
4.13 6-speed dual clutch gearbox 0D9: changing gear oil and filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5086
4.14 Window regulators: checking positioning (open and close functions)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5086
4.15 Reading fault memory of all systems with vehicle diagnostic tester, correcting possible faults according to repair guidelines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5087
4.16 Protective bellows: visual check…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5088
4.17 Interior and exterior body: performing visual check for corrosion when doors and flaps are open…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5088
4.18 Poly V-belt: renewing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5088
4.19 Poly V-belt: checking condition……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5088
4.20 Cooling system: checking frost protection and coolant level…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5090
4.20.1 Checking frost protection, if necessary replenish coolant additive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5090
4.20.2 Checking coolant level, replenish coolant if necessary………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5091
4.20.3 Mixture ratio………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5092
4.21 Diesel fuel filter: renewing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5092
4.22 Air filter: cleaning housing and renewing filter element……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5095
4.22.1 Removing and installing air filter element, 1.4 l TSI engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5096
4.22.2 Removing and installing air filter element, common rail engines………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5098
4.22.3 Cleaning fuel filter housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5099
4.23 Multi-purpose additive for petrol fuels: adding……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5099
4.24 Engine and components in engine compartment (from above and below): performing visual check for leaks and damage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5100
4.25 Engine cover panel “top”: removing and installing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5101
4.25.1 Removing and installing engine cover panel, common rail diesel engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5101
4.26 Removing and installing engine compartment cover (noise insulation) “bottom”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5101
4.27 Engine oil level: checking………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5101
4.28 Engine oil: draining; renewing oil filter and replenishing engine oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5102
4.28.1 Notes on engines with turbocharger……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5102
4.28.2 Draining engine oil and renewing oil filter, 1.4 l TSI engines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5102
4.28.3 Draining engine oil and renewing oil filter, common rail diesel engines…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5105
4.28.4 Replenishing engine oil……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5107
4.29 Engine oil: capacities and specifications…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5107
4.30 Panorama tilting/sliding roof with rear panorama roof: checking function, cleaning and greasing guide rails, and cleaning wind deflector………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5107
4.30.1 Checking function, cleaning and greasing guide rails …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5107
4.30.2 Cleaning wind deflector……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5108
4.31 Performing road test (driving behaviour, noises, air conditioner etc.)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5109
4.32 Wheel securing bolts: tightening to specified torque…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5110
4.33 Reducing agent (AdBlue®): replenishing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5113
4.33.1 General……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5114
4.33.2 Health/endangerment and cleaning……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5116
4.33.3 Disposal instructions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5116
4.33.4 Filling reducing agent tank………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5116
4.34 Reducing agent (AdBlue®): changing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5117
4.35 Tyre pressure indicator: calibrating……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5117
4.36 Checking tyre mobility set………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5118
4.37 Window wash/wipe system and headlight washer system: functional check………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5119
4.37.1 Checking anti-freeze protection of fluid, topping up fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5119
4.37.2 Window wash/wipe system: checking spray jet settings and adjusting if necessary……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5120
4.37.3 Headlight washer system: checking spray jet settings……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5121
4.37.4 Wiper blades: checking park position………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5122
4.37.5 Rear window wiper blades: checking park position……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5122
4.38 Wiper blade protection: removing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5122
4.38.1 Removing wiper blade protection, version 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5123
4.38.2 Removing wiper blade protection, version 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5124
4.38.3 Renewing wiper blade protection, version 3 “transport wiper blade”……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5124
4.39 Headlight adjustment: checking halogen headlights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5125
4.39.1 Test and adjustment conditions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5125
4.39.2 Checking headlight adjustment (ECE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5125
4.39.3 Checking headlight adjustment (SAE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5126
4.39.4 Adjusting halogen headlights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5127
4.40 Headlight adjustment: checking LED headlights with cornering light…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5128
4.40.1 Test and adjustment conditions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5128
4.40.2 Checking headlight adjustment (ECE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5129
4.40.3 Checking headlight adjustment (SAE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5130
4.40.4 LED headlights with cornering light: adjusting…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5132
4.41 Headlight adjustment: checking LED headlights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5133
4.41.1 Test and adjustment conditions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5134
4.41.2 Checking headlight adjustment (ECE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5134
4.41.3 Checking headlight adjustment (SAE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5135
4.41.4 LED headlights: adjusting……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5136
4.42 Headlight adjustment: checking fog lights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5138
4.42.1 Test and adjustment conditions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5138
4.42.2 Checking headlight adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5138
4.42.3 Adjusting fog lights and other additional lights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5139
4.43 Service interval display: resetting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5139
4.43.1 Resetting service interval display using vehicle diagnostic tester……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5140
4.43.2 Resetting service interval display without vehicle diagnostic tester……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5140
4.44 Service interval display: recoding…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5141
4.45 Track rod ends: checking clearance, security and boots……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5142
4.46 Dust and pollen filter: cleaning housing and renewing filter element…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5142
4.47 Transportation mode: switching off…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5142
4.48 Transport locks: removing blocking pieces…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5143
4.49 Clock and date: setting to correct time…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5144
4.50 Underbody: visual check for damage to underbody sealant, underbody panels, routing of lines, plugs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5144
4.51 Camshaft drive toothed belt: renewing (diesel engines)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5145
4.52 Camshaft drive toothed belt: checking………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5145
4.52.1 Checking toothed belt condition………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5145
4.53 Coolant pump toothed belt: checking………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5146
4.54 Spark plugs: renewing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5147
4.54.1 Renewing spark plugs, 1.4 l TSI engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5148
5 Exhaust emissions test………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5151
5.1 Exhaust emissions test for petrol engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5151
5.2 Exhaust emissions test for diesel engines……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5159
6 Glossary………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5170
Touran2016-Manual_for_Troubleshooting_and_Diagnosing_Noises………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5173
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5177
1 Introduction……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5177
1.1 Definition of sound……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5177
1.2 Acoustic range………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5177
1.3 Physical characteristics of sound……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5179
1.3.1 Pitch…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5179
1.3.2 Intensity……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5179
1.3.3 Duration………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5180
1.3.4 Timbre………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5180
1.4 Characteristics of a sound wave…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5180
1.4.2 Period………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5180
1.4.3 Frequency……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5180
1.4.4 Resonance……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5181
2 Definition of noise…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5182
2.1 Types of noises……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5182
2.1.1 Audible noise……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5182
2.1.2 Inaudible noise………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5182
2.2 Acoustic considerations during vehicle development………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5183
2.2.1 Vibration insulation film…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5183
2.2.2 Insulation………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5185
3 General procedure for identifying noises………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5186
3.1 General procedure……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5186
3.2 Identifying a noise……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5186
3.2.2 Identifying the type of noise……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5186
3.2.3 Identifying the point in time when the noise occurs………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5187
3.2.4 Identifying the noise by definition or designation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5187
3.3 Checklist…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5187
4 Examples…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5191
5 Volkswagen equipment for localising noises…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5193
5.1 Ultrasonic tester -VAG 1842-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5193
5.1.2 Procedure for identifying noises using ultrasound……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5197
5.2 Wireless fault detector -SAT 4500-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5200
5.2.2 Procedure for identifying noises using the wireless fault detector…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5201
5.3 Endoscope -VAS 6748A-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5203
5.3.1 Design of the endoscope -VAS 6748A-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5203
5.3.2 Procedure for identifying noises using the endoscope…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5206
5.4 Assistance for identifying noises by listening to audio tracks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5207
5.4.1 Preparing the audio CD using downloaded files……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5207
5.4.2 List of audio tracks……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5207
5.4.3 List of volume levels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5208
5.4.4 Conditions for performing the audio test……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5208
6 Attachments………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5210
6.1 Checklist…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5210
6.2 Designations for noises………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5212
6.2.1 Common noises……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5212
6.2.2 Uncommon noises………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5216
Touran2016-Manual_on_Localising_the_Ingress_of_Water…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5220
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5224
1 Introduction……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5224
2 Identifying the type of water ingress…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5225
2.1 External factors………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5225
2.2 Vehicle fluids………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5225
3 Causes for the ingress of water………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5226
4 General procedure for localising the ingress of water…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5229
4.1 General procedure……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5229
4.2 Localising the ingress of water…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5229
4.2.2 Circumstances under which the water enters………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5230
4.2.3 Type of fluid……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5230
4.3 Checklist…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5230
4.3.1 Notes on acquiring data…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5230
4.3.2 Description of the checklist………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5231
5 Examples…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5232
6 Volkswagen equipment for localising the ingress of water………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5234
6.1 Ultrasonic tester -VAG 1842S-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5234
6.1.2 Procedure for localising the ingress of water……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5237
6.2 Endoscope -VAS 6748A-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5238
6.2.1 Components of the endoscope -VAS 6748A-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5238
6.2.2 Procedure for identifying the ingress of water using the endoscope…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5241
6.3 Cleaning and insertion aid -VAS 6620-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5241
7 Attachments………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5242
7.1 Checklist…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5242
Touran2016-Running_gear__axles__steering……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5244
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5250
1 Notes on safety…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5250
1.1 Safety precautions when working on vehicles with start/stop system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5250
1.2 Safety precautions when working on subframe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5250
2 Evaluating accident vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5251
2.1 Checklist for evaluating running gear on accident vehicles…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5251
3 Repair instructions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5253
3.1 Leaks at shock absorbers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5253
3.2 Noises from shock absorbers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5253
3.3 Checking shock absorbers when removed……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5254
3.4 Steering rack…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5254
3.5 Gaskets and seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5255
3.6 Nuts and bolts………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5255
3.7 Electrical components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5255
3.8 Raising wheel bearing assembly to unladen position (vehicles with coil springs)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5255
3.8.1 Raising wheel bearing assembly to unladen position (vehicles with coil springs), front axle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5255
3.8.2 Raising wheel bearing assembly to unladen position (vehicles with coil springs), rear axle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5257
4 Disposal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5260
