Description of work Стр.

1 из 75

Description of work

Ball joints, visual inspection

- Check ball joint boots - arrow - for leaks and damage.

Automatic transmission, check ATF level

- Work procedure

Repair Manual, Automatic Transmission, Repair Group

37,

Tilt/slide sunroof, lubricating guide tracks

- Open CSC™ roof in order to lubricate tracks.

„ Conditions and warning notes, 01-4, Conditions

and warning notes .

„ CSC™ roof, opening, 01-4, CSC™ roof,

opening .

„ Lubricate guide tracks, 01-4, Guide tracks from

tilt/slide sunroof, lubricating .

„ Guide tracks from front sunroof channel, clean and

lubricate, 01-4, Guide tracks from front tilt/slide
sunroof channel, cleaning and lubricating .

„ CSC™ roof, closing, 01-4, CSC™ roof, closing .

Description of work Стр. 2 из 75

Conditions and warning notes

In order to be able to open or close the CSC™ roof, the

following conditions, among other things, must be fulfilled:

„ Vehicle must be standing.

„ Ignition must be switched on.

„ Battery must be sufficiently charged.

„ Luggage compartment cover must be engaged.

„ Exterior temperature must be over 5 F (-15 C).

„ There must not be a trailer on the trailer hitch and no

connector in the trailer socket.

„ There must be sufficient room behind the vehicle for

the luggage compartment lid to fold back.

Warning!

„ When opening or closing CSC™ roof, ensure

nobody can be injured by roof rods and other
moving parts.

„ Do not open or close the CSC™ roof if people,

especially children, are in the back seat. There is
a very high risk of being injured due to the slots,
bars and moving parts.

„ When interrupting opening or closing procedure,

be aware CSC™ roof probably will not stop
immediately in the corresponding position. The
roof may continue to move due to gravity - risk
of injury!

„ Note that the CSC™ roof sinks toward balance

point by itself after a little while (up to eight
minutes) if opening or closing procedure is
interrupted (e.g. by releasing lever or switching
ignition off).

„ For safety reasons, the CSC™ roof should only

be opened or closed when vehicle is parked -
Description of work Стр. 3 из 75

risk of accident!

„ Never drive when CSC™ roof is not completely

closed, opened or locked. There is the risk that
the CSC™ roof could open due to the wind when
driving. This could cause injuries or damage to
the vehicle.

Before opening and closing the CSC™ roof, ensure:

Caution!

„ There is sufficient space above and behind the

vehicle for the CSC™ roof to raise up and the
rear lid to fold back.

„ That the rear lid is closed correctly.

„ That there is no trailer attached to the trailer

hitch.

„ That there is no luggage rack on the roof or the

rear lid.

„ That there are no objects near right or left or on

closed luggage compartment cover because the
CSC™ roof is stored.

„ That there are no objects on the stored CSC™

roof.

CSC™ roof, opening

- Observe conditions and warning notes, 01-4,

Conditions and warning notes !

- Get in vehicle and switch ignition on.

If there is an obstacle behind the vehicle that is recognized

by the Electronic Parking Assistance system, the roof
procedure is stopped.

- Before and during each CSC™ roof opening and closing,

check area behind vehicle for possible obstacles and
ensure sufficient space, if necessary, to prevent damage.

- Press roof button - A - until roof is approx. 80% closed.

Description of work Стр. 4 из 75

Roof operation continues when roof button - A - is

pressed again.

Roof crossmembers should be as far apart as possible.

- Allow roof to remain in this intermediate position.

Block roof mechanics at hinges in luggage compartment

with suitable tool so that roof remains open in this position.

Suitable tool,

Repair Manual, Body Exterior, Repair Group 61,

Caution!

„ After 8 minutes, roof is automatically stored,

pressure drops in hydraulic system - risk of
injury!

„ Roof moves in the direction gravity pulls it.

„ If ignition key is removed in intermediate

position, lowering process is started
immediately.

Roof bars are now in position so that guide tracks are

accessible and can be lubricated.

Guide tracks from tilt/slide sunroof, lubricating

- CSC™ roof, opening, 01-4, CSC™ roof, opening .

Note:

„ Locations to be lubricated on guide tracks are

identified later.
Description of work Стр. 5 из 75

Guide tracks from front tilt/slide sunroof channel, cleaning and

lubricating

Note:

„ Locations to be lubricated on guide tracks are

identified later.

CSC™ roof, closing

- Observe conditions and warning notes, 01-4,

Conditions and warning notes !

- Pull roof button - A - until roof is closed.

A tone sounds and indicator light in instrument cluster turns

off.

- The closing process is interrupted as soon as the button

is released.

- If you continue to hold the button after opening or press it

again after releasing, side windows are raised