4.1 Releasing gas and draining front gas-filled shock absorbers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5260
4.1.1 Releasing gas and draining front gas-filled shock absorbers, conventional shock absorbers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5260
4.1.2 Releasing gas and draining front gas-filled shock absorbers, DCC shock absorbers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5261
4.2 Releasing gas and draining rear gas-filled shock absorbers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5262
4.2.1 Releasing gas and draining rear gas-filled shock absorbers, conventional shock absorbers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5262
4.2.2 Releasing gas and draining rear gas-filled shock absorbers, DCC shock absorbers…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5263
40 – Front suspension…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5264
1 Front axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5264
1.1 Fitting location overview – front axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5264
2 Subframe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5265
2.1 Assembly overview – subframe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5265
2.2 Fixing position of subframe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5266
2.3 Lowering subframe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5270
2.4 Removing and installing subframe without steering rack…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5273
2.5 Removing and installing subframe with steering rack……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5278
2.6 Repairing subframe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5285
2.7 Removing and installing anti-roll bar……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5293
2.8 Removing and installing coupling rod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5297
2.9 Repairing thread in longitudinal member………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5298
3 Suspension strut, upper suspension link……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5299
3.1 Assembly overview – suspension strut, upper suspension link………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5299
3.2 Removing and installing suspension strut…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5300
3.3 Repairing suspension strut……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5308
4 Lower suspension link, swivel joint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5311
4.1 Assembly overview – lower suspension link, swivel joint……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5311
4.2 Removing and installing lower suspension link…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5312
4.2.1 Removing and installing lower suspension link, vehicle with manual gearbox or dual clutch gearbox 0CW……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5312
4.2.2 Removing and installing lower suspension link, vehicle with dual clutch gearbox 0D9……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5314
4.3 Checking swivel joint………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5319
4.4 Removing and installing swivel joint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5319
4.5 Renewing front bonded rubber bush for lower suspension link………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5324
4.6 Renewing rear bonded rubber bush for lower suspension link…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5326
5 Wheel bearing assembly………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5330
5.1 Assembly overview – wheel bearing assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5330
5.2 Removing and installing wheel bearing housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5331
5.3 Removing and installing wheel bearing unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5334
6 Drive shaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5338
6.1 Overview – drive shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5338
6.2 Assembly overview – drive shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5339
6.2.1 Assembly overview – drive shaft, constant velocity joint VL100………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5339
6.2.2 Assembly overview – drive shaft, constant velocity joint VL107………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5341
6.2.3 Assembly overview – drive shaft, triple roller joint AAR3300i…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5343
6.3 Removing and installing drive shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5344
6.3.1 Removing and installing drive shaft, left drive shaft, constant velocity joints VL100 and VL107…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5344
6.3.2 Removing and installing drive shaft, right drive shaft, constant velocity joints VL100 and VL107………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5348
6.3.3 Removing and installing drive shaft, triple roller joint AAR3300i inserted……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5352
6.3.4 Removing and installing drive shafts, triple roller joint AAR3300i bolted………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5357
6.4 Loosening and tightening threaded connections of drive shaft……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5361
6.5 Removing and installing drive shaft heat shield…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5363
6.6 Dismantling and assembling drive shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5363
6.6.1 Dismantling and assembling drive shaft, constant velocity joint VL100………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5363
6.6.2 Dismantling and assembling drive shaft, constant velocity joint VL107………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5368
6.6.3 Dismantling and assembling drive shaft, triple roller joint AAR3300i…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5373
6.7 Checking outer constant velocity joint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5378
6.8 Checking inner constant velocity joint…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5379
42 – Rear suspension……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5381
1 Rear axle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5381
1.1 Overview – rear axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5381
1.2 Lowering rear axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5383
1.3 Removing and installing rear axle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5385
2 Subframe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5389
2.1 Assembly overview – subframe……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5389
2.2 Fixing position of subframe…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5390
3 Anti-roll bar………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5395
3.1 Assembly overview – anti-roll bar……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5395
3.2 Removing and installing anti-roll bar……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5395
3.3 Removing and installing coupling rod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5397
4 Suspension link, track rod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5400
4.1 Assembly overview – transverse link……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5400
4.2 Assembly overview – track rod…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5401
4.3 Removing and installing upper transverse link…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5401
4.4 Removing and installing lower transverse link…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5402
4.5 Removing and installing track rod……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5404
5 Suspension strut, shock absorber, spring………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5407
5.1 Assembly overview – suspension strut, shock absorber, spring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5407
5.2 Removing and installing shock absorbers………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5408
5.3 Repairing shock absorber……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5410
5.4 Removing and installing spring………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5413
6 Wheel bearing assembly, trailing arm………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5418
6.1 Assembly overview – wheel bearing assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5418
6.2 Assembly overview – trailing arm………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5419
6.3 Removing and installing wheel bearing housing…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5419
6.4 Removing and installing wheel bearing unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5424
6.5 Renewing bonded rubber bush for wheel bearing housing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5427
6.6 Removing and installing trailing arm with mounting bracket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5430
6.7 Repairing trailing arm…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5433
43 – Self-levelling suspension…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5437
1 Electronically controlled damping system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5437
1.1 Assembly overview – electronically controlled damping system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5437
1.2 Removing and installing electronically controlled damping control unit -J250-, saloon…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5438
1.3 Removing and installing front body acceleration senders -G341-/-G342-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5439
1.3.1 Removing and installing front left body acceleration sender -G341-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5439
1.3.2 Removing and installing front right body acceleration sender -G342-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5441
1.4 Removing and installing rear left body acceleration sender -G699-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5442
2 Vehicle level senders……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5444
2.1 Assembly overview – front vehicle level senders…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5444
2.2 Assembly overview – rear vehicle level senders……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5445
2.3 Removing and installing front vehicle level senders -G78-/-G289-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5445
2.4 Removing and installing rear vehicle level senders -G76-/-G77-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5447
44 – Wheels, tyres, vehicle geometry……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5449
1 Wheels, tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5449
1.1 Torque settings for wheel bolts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5449
1.2 Pressing tyre off wheel rim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5449
1.3 Removing tyre from wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5450
1.4 Mounting tyre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5450
1.5 Wheel change………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5451
1.5.1 Wheel change, protecting wheel centring seat against corrosion………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5451
1.5.2 Wheel change, installation requirements…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5452
1.5.3 Wheel change, installation instructions for wheel change……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5453
1.5.4 Wheel change, wheel installation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5454
1.5.5 Wheel change, position of anti-theft wheel bolts for steel wheels……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5454
1.6 Tyre sealant disposal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5455
1.7 Models with breakdown set………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5455
2 Tyre pressure monitoring system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5456
2.1 Overview of fitting locations – tyre pressure monitoring system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5456
2.2 System description – tyre pressure monitoring system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5457
2.2.1 System description – tyre pressure monitoring system, tyre pressure monitor display……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5457
2.2.2 System description – tyre pressure monitoring system, tyre pressure monitoring system (TPMS) with autolocation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5458
2.3 Assembly overview – tyre pressure sensor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5458
2.4 Removing and installing tyre pressure monitor control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5459
2.5 Removing and installing tyre pressure sensor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5460
3 Wheel alignment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5462
3.1 Notes for wheel alignment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5462
3.2 Test prerequisites…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5463
3.3 Test preparations……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5463
3.3.1 Test preparations, wheel alignment with no driver assist systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5463
3.3.2 Test preparations, wheel alignment with driver assist systems…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5464
3.4 Specified values for wheel alignment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5465
3.5 Wheel alignment procedure………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5466
3.6 Necessity of wheel alignment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5467
3.7 Vehicle data sticker…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5468
3.8 Adjusting camber at front wheels………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5469
3.9 Adjusting camber on rear axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5470
3.10 Adjusting toe at rear axle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5471
3.11 Adjusting front axle toe………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5472
3.12 Wheel runout compensation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5473
3.13 Checking maximum wheel lock……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5473
4 Vibration due to wheels/tyres – causes and rectification………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5475
4.1 Causes of vibration……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5475
4.2 Conducting a road test before balancing wheels……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5475
4.3 Balancing wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5476
4.3.1 Balancing wheel, conditions……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5476
4.3.2 Balancing wheel, balancing wheel on stationary wheel balancer…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5476
4.3.3 Balancing wheel, balancing wheel with finish balancer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5479
4.4 Vibration control system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5480
4.5 Checking radial and lateral runout of wheels and tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5480
4.5.1 Checking radial and lateral runout of wheels and tyres, tolerances…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5480
4.5.2 Checking radial and lateral runout on wheels and tyres with tyre gauge…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5481
4.6 Checking radial and lateral run-out on wheel rim………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5481
4.7 Matching wheels and tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5482
4.8 Determining flat spots on tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5483
5 Adaptive cruise control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5485
5.1 Calibrating adaptive cruise control……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5485
6 Front camera for driver assist systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5491
6.1 Calibrating front camera for driver assist systems………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5491
48 – Steering……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5498
1 Steering wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5498
1.1 Assembly overview – steering wheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5498
1.2 Removing and installing steering wheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5498
2 Steering column…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5501
2.1 Assembly overview – steering column……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5501
2.2 Checking steering column for damage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5502
2.3 Handling and transporting steering column………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5502
2.4 Removing and installing steering column………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5503
2.5 Removing and installing control unit for electronic steering column lock -J764-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5510
3 Steering rack………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5513
3.1 Assembly overview – steering rack……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5513
3.1.1 Assembly overview – steering rack, left-hand drive…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5513
3.1.2 Assembly overview – steering rack, right-hand drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5515
3.2 Removing and installing steering rack……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5516
3.3 Removing and installing boot……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5524
3.4 Removing and installing track rod……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5527
3.5 Removing and installing track rod ball joint……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5530
3.6 Repairing steering rack………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5531
4 Sensors……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5534
4.1 Removing and installing steering angle sender -G85-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5534
Touran2016-Vehicle-specific_paint_information…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5535
00 – Technical data………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5539
1 Explanation of symbols………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5539
1.1 Sanding………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5539
1.2 Seam seals……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5539
1.3 Cavity sealing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5541
2 Areas exposed to stone chipping………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5542
2.1 Areas exposed to stone chipping – overview……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5542
3 Masking areas………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5543
3.1 Masking areas, front body………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5543
3.2 Masking areas, rear body……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5544
4 Seam seals…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5545
4.1 Seam seals, front body…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5545
4.2 Seam seals, body middle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5549
4.3 Seam seals, rear body………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5550
5 Underseal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5553
5.1 Underseal, body – overview with differing layer thicknesses………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5553
5.2 Undersealed areas……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5554
6 Cavity sealing……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5557
6.1 Cavity sealing, body – overview…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5557
6.2 Cavity sealing, doors and rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5557
Touran2016-Wheels_and_Tyres_Guide……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5560
44 – Wheels, tyres, vehicle geometry……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5564
1 General notes on using the “Wheels and Tyres Guide”…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5564
1.1 General………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5564
1.2 Explanations regarding world regions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5565
1.3 Definition of tyre package……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5566
1.4 Procedure for determining the required tyre package……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5566
2 Notes on the vehicle registration certificate………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5567
2.1 Vehicle registration certificate part 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5567
2.2 Version key, D2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5567
3 Overview of possible wheel and tyre combinations depending on tyre packages……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5569
3.1 Type Approval No. (K): e1*2001/116*0211*36……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5569
4 Wheel allocation……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5571
4.1 6.5 J x 16 offset 48…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5571
4.2 6.5 J x 17 offset 48.5…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5572
4.3 6.5 J x 17 offset 52…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5572
4.4 7 J x 18 offset 52…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5573
5 Recommended summer tyres, worldwide except North America and China……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5575
6 Recommended all-season tyres, worldwide except North America and China……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5576
7 Recommended winter tyres, worldwide except North America and China……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5577
8 Recommended temporary spare tyres and wheels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5578
Touran2016-Wheels_and_Tyres_Guide_-_General_Information………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5579
44 – Wheels, tyres, vehicle geometry……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5583
1 Specifications for converting wheel and tyre combinations……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5583
1.1 Legislative conditions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5583
1.1.1 Permissible wheel and tyre combinations in Germany…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5583
1.1.2 Vehicles with Tyre Pressure Monitoring System……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5584
1.2 Technical conditions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5584
1.3 Load-carrying capacity depending on vehicle speed, winter tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5584
1.4 Vehicle registration documents since 01-10-2005…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5586
1.5 COC document (EEC Certificate of Conformity)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5587
1.6 EU general type approval number, sales type and sales or trade designation…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5587
2 Handling problems…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5589
2.1 Rolling noise…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5589
2.1.1 General notes on tyre noise……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5589
2.1.2 Flat spots (from locking wheels)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5590
2.2 Vehicle pulls to one side………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5591
2.2.1 General…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5591
2.2.2 Conicity………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5591
2.2.3 Remedies when vehicle pulls to one side…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5592
2.2.4 Strategic rotation of wheels for non-directional tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5593
2.2.5 Strategic rotation of wheels having unidirectional tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5594
2.3 Vibration…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5595
2.3.1 Vibration, causes for vibration……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5595
2.3.2 Vibration, conducting a road test before balancing wheels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5595
2.3.3 Vibration, vibration control system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5596
2.4 Eliminating flat spots caused by storage or handling………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5596
3 Evaluating tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5598
3.1 Flat spots caused by storage or handling…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5598
3.2 Undulations…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5598
3.3 Saw-tooth wear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5599
3.4 Flat spots caused by hard braking……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5599
3.5 Swellings in the tyre sidewall………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5599
3.6 Cuts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5601
3.7 Damage caused by foreign bodies…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5601
3.8 Stripped profile………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5601
3.9 Tyre damage due to insufficient tyre pressure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5602
3.10 Checking tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5602
3.11 Damage caused when fitting…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5603
4 Tyre wear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5605
4.1 Factors influencing the service life of tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5605
4.2 Saw-tooth wear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5606
4.3 Wear behaviour of high-speed tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5606
4.4 Measuring tread depth………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5607
4.5 One-sided wear………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5607
4.6 Outer shoulder wear……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5610
4.7 Diagonal washout………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5611
4.8 Wear in middle of tyre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5611
4.9 Permissible deviation in tread depth…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5612
5 Overview of components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5613
5.1 Assembly overview – wheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5613
5.1.1 Assembly overview – standard wheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5613
5.1.2 Assembly overview – wheel, PAX…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5614
6 Fitting tyre……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5616
6.1 Pressing tyre off wheel rim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5616
6.2 Removing tyre sealant………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5616
6.3 Removing tyre from wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5617
6.3.1 Removing tyres, wheels without and with tyre pressure monitoring………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5617
6.3.2 Removing tyres, run-flat tyres, ultra-high-performance tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5618
6.4 Ensuring proper assembly temperature for tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5620
6.5 Mounting tyre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5620
6.5.1 Mounting tyre, wheels without and with tyre pressure monitoring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5620
6.5.2 Mounting tyre, run-flat tyres, ultra-high performance tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5622
6.6 Matching wheel rims and tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5624
6.7 Balancing wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5625
6.7.1 Balancing wheel, balancing wheel on stationary wheel balancer…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5625
6.7.2 Balancing wheel, balancing wheel with finish balancer………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5628
6.7.3 Balancing wheel, checking radial and lateral run-out of wheels and tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5629
6.7.4 Balancing wheel, checking radial and lateral run-out on wheel rim……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5630
7 Fitting wheels……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5632
7.1 Fitting wheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5632
7.1.1 Fitting wheel, fitting instructions for Volkswagen…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5632
7.1.2 Fitting wheel, fitting instructions for Audi………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5636
7.1.3 Fitting wheel, position of anti-theft wheel bolts for steel wheels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5643
8 Information on tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5644
8.1 Identification markings on the tyre sidewall……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5644
8.1.1 Identification markings on the tyre sidewall, standard tyres………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5644
8.1.2 Identification markings on the tyre sidewall, tyres with run-flat system (PAX)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5646
8.2 Tyre dimension………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5646
8.3 Load rating code/load index (LI)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5646
8.4 Speed rating code……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5647
8.5 EU tyre label…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5648
8.5.1 EU tyre label, summary……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5648
8.5.2 EU tyre label, objectives…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5649
8.5.3 EU tyre label, categories…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5650
8.6 Structure of a radial belted tyre……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5653
8.6.1 Cross section of a radial belted tyre………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5653
8.6.2 Run-flat tyres, structure and identification of a SST tyre……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5654
8.6.3 Run-flat tyres, seal inside technology……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5655
8.6.4 Run-flat tyres, structure of a PAX tyre…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5657
8.7 Run-flat tyre, SST (Self Supporting Tyre)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5659
8.7.1 Run-flat tyres – general information……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5659
8.7.2 Run-flat tyres, retrofitting/requirements when using run-flat tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5660
8.7.3 Run-flat tyres, repair work……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5661
8.8 Run-flat tyres, PAX……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5661
8.8.1 Run-flat tyres, PAX, inflating tyre………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5661
8.8.2 Run-flat tyres, PAX, wheel alignment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5662
8.8.3 Repairing run-flat tyres, PAX……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5662
8.8.4 Run-flat tyres, PAX, checking……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5662
8.9 Tyre storage………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5663
8.10 Reinforced and Extra Load (XL) tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5664
8.11 Winter tyres…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5664
8.12 Winter tyres with speed symbol V……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5666
8.13 Rolling resistance optimised tyres……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5667
8.14 Tyre ageing………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5667
8.15 Tyres with flange protection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5669
8.16 Tyre sizes for vehicles with four-wheel drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5669
8.17 Increase in temperature due to insufficient tyre pressure…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5670
9 Information on wheel rims……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5671
9.1 Structure of wheel rim…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5671
9.2 Identification………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5672
9.3 Composite wheels………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5672
9.4 Care and maintenance of alloy wheel rims…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5672
9.5 Restoring alloy wheels…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5673
9.6 Removing and installing hub cover for alloy wheels with open threaded connection……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5673
9.7 Renewing trim elements…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5674
9.7.1 Renewing trim elements, bonded trim elements………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5674
9.7.2 Renewing trim elements, bolted trim elements………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5678
9.8 Removing and installing valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5680
9.8.1 Removing and installing valve, description of the valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5680
9.8.2 Removing and installing valve, rubber valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5680
9.8.3 Removing and installing valve, metal valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5681
9.9 Run-flat tyre system PAX……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5682
9.9.1 Run-flat tyre system PAX, support ring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5682
9.9.3 Run-flat tyre system PAX, checking support ring……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5683
10 Tyre Pressure Monitoring System……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5685
10.1 Tyre pressure monitor display………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5685
10.2 Tyre Pressure Monitoring System………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5685
11 Tyre pressure sensor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5686
11.1 Assembly overview – tyre pressure sensor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5686
11.1.1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5686
11.1.2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5687
11.2 Removing and installing tyre pressure sensor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5689
11.2.1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5689
11.2.2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, customer service version………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5690
11.2.3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, production version……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5691
11.2.4 Removing and installing tyre pressure sensor, metal valve body……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5693
11.2.6 Removing and installing tyre pressure sensor, Siemens tyre pressure monitoring system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5695
12 Tyre sealant………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5697
12.1 Tyre sealant, use-by date……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5697
12.2 Tyre sealant, disposal………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5697
13 Wheel bolts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5698
13.1 Wheel bolts, versions…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5698
13.2 Wheel bolts, anti-theft wheel bolt……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5699
13.3 Wheel bolts, adapter sets for anti-theft wheel bolts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5699
14 Snow chains……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5701
14.1 Assembly and use of snow chains………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5701
15 Temporary spare wheels……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5702
15.1 Notes on temporary spare wheels………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5702
Touran2016-Wiring diagrams-Basic_equipment__From_September_2015…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5703
001 –
Basic equipment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5703
1.
Basic equipment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5703
2. Treble horn, Bass horn, Horn relay, Fuse holder B, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5704
3. Heated rear window relay, Onboard supply control unit, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5705
4. Reversing light switch, Brake fluid level warning contact, Ambient temperature sensor, Coolant shortage indicator sender, Onboard supply control unit, Left fog light bulb………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5706
5. Onboard supply control unit, Front left headlight……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5707
6. Bonnet contact switch, Onboard supply control unit, Engine control unit, Right fog light bulb, Front right headlight………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5708
7. Rotary light switch, Onboard supply control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5709
8. Hazard warning light switch, Glove compartment light switch, Headlight range control regulator, Onboard supply control unit, Glove compartment light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5710
9. Onboard supply control unit, Front interior light, Rear interior light, Rear centre reading light…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5711
10. Ignition/starter switch, Intermittent wiper switch, Multifunction display call-up button, Selector lever, Onboard supply control unit, Steering column electronics control unit, Ignition key withdrawal lock solenoid………………………………………………………………………………………………………………………………………………………………………………………………………….5712
11. Turn signal switch, Cruise control system switch, Cruise control system (CCS) SET button, Horn plate, Airbag control unit, Onboard supply control unit, Steering column electronics control unit, Driver side airbag igniter…………………………………………………………………………………………………………………………………………………………………………………………………….5713
12. Onboard supply control unit, Data bus diagnostic interface, Control unit for electronic steering column lock………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5714
13. Heater and air conditioning controls, Fresh air blower control unit, Onboard supply control unit, Fresh air blower, Air recirculation flap control motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5715
14. Heater and air conditioning controls, Potentiometer for temperature flap control motor, Potentiometer for air distribution flap control motor, Onboard supply control unit, Temperature flap control motor, Air distribution flap control motor……………………………………………………………………………………………………………………………………………………………………………………5716
15. Onboard supply control unit, Left tail light, Left tail light 2, Right tail light 2, Left number plate light, Right number plate light…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5717
16. Tank flap release, Onboard supply control unit, Right tail light, High-level brake light bulb, Luggage compartment light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5718
17. Onboard supply control unit, Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Rear lid lock unit, Heated rear window………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5719
18. Immobiliser reader coil, Control unit in dash panel insert, Dash panel insert……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5720
19. Dash panel insert…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5721
002 –
Convenience system, left-hand drive , (L0L)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5722
1.
Convenience system, left-hand drive , (L0L)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5722
2. Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5723
3. Driver door control unit, Driver side exterior mirror, Driver side mirror adjustment motor 2, Driver side fold-in mirror motor, Driver side mirror adjustment motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5724
4. Driver door control unit, Driver side turn signal repeater bulb, Driver side exterior mirror, Driver side automatic anti-dazzle exterior mirror, Heated exterior mirror on driver side……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5725
5. Driver side interior locking button for central locking system, Operating unit for window regulator in driver door, Driver door control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5726
6. Exterior mirror adjuster, Driver door control unit, Central locking SAFELOCK function warning lamp, Light 1 for front left door background lighting, Light 2 for front left door background lighting, Light for driver side interior door handle illuminatio
, Left window regulator motor, Driver door lock unit, Driver door central locking motor…………………………………………………………………………………………..5727
7. Driver door contact switch, Driver side contact switch in lock cylinder, Driver door central locking actuator for SAFELOCK function, Driver door control unit, Driver door lock unit, Driver door central locking SAFELOCK function motor………………………………………………………………………………………………………………………………………………………………………………………….5728
8. Front passenger door control unit, Front passenger door lock unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5729
9. Window regulator switch in front passenger door, Front passenger door control unit, Light 1 for front right door background lighting, Light 2 for front right door background lighting, Light for passenger side interior door handle illumination, Right wi
dow regulator motor……………………………………………………………………………………………………………………………………………………….5730
10. Front passenger door control unit, Front passenger side exterior mirror, Front passenger side fold-in mirror motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5731
11. Front passenger door control unit, Front passenger side turn signal repeater bulb, Front passenger side exterior mirror, Front passenger side automatic anti-dazzle exterior mirror, Heated exterior mirror on front passenger side………………………………………………………………………………………………………………………………………………………………………………………………5732
12. Rear left door control unit, Rear left door lock unit, Rear left window regulator motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5733
13. Rear left window regulator switch, in door, Rear left door control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5734
14. Rear left door control unit, Rear left door lock unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5735
15. Rear right door contact switch, Rear right door control unit, Rear right door lock unit, Rear right window regulator motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5736
16. Rear right window regulator switch, in door, Rear right door control unit, Rear right window regulator motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5737
17. Rear right door contact switch, Rear right door control unit, Rear right door lock unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5738
18. Interior mirror, Rain and light sensor, Data bus diagnostic interface…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5739
19. Front left footwell light, Front right footwell light, Front interior light……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5740
20. Driver vanity mirror contact switch, Front passenger vanity mirror contact switch, Front passenger side illuminated vanity mirror, Driver side illuminated vanity mirror, Rear left interior light, Rear right interior light, Interior light……………………………………………………………………………………………………………………………………………………………………………………..5741
21. Rear lid release switch, Rear lid lock unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5742
22. Rear lid control unit, Motor 1 for rear lid, Motor 2 for rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5743
23. Anti-trapping sender, Anti-trapping sender 2, Rear lid control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5744
24. Rear lid closure button, Anti-trapping sender 3, Rear lid warning buzzer, Rear lid control unit, Power latching for rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5745
25. Rear lid power opening sender, Rear lid power opening sender 2, Onboard supply control unit, Rear lid power opening control unit, Interface for entry and start system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5746
26. Onboard supply control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5747
27. Centre switch module in dash panel, Onboard supply control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5748
005 –
Earthing concept…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5749
1.
Earthing concept………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5749
2. Earth point, on left in engine compartment, Earth point, on cylinder head, Earth connection (engine earth), in engine wiring harness, Earth connection (ignition coils), in engine prewiring harness, Earth point, engine and gearbox earth, Earth point 2, on front of left longitudinal member, Earth point on alternator…………………………………………………………………………………………………………………5750
3. Earth connection 1, in engine compartment wiring harness, Earth connection 4, in engine compartment wiring harness, Earth connection, in left headlight wiring harness, Earth point 3, on front of left longitudinal member………………………………………………………………………………………………………………………………………………………………………………………………………5751
4. Earth connection 3, in headlight wiring harness, Earth connection 2 in automatic gearbox wiring harness, Earth connection, in left headlight wiring harness……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5752
5. Earth connection 3, in headlight wiring harness, Earth connection 2, in engine compartment wiring harness, Earth connection, in left headlight wiring harness……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5753
6. Earth connection, in dual tone horn wiring harness, Earth connection 6, in engine compartment wiring harness, Earth point 1, on front of left longitudinal member, Earth point 2, on front of left longitudinal member, Earth point 1 at front of right longitudinal member, Connection (right brake wear indicator), in engine compartment wiring harness……………………………………………………………………………………..5754
7. Earth connection, in dual tone horn wiring harness, Earth connection 3, in engine compartment wiring harness, Earth point, on right headlight, Connection 23 in engine compartment wiring harness, Connection 1, in centre console wiring harness…………………………………………………………………………………………………………………………………………………………………………………..5755
8. Earth point, lower part of left A-pillar, Earth connection 1, in interior wiring harness, Earth connection 2, in drive side door wiring harness, Earth connection 5, in interior wiring harness, Earth connection 8, in interior wiring harness…………………………………………………………………………………………………………………………………………………………………………………….5756
9. Earth connection 1, in interior wiring harness, Earth connection 3, in interior wiring harness, Earth connection (HRC), in dash panel wiring harness……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5757
10. Earth connection 3, in interior wiring harness, Earth connection, in roof wiring harness………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5758
11. Earth connection 1, in dash panel wiring harness, Earth connection 1, in seat adjustment wiring harness, Earth connection, in rear left door wiring harness, Earth point on mounting for seat cross member (front left), Connection 2, in driver seat wiring harness…………………………………………………………………………………………………………………………………………………………………5759
12. Earth connection 4, in interior wiring harness……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5760
13. Earth connection 1, in front left wiring harness, Earth connection 1, in radio wiring harness, Earth connection 2, in radio wiring harness, Earth connection 4, in interior wiring harness, Earth point on front of right side member, Earth point on central tube for dash panel, centre left, Earth point on central tube for dash panel, centre right, Earth point on heater element for auxiliary air heating, Connection 2, in main wiring harness….5761
14. Earth point, lower part of right A-pillar, Earth connection 2, in interior wiring harness, Earth connection 2, in front passenger side door wiring harness, Earth connection 2, in roof wiring harness………………………………………………………………………………………………………………………………………………………………………………………………………………………..5763
15. Earth connection 1, in dash panel wiring harness, Earth connection 2, in seat adjustment wiring harness, Earth connection, in rear right door wiring harness, Connection 1, in front passenger seat wiring harness……………………………………………………………………………………………………………………………………………………………………………………………………………..5764
16. Earth connection, in fuel tank wiring harness, Earth point on mounting for seat cross member (front right)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5765
17. Earth connection, in rear lid wiring harness, Earth connection 7, in interior wiring harness………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5766
18. Earth point, right C-pillar, Earth connection 7, in interior wiring harness, Earth connection 10, in interior wiring harness, Earth connection 3, in rear lid wiring harness, Earth point, centre on rear lid………………………………………………………………………………………………………………………………………………………………………………………………………………….5767
19. Earth connection 1, in front wiring harness, Earth connection 5, in rear wiring harness, Earth point, rear right side panel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5768
006 –
Anti-lock brake system (ABS) , (L0L)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5769
1.
Anti-lock brake system (ABS) , (L0L)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5769
2. ABS control unit, Fuse holder B, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5770
3. Front right speed sensor, Front left speed sensor, Clutch position sender, Vacuum sender, ABS control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5771
4. Rear right speed sensor, ABS control unit, Left parking brake motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5772
5. Rear left speed sensor, ABS control unit, Tyre Pressure Monitoring System control unit, Data bus diagnostic interface, Dash panel insert, Right parking brake motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5773
6. Electromechanical parking brake button, Onboard supply control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5774
008 –
Entry and start authorisation , (4F2),(4L3)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5775
1.
Entry and start authorisation , (4F2),(4L3)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5775
2. Starter button, Onboard supply control unit, Interface for entry and start system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5776
3. Driver exterior door handle, Front passenger exterior door handle, Interface for entry and start system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5777
4. Data bus diagnostic interface, Engine control unit, Interface for entry and start system, Rear bumper aerial for entry and start system, Luggage compartment aerial for entry and start system, Interior aerial 1 for entry and start system, Interior aerial 2 for entry and start system………………………………………………………………………………………………………………………………………………5778
5. Rear lid power opening control unit, Interface for entry and start system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5779
009 –
Window wash/wipe system, headlight washer system………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5780
1.
Window wash/wipe system, headlight washer system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5780
2. Windscreen washer fluid level sender, Wiper motor control unit, Onboard supply control unit, Fuse holder B, Washer pump, Headlight washer system pump, Left washer jet heater element, Right washer jet heater element…………………………………………………………………………………………………………………………………………………………………………………………………………..5781
3. Onboard supply control unit, Fuse holder C, Rear window wiper motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5782
010 –
Adaptive cruise control , (6K2),(6K3)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5783
1.
Adaptive cruise control , (6K2),(6K3)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5783
2. Adaptive cruise control unit, Data bus diagnostic interface, Front camera for driver assist systems, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5784
011 –
Anti-theft alarm system , (7AS)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5785
1.
Anti-theft alarm system , (7AS)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5785
2. Button for deactivating interior monitoring and vehicle inclination sensor, Anti-theft alarm sensor, Alarm horn, Onboard supply control unit, Fuse holder B, Fuse holder C, Front interior light………………………………………………………………………………………………………………………………………………………………………………………………………………………………5786
012 –
12 V sockets………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5788
1.
12 V sockets……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5788
2. Onboard supply control unit, Fuse holder C, Cigarette lighter, 12 V socket, 12 V socket 2, 12 V socket 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5789
013 –
Dual clutch gearbox 09D , (0ES)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5790
1.
Dual clutch gearbox 09D , (0ES)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5790
2. Engine control unit, Mechatronic unit for dual clutch gearbox, Fuse holder B……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5791
3. Mechatronic unit for dual clutch gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5792
4. Selector lever, Onboard supply control unit, Steering column electronics control unit, Data bus diagnostic interface, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5793
5. Selector lever, Selector lever locked in position P switch, Selector lever lock solenoid, Selector lever position display……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5794
014 –
Dual clutch gearbox 0CW , (0EG)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5795
1.
Dual clutch gearbox 0CW , (0EG)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5795
2. Engine control unit, Mechatronic unit for dual clutch gearbox, Fuse holder B……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5796
3. Mechatronic unit for dual clutch gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5797
4. Selector lever, Onboard supply control unit, Steering column electronics control unit, Data bus diagnostic interface, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5798
5. Selector lever, Selector lever locked in position P switch, Selector lever lock solenoid, Selector lever position display……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5799
015 –
Front camera for driver assist systems , (QK1)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5800
1.
Front camera for driver assist systems , (QK1)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5800
2. Adaptive cruise control unit, Data bus diagnostic interface, Front camera for driver assist systems, Fuse holder C, Windscreen heater for front sensors…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5801
016 –
Electromechanical steering………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5802
1.
Electromechanical steering…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5802
2. Power steering control unit, Data bus diagnostic interface, Fuse holder A………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5803
3. Steering moment sender, Power steering control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5804
017 –
Parking aid (PDC) , (7X2),(7X5)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5805
1.
Parking aid (PDC) , (7X2),(7X5)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5805
2. Centre switch module in dash panel, Parking aid button, Park assist steering button, Parking aid control unit, Park assist steering control unit, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5806
3. Front left parking aid sender, Front left sender for park assist steering on left side of vehicle, Rear parking aid warning buzzer, Front parking aid warning buzzer, Parking aid control unit, Data bus diagnostic interface, Park assist steering control unit……………………………………………………………………………………………………………………………………………………………………..5807
4. Front right parking aid sender, Front centre right parking aid sender, Front centre left parking aid sender, Front right sender for park assist steering on right side of vehicle, Parking aid control unit, Park assist steering control unit……………………………………………………………………………………………………………………………………………………………………………………..5808
5. Rear left parking aid sender, Rear centre left parking aid sender, Rear centre right parking aid sender, Rear left park assist steering sender, Parking aid control unit, Park assist steering control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………….5809
6. Rear right parking aid sender, Rear right park assist steering sender, Parking aid control unit, Park assist steering control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5810
018 –
Trailer coupling , (1M6)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5811
1.
Trailer coupling , (1M6)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5811
2. Trailer detector control unit, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5812
3. Electric hinged tow coupling attachment button, Trailer detector control unit, Onboard supply control unit, Data bus diagnostic interface, Trailer towing coupling…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5813
4. Trailer detector control unit, Trailer socket, Trailer towing coupling…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5814
019 –
Air conditioning system , (KH6)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5815
1.
Air conditioning system , (KH6)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5815
2. Heater and air conditioning controls, Fresh air blower control unit, Air conditioning system control unit, Fuse holder C, Fresh air blower………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5816
3. Heater and air conditioning controls, Pressure sender for refrigerant circuit, Air conditioning system control unit, Air conditioner compressor regulating valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5817
4. Heater and air conditioning controls, Evaporator temperature sensor, Air conditioning system control unit, Data bus diagnostic interface, Air recirculation flap control motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5818
5. Heater and air conditioning controls, Potentiometer for temperature flap control motor, Potentiometer for air distribution flap control motor, Air conditioning system control unit, Temperature flap control motor, Air distribution flap control motor…………………………………………………………………………………………………………………………………………………………………………….5819
020 –
Climatronic , (KH7)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5820
1.
Climatronic , (KH7)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5820
2. Heater and air conditioning controls, Operating and display unit for rear air conditioning system, Rear vent temperature sender, Fresh air blower control unit, Fuse holder C, Fresh air blower……………………………………………………………………………………………………………………………………………………………………………………………………………………………….5821
3. Heater and air conditioning controls, Air quality sensor, Pressure sender for refrigerant circuit, Air conditioner compressor regulating valve…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5822
4. Heater and air conditioning controls, Sunlight penetration photosensor, Front left chest vent temperature sensor, Front right chest vent temperature sensor, Data bus diagnostic interface……………………………………………………………………………………………………………………………………………………………………………………………………………………………………5823
5. Heater and air conditioning controls, Potentiometer for left temperature flap control motor, Potentiometer for right temperature flap control motor, Left temperature flap control motor, Right temperature flap control motor……………………………………………………………………………………………………………………………………………………………………………………………………5824
6. Heater and air conditioning controls, Potentiometer for front air distribution flap control motor, Potentiometer for fresh air/air recirculation, air flow flap control motor, Fresh air/air recirculation, air flow flap control motor, Front air distribution flap control motor……………………………………………………………………………………………………………………………………………………..5825
7. Heater and air conditioning controls, Potentiometer for defroster flap control motor, Potentiometer for rear temperature flap motor, Defroster flap control motor, Rear temperature flap control motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………5826
8. Heater and air conditioning controls, Footwell vent temperature sender, Evaporator temperature sensor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5827
021 –
Radiator fan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5828
1.
Radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5828
2. Radiator fan control unit, Fuse holder A, Fuse holder B, Radiator fan, Radiator fan 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5829
3. Radiator fan control unit, Engine control unit, Radiator fan control unit 2, Radiator fan, Radiator fan 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5830
022 –
Auxiliary coolant heater , (9M9)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5831
1.
Auxiliary coolant heater , (9M9)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5831
2. Temperature sensor, Overheating sensor, Auxiliary heater control unit, Data bus diagnostic interface, Heater coolant shut-off valve, Glow plug with flame monitor, Fuse holder B, Metering pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………….5832
3. Auxiliary heater control unit, Roof aerial, Remote control receiver for auxiliary coolant heater, Fuse holder C, Combustion air blower, Circulation pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5833
023 –
Adjustable seat , (3L5),(3PB),(3PE)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5834
1.
Adjustable seat , (3L5),(3PB),(3PE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5834
2. Operating unit for front left seat adjustment, Fuse holder C, Front left seat pan…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5835
3. Operating unit for front right seat adjustment, Front passenger seat adjustment thermal fuse 1, Front right seat pan………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5836
024 –
Adjustable seat , (8I2),(8I3),(8I9)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5837
1.
Adjustable seat , (8I2),(8I3),(8I9)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5837
2. Driver seat lumbar support adjustment switch, Massage control unit, Lumbar support for driver seat………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5838
3. Driver seat lumbar support adjustment switch, Massage function button, Massage control unit, Front passenger seat adjustment thermal fuse 1, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5839
4. Massage control unit, Lumbar support for driver seat…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5840
025 –
Seat heating , (4A3),(4A4)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5841
1.
Seat heating , (4A3),(4A4)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5841
2. Onboard supply control unit, Fuse holder C, Heated seat cushion for driver seat, Heated backrest for driver seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5842
3. Heater and air conditioning controls, Onboard supply control unit, Data bus diagnostic interface, Heated seat cushion for front passenger seat, Heated backrest for front passenger seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5843
4. Operating and display unit for rear air conditioning system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5844
5. Heated bench seat cushion for rear left seat, Heated backrest for rear left seat, Heated bench seat cushion for rear right seat, Heated backrest for rear right seat……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5845
026 –
Data bus network…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5846
1.
Data bus network………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5846
2. Fuse holder C, Diagnostic connection…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5847
3. Data bus diagnostic interface, Display unit for front information display and operating unit control unit, Control unit 1 for information electronics, Reversing camera, Fuse holder B……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5848
4. Heater and air conditioning controls, Operating and display unit for rear air conditioning system, Pressure sender for refrigerant circuit, Fresh air blower control unit, Electronically controlled damping control unit, Auxiliary heater control unit, Da a bus diagnostic interface, Remote control receiver for auxiliary coolant heater, Auxiliary air heater element………………………………………………………………………5849
5. ABS control unit, Adaptive cruise control unit, Parking aid control unit, Power steering control unit, Data bus diagnostic interface, Control unit for cornering light and headlight range control…………………………………………………………………………………………………………………………………………………………………………………………………………………………….5850
6. Alternator with voltage regulator, Battery monitor control unit, Data bus diagnostic interface, Mechatronic unit for dual clutch gearbox, Control unit for cornering light and headlight range control, Front left headlight, Front right headlight, DC/AC converter with socket, 12 V – 230 V…………………………………………………………………………………………………………………………………………..5851
7. Selector lever, NOx sender, Airbag control unit, Tyre Pressure Monitoring System control unit, Data bus diagnostic interface, Engine control unit, Lane change assist control unit, Control unit for front left belt tensioner, Control unit for front right belt tensioner……………………………………………………………………………………………………………………………………………………………5852
8. Interior mirror, Data bus diagnostic interface, Lane change assist control unit 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5853
9. Data bus diagnostic interface, Rear lid control unit, Rear lid power opening control unit, Interface for entry and start system, Front camera for driver assist systems…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5854
10. Trailer detector control unit, Front passenger door control unit, Rear right door control unit, Data bus diagnostic interface, Rear right window regulator motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5855
11. Driver door control unit, Rear left door control unit, Steering column electronics control unit, Data bus diagnostic interface, Control unit for electronic steering column lock, Dash panel insert, Rear left window regulator motor…………………………………………………………………………………………………………………………………………………………………………………………….5856
12. Rain and light sensor, Anti-theft alarm sensor, Alarm horn, Wiper motor control unit, Onboard supply control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5857
027 –
Sliding/tilting sunroof , (3FU)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5858
1.
Sliding/tilting sunroof , (3FU)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5858
2. Sliding sunroof adjustment control unit, Light 1 for roof contour lighting, Light 2 for roof contour lighting………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5859
3. Sunroof button, Button 1 for roof roller blind, Sliding sunroof adjustment control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5860
4. Sliding sunroof adjustment control unit, Sliding sunroof motor, Sunroof roller blind motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5861
028 –
Radio navigation system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5862
1.
Radio navigation system……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5862
2. Display unit for front information display and operating unit control unit, Control unit 1 for information electronics, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5863
3. Data bus diagnostic interface, Display unit for front information display and operating unit control unit, Control unit 1 for information electronics, Telephone microphone…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5864
4. Control unit 1 for information electronics, USB hub, Coupling point in interior, USB connection 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5865
5. Control unit 1 for information electronics, Connection for external audio sources, USB connection 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5866
6. Control unit 1 for information electronics, Front left treble loudspeaker, Front left bass loudspeaker, Front right treble loudspeaker, Front right bass loudspeaker……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5867
7. Control unit 1 for information electronics, Rear left treble loudspeaker, Rear left bass loudspeaker, Rear right treble loudspeaker, Rear right bass loudspeaker…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5868
8. Control unit 1 for information electronics, Radio aerial 2, Left aerial module, Digital radio aerial, Radio aerial……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5869
9. Control unit 1 for information electronics, Roof aerial, Amplitude modulation (AM) frequency filter, Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Fuse holder C, Heated rear window……………………………………………………………………………………………………………………………………………………………………..5870
029 –
Reversing camera (Rear Assist) , (KA2)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5871
1.
Reversing camera (Rear Assist) , (KA2)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5871
2. Data bus diagnostic interface, Control unit 1 for information electronics, Reversing camera, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5872
030 –
Mobile telephone systems , (9ZE)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5873
1.
Mobile telephone systems , (9ZE)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5873
2. Control unit 1 for information electronics, Two-way signal amplifier for mobile telephone/data services, Roof aerial, Storage compartment with interface for mobile telephone, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5874
031 –
Airbag systems , (L0L)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5875
1.
Airbag systems , (L0L)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5875
2. Key operated switch to deactivate front passenger side airbag, Airbag control unit, Front passenger side airbag deactivated warning lamp, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5876
3. Airbag control unit, Control unit for front left belt tensioner, Control unit for front right belt tensioner, Driver seat belt tensioner igniter 1, Front passenger seat belt tensioner igniter 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………..5877
4. Driver side belt switch, Airbag control unit, Steering column electronics control unit, Driver side airbag igniter, Driver side curtain airbag igniter, Driver side knee airbag igniter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5878
5. Side airbag crash sensor on front passenger side, Airbag control unit, Front passenger side airbag igniter 1, Side airbag igniter on driver side, Front passenger side curtain airbag igniter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………5879
6. Front passenger side belt switch, Seat occupied sensor, front passenger side, Side airbag crash sensor on front passenger side, Airbag control unit, Side airbag igniter on front passenger side………………………………………………………………………………………………………………………………………………………………………………………………………………………………5880
7. Airbag control unit, Data bus diagnostic interface, Rear side airbag igniter on driver side, Rear side airbag igniter on front passenger side, Diagnostic connection……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5881
8. Crash sensor for front airbag, Rear side airbag crash sensor on driver side, Rear side airbag crash sensor on front passenger side, Trigger 1 for pedestrian protection, Trigger 2 for pedestrian protection, Airbag control unit…………………………………………………………………………………………………………………………………………………………………………………………………5882
9. Driver side crash sensor for pedestrian protection, Front passenger side crash sensor for pedestrian protection, Front pressure hose sensor for pedestrian protection, Centre crash sensor for pedestrian protection, Airbag control unit………………………………………………………………………………………………………………………………………………………………………………………….5883
10. Rear belt switch, driver side, Rear belt switch, front passenger side, Belt switch for seat row 2, middle left, Belt switch for seat row 2, middle right, Belt switch for seat row 3, passenger side, Belt switch 2 for seat row 3, passenger side, Airbag control unit………………………………………………………………………………………………………………………………………………………………5884
11. Belt switch for seat row 3, driver side, Belt switch 2 for seat row 3, driver side, Airbag control unit, Rear belt tensioner igniter on driver side, Rear belt tensioner igniter on front passenger side………………………………………………………………………………………………………………………………………………………………………………………………………………………5885
032 –
Anti-lock brake system (ABS) , (L0R)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5886
1.
Anti-lock brake system (ABS) , (L0R)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5886
2. ABS control unit, Fuse holder B, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5887
3. Front left speed sensor, Clutch position sender, Vacuum sender, ABS control unit, Right parking brake motor………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5888
4. Front right speed sensor, ABS control unit, Left parking brake motor…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5889
5. Rear right speed sensor, Rear left speed sensor, ABS control unit, Tyre Pressure Monitoring System control unit, Data bus diagnostic interface, Dash panel insert………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5890
6. Electromechanical parking brake button, Front right brake pad wear sender, Onboard supply control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5891
033 –
Multifunction steering wheel………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5892
1.
Multifunction steering wheel……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5892
2. Selector lever, Airbag coil connector and return ring with slip ring, Horn plate, Airbag control unit, Multifunction steering wheel control unit, Steering column electronics control unit, Data bus diagnostic interface, Driver side airbag igniter, Fuse holder C………………………………………………………………………………………………………………………………………………………………….5893
3. Multifunction buttons on left in steering wheel, Multifunction buttons on right in steering wheel, Tiptronic switch (shift up), Tiptronic switch (shift down), Multifunction steering wheel control unit, Steering column electronics control unit, Engi
e control unit……………………………………………………………………………………………………………………………………………………………….5894
034 –
1.2l petrol engine , CYVB…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5895
1.
1.2l petrol engine , CYVB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5895
2. Battery, Starter, Alternator with voltage regulator, Starter relay 1, Starter relay 2, Fuse holder B………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5896
3. Main relay, Fuse holder B…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5897
4. Centre switch module in dash panel, Onboard supply control unit, Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5898
5. Accelerator pedal module, Radiator outlet coolant temperature sender, Engine control unit, Radiator fan……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5899
6. Brake light switch, Clutch position sender, Gearbox neutral position sender, ABS control unit, Engine control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5900
7. Lambda probe 1 after catalytic converter, Lambda probe 1 before catalytic converter, Data bus diagnostic interface, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5901
8. Steering column electronics control unit, Engine control unit, Interface for entry and start system, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5902
9. Oil level and oil temperature sender, Power steering control unit, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5903
10. Engine speed sender, Knock sensor 1, Coolant temperature sender, Engine control unit, Charge pressure positioner…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5904
11. Intake manifold sender, Charge pressure sender, Hall sender, Fuel pressure sender, Engine control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5905
12. Oil pressure switch for reduced oil pressure, Throttle valve module, Engine control unit, Activated charcoal filter solenoid valve 1, Camshaft control valve 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5906
13. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Fuel pressure regulating valve, Charge air cooling pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5907
14. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage, Spark plug 1, Spark plug 2, Spark plug 3, Spark plug 4…………………………………………………………………………………………………………………………………………………………………………………………………………5908
15. Fuel delivery unit, Fuel pump control unit, Dash panel insert………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5909
036 –
1.6l diesel engine , CRKB…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5910
1.
1.6l diesel engine , CRKB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5910
2. Battery, Starter, Battery monitor control unit, Starter relay 1, Starter relay 2, Fuse holder B…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5911
3. Terminal 30 voltage supply relay, High heat output relay, Fuse holder B, Auxiliary air heater element……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5912
4. Automatic glow period control unit, Fuse holder B……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5913
5. Low heat output relay, Relay for reducing agent metering system, Fuse holder B, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5914
6. Centre switch module in dash panel, Onboard supply control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5915
7. Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5916
8. Air mass meter, Exhaust gas temperature sender 2, Exhaust gas temperature sender 3, Engine control unit, Heater element for crankcase breather…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5917
9. Water separator sender, Gearbox neutral position sender, Engine control unit, Exhaust flap control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5918
10. Delivery unit for reducing agent metering system, Engine control unit, Control unit for reducing-agent heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5919
11. Delivery unit for reducing agent metering system, Oil level and oil temperature sender, Engine control unit, Radiator fan, Auxiliary pump for heating……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5920
12. Alternator with voltage regulator, Brake light switch, Engine control unit, Charge air cooling pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5921
13. Lambda probe 1 before catalytic converter, NOx sender, Engine control unit, Injector for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5922
14. Accelerator pedal module, Clutch position sender, ABS control unit, Engine control unit, Mechatronic unit for dual clutch gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5923
15. Steering column electronics control unit, Data bus diagnostic interface, Engine control unit, Interface for entry and start system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5924
16. Cylinder 3 combustion chamber pressure sender, Engine control unit, Glow plug 3, Glow plug 1, Glow plug 2, Glow plug 4……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5925
17. Oil pressure switch, Oil pressure switch for reduced oil pressure, Exhaust gas temperature sender 4, Engine control unit, Charge pressure control solenoid valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5926
18. Engine control unit, Fuel pressure regulating valve, Fuel metering valve, Valve for oil pressure control, Coolant valve for cylinder head………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5927
19. Hall sender, Fuel temperature sender, Exhaust gas temperature sender 1, Position sender for charge pressure positioner, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5928
20. Throttle valve module, Exhaust gas pressure sensor 1, Engine control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5929
21. Exhaust gas recirculation valve 1, Exhaust gas recirculation valve 2, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5930
22. Engine speed sender, Fuel pressure sender, Pressure differential sender, Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5931
23. Charge pressure sender, Intake air temperature sender, Coolant temperature sender, Charge air temperature sender after charge air cooler, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5932
24. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5933
25. Fuel delivery unit, Fuel pump control unit, Dash panel insert………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5934
037 –
2.0l diesel engine , CRMB…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5935
1.
2.0l diesel engine , CRMB………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5935
2. Battery, Starter, Battery monitor control unit, Starter relay 1, Starter relay 2, Fuse holder B…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5936
3. Terminal 30 voltage supply relay, High heat output relay, Fuse holder B, Auxiliary air heater element……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5937
4. Automatic glow period control unit, Fuse holder B……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5938
5. Low heat output relay, Relay for reducing agent metering system, Fuse holder B, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5939
6. Centre switch module in dash panel, Onboard supply control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5940
7. Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5941
8. Air mass meter, Exhaust gas temperature sender 2, Exhaust gas temperature sender 3, Engine control unit, Heater element for crankcase breather…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5942
9. Water separator sender, Gearbox neutral position sender, Engine control unit, Exhaust flap control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5943
10. Delivery unit for reducing agent metering system, Engine control unit, Control unit for reducing-agent heater……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5944
11. Delivery unit for reducing agent metering system, Oil level and oil temperature sender, Engine control unit, Radiator fan, Auxiliary pump for heating……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5945
12. Alternator with voltage regulator, Brake light switch, Engine control unit, Charge air cooling pump………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5946
13. Lambda probe 1 before catalytic converter, NOx sender, Engine control unit, Injector for reducing agent…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5947
14. Accelerator pedal module, Clutch position sender, ABS control unit, Engine control unit, Mechatronic unit for dual clutch gearbox……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5948
15. Steering column electronics control unit, Data bus diagnostic interface, Engine control unit, Interface for entry and start system…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5949
16. Cylinder 3 combustion chamber pressure sender, Engine control unit, Glow plug 3, Glow plug 1, Glow plug 2, Glow plug 4……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5950
17. Oil pressure switch, Oil pressure switch for reduced oil pressure, Exhaust gas temperature sender 4, Engine control unit, Charge pressure control solenoid valve………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5951
18. Engine control unit, Camshaft control valve 1, Fuel pressure regulating valve, Fuel metering valve, Valve for oil pressure control, Coolant valve for cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5952
19. Hall sender, Fuel temperature sender, Exhaust gas temperature sender 1, Position sender for charge pressure positioner, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5953
20. Throttle valve module, Exhaust gas pressure sensor 1, Engine control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5954
21. Exhaust gas recirculation valve 1, Exhaust gas recirculation valve 2, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5955
22. Engine speed sender, Fuel pressure sender, Pressure differential sender, Engine control unit………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5956
23. Charge pressure sender, Intake air temperature sender, Coolant temperature sender, Charge air temperature sender after charge air cooler, Engine control unit…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5957
24. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5958
25. Fuel delivery unit, Fuel pump control unit, Dash panel insert………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5959
038 –
Heated windscreen , (4GX)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5960
1.
Heated windscreen , (4GX)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5960
2. Heated windscreen relay, Onboard supply control unit, Heated windscreen relay 2, Fuse holder B, Heated windscreen…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5961
039 –
Steering column electronics for heated steering wheel , (2ZD),(2ZW)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5962
1.
Steering column electronics for heated steering wheel , (2ZD),(2ZW)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5962
2. Selector lever, Airbag control unit, Onboard supply control unit, Steering column electronics control unit, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5963
3. Steering column electronics control unit, Data bus diagnostic interface, Engine control unit, Heated steering wheel…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5964
040 –
Lane departure warning , (7Y1),(7Y5)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5965
1.
Lane departure warning , (7Y1),(7Y5)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5965
2. Data bus diagnostic interface, Lane change assist control unit 2, Lane change assist warning lamp in left exterior mirror, Fuse holder C, Left exterior mirror…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5966
3. Lane change assist control unit, Lane change assist warning lamp in right exterior mirror, Right exterior mirror……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5967
041 –
LED headlights , (8IT)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5968
1.
LED headlights , (8IT)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5968
2. Onboard supply control unit, Control unit for cornering light and headlight range control, Front left headlight………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5969
3. Rear left vehicle level sender, Front left vehicle level sender, Onboard supply control unit, Data bus diagnostic interface, Control unit for cornering light and headlight range control, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………………………………….5970
4. Onboard supply control unit, Control unit for cornering light and headlight range control, Front right headlight……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5971
042 –
DC/AC converter with socket , (9Z3)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5972
1.
DC/AC converter with socket , (9Z3)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5972
2. Data bus diagnostic interface, Fuse holder C, DC/AC converter with socket, 12 V – 230 V……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5973
043 –
LED headlights , (8IU)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5974
1.
LED headlights , (8IU)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5974
2. Output module 1 for left LED headlight, Onboard supply control unit, Output module for left headlight, Front left headlight, Fuse holder C………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5975
3. Rear left vehicle level sender, Onboard supply control unit, Data bus diagnostic interface, Control unit for cornering light and headlight range control………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5976
4. Output module 1 for right LED headlight, Front left vehicle level sender, Onboard supply control unit, Output module for right headlight, Control unit for cornering light and headlight range control, Front right headlight…………………………………………………………………………………………………………………………………………………………………………………………………….5977
044 –
Electrically adjustable backrest and lumbar support , (7P1),(7P7),(7P8)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5978
1.
Electrically adjustable backrest and lumbar support , (7P1),(7P7),(7P8)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5978
2. Operating unit for front left seat adjustment, Front left lumbar support adjustment switch, Fuse holder C, Lumbar support for driver seat, Front left backrest adjustment motor……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5979
3. Operating unit for front right seat adjustment, Front right lumbar support adjustment switch, Front passenger seat adjustment thermal fuse 1, Lumbar support for front passenger seat, Front right backrest adjustment motor……………………………………………………………………………………………………………………………………………………………………………………………………..5980
045 –
Dynamic Chassis Control , (2H4)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5981
1.
Dynamic Chassis Control , (2H4)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5981
2. Rear left vehicle level sender, Rear body acceleration sender, Electronically controlled damping control unit, Rear left shock absorber damping adjustment valve, Rear right shock absorber damping adjustment valve, Fuse holder C……………………………………………………………………………………………………………………………………………………………………………………………….5982
3. Front right vehicle level sender, Front left body acceleration sender, Electronically controlled damping control unit, Data bus diagnostic interface, Front left shock absorber damping adjustment valve, Front right shock absorber damping adjustment valve………………………………………………………………………………………………………………………………………………………………………..5983
4. Centre switch module in dash panel, Front left vehicle level sender, Front right body acceleration sender, Electronically controlled damping control unit, Onboard supply control unit……………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5984
046 –
Tail light cluster with LED , (8SK)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5985
1.
Tail light cluster with LED , (8SK)…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5985
2. Onboard supply control unit, Left tail light, Right tail light, Left tail light 2, Right tail light 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5986
048 –
Reversing camera (Rear Assist) , (KA1)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5987
1.
Reversing camera (Rear Assist) , (KA1)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5987
2. Onboard supply control unit, Control unit 1 for information electronics, Reversing camera, Fuse holder C…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5988
801 – – Fitting locations: Earth points – 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5989
1. Earth points………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5989
1.1 Earth points in front part of vehicle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5989
1.2 Earth points in middle part of vehicle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5991
1.3 Earth points in rear part of vehicle…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5993
802 – – Fitting locations: Fuses – 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5995
1. Fuses ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5995
1.1 Overview of fuse holders……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5995
1.2 Fitting location of fuse holder C -SC-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5996
1.2.1 Fitting location, fuse holder C -SC-, left-hand drive………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..5996
1.2.2 Fitting location, fuse holder C -SC-, right-hand drive……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….5997
1.3 Fuse assignment of fuse holder C -SC-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5998
1.3.1 Fuse assignment of fuse holder C -SC-, from September 2015……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………5998
1.4 Fitting location of fuse holder B -SB-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6002
1.5 Fuse assignment on fuse holder B -SB-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6004
1.5.1 Fuse assignment of fuse holder B -SB-, from September 2015……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6004
1.6 Fitting location, fuse holder A -SA-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6006
1.7 Fuse assignment on fuse holder A -SA-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6008
1.7.1 Fuse assignment of fuse holder A -SA-, from September 2015……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6008
803 – – Fitting locations: Relays – 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6009
1. Relays……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6009
1.1 Overview of relay carriers……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6009
1.2 Relay and fuse carrier 2 -SR2-, under dash panel, left…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6011
1.2.1 Fitting location and relay assignment of relay and fuse carrier 2 -SR2-, left-hand drive models, from September 2015………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6011
1.2.2 Fitting location and relay assignment of relay and fuse carrier 2 -SR2-, right-hand drive models, from September 2015……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6012
1.3 Relay and fuse carrier 1 -SR1-, in E-box in engine compartment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6013
1.3.1 Fitting location and relay assignment of relay and fuse carrier 1 -SR1-, on E-box, from September 2015…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6013
804 – – Fitting locations: Control units in front part of vehicle – 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6014
1. Control units in front part of vehicle……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6014
1.1 Overview of control units………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6014
1.2 Auxiliary heater control unit -J364-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6016
1.3 Front right headlight -MX2-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6017
1.3.1 Front right headlight -MX2-, with no variable front lights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6017
1.3.2 Front right headlight -MX2-, with variable front lights………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6019
1.4 ABS control unit -J104-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6021
1.5 Battery monitor control unit -J367-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6023
1.6 Wiper motor control unit -J400-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6025
1.6.1 Wiper motor control unit -J400-, left-hand drive models………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6025
1.6.2 Wiper motor control unit -J400-, right-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6026
1.7 Engine control unit -J623-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6028
1.7.1 Engine control unit -J623-, 60-pin connector -T60-/94-pin connector -T94-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6028
1.7.2 Engine control unit -J623-, 91-pin connector -T91-/105-pin connector -T105-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6030
1.8 Power steering control unit -J500-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6031
1.9 Front left headlight -MX1-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6032
1.9.1 Front left headlight -MX1-, with no variable front lights…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6032
1.9.2 Front left headlight -MX1-, with variable front lights……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6034
1.10 Mechatronic unit for dual clutch gearbox -J743-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6036
1.10.1 Mechatronic unit for dual clutch gearbox -J743-, 20-pin connector -T20c-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6036
1.10.2 Mechatronic unit for dual clutch gearbox -J743-, 25-pin connector -T25a-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6038
1.11 Radiator fan -VX57-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6040
1.11.1 Radiator fan -VX57-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6040
1.11.2 Radiator fan -VX57-, 2x400W………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6042
1.12 Adaptive cruise control unit -J428-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6043
1.13 NOx sender -G295-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6045
1.14 Exhaust flap control unit -J883-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6047
805 – – Fitting locations: Control units in middle part of vehicle – 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6049
1. Control units in middle part of vehicle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6049
1.1 Overview of control units………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6049
1.2 Sliding sunroof adjustment control unit -J245-/sunroof roller blind control unit -J394-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6052
1.3 Fuel pump control unit -J538-, for models with petrol engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6053
1.4 Fuel pump control unit -J538-, for models with diesel engine……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6055
1.5 Multifunction steering wheel control unit -J453-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6056
1.6 Massage control unit -J740-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6058
1.6.1 Massage control unit -J740-, only left-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6058
1.6.2 Massage control unit -J740-, only right-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6060
1.7 Driver door control unit -J386-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6061
1.8 Steering column electronics control unit -J527-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6064
1.9 Control unit for electronic steering column lock -J764-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6067
1.10 Interface for entry and start system -J965-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6069
1.10.1 Interface for entry and start system -J965-, only left-hand drive models………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6069
1.10.2 Interface for entry and start system -J965-, only right-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6071
1.11 Onboard supply control unit -J519-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6072
1.12 Parking aid control unit -J446-/park assist steering control unit -J791-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6077
1.12.1 Parking aid control unit -J446-/park assist steering control unit -J791-, only left-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6077
1.12.2 Parking aid control unit -J446-/park assist steering control unit -J791-, only right-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6080
1.13 Data bus diagnostic interface -J533-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6082
1.13.1 Data bus diagnostic interface -J533-, only left-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6082
1.13.2 Data bus diagnostic interface -J533-, only right-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6083
1.14 Control unit for cornering light and headlight range control -J745-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6084
1.15 Airbag control unit -J234-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6086
1.16 Fresh air blower control unit -J126-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6087
1.17 Control unit 1 for information electronics -J794-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6089
1.17.1 Control unit 1 for information electronics -J794-, only left-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6089
1.17.2 Control unit 1 for information electronics -J794-, only right-hand drive models………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6092
1.18 Dash panel insert -KX2-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6094
1.19 Climatronic control unit -J255-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6096
1.20 Air conditioning system control unit -J301-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6099
1.21 Display unit for front information display and operating unit control unit -J685-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6101
1.21.1 Display unit for front information display and operating unit control unit -J685-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6101
1.21.2 Display unit for front information display and operating unit control unit -J685-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6103
1.22 Front passenger door control unit -J387-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6105
1.23 Front camera for driver assist systems -R242-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6108
1.24 Main beam assist control unit -J844-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6110
1.25 Selector lever -E313-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6112
1.26 Rear left door control unit -J388-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6114
1.27 Rear right door control unit -J389-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6117
1.28 Operating and display unit for rear air conditioning system -E265-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6120
806 – – Fitting locations: Control units in rear part of vehicle – 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6123
1. Control units in rear part of vehicle………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6123
1.1 Overview of control units………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6123
1.2 Control unit for reducing agent metering system -J880-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6124
1.3 Trailer detector control unit -J345-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6125
1.4 Electronically controlled damping control unit -J250-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6127
1.5 Rear lid control unit -J605-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6129
1.6 Tyre Pressure Monitoring System control unit -J502-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6131
1.7 Rear lid power opening control unit -J938-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6133
1.8 Blind Spot Monitor control unit -J1086-/Blind Spot Monitor control unit 2 -J1087-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6134
807 – – Fitting locations: Coupling points – 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6137
1. Coupling points……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6137
1.1 Coupling point on left in engine compartment -TML-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6137
1.2 Diagnostic connection -U31-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6138
1.2.1 Diagnostic connection -U31-, left-hand drive models………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6138
1.2.2 Diagnostic connection -U31-, right-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6139
1.3 Coupling point on front left door -TTVL-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6140
1.4 Coupling point in front left door -TTIVL-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6141
1.5 Coupling point on rear left door -TTHL-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6142
1.6 Coupling point in interior, below left -TIUL-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6143
1.7 Coupling point for front left seat -TSVL-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6144
1.7.1 Coupling point for front left seat -TSVL-, left-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6144
1.7.2 Coupling point for front left seat -TSVL-, right-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6145
1.7.3 Coupling point in front left seat -TISVL-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6146
1.8 Coupling point in interior -TI-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6147
1.9 Coupling point for rear left seat -TSHL-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6148
1.10 Coupling point for roof -TH-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6149
1.11 Coupling point on front right door -TTVR-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6150
1.12 Coupling point in front right door -TTIVR-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6151
1.13 Coupling point on rear right door -TTHR-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6152
1.14 Coupling point in interior, below right -TIUR-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6153
1.15 Coupling point for front right seat -TSVR-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6154
1.15.1 Coupling point for front right seat -TSVR-, left-hand drive models……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6154
1.15.2 Coupling point for front right seat -TSVR-, right-hand drive models…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..6155
1.15.3 Coupling point in front right seat -TISVR-…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6156
1.16 Coupling point for rear right seat -TSHR-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6157
1.17 Coupling point for exhaust flap control unit -TAGK-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6158
1.18 Coupling point on rear lid -THK-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6159
1.19 Coupling point in luggage compartment, left -THRL-……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….6160
1.20 Coupling point in luggage compartment, right -THRR-………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………6161

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Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

Volkswagen Touran 2016 Workshop Manuals – PDF DOWNLOAD

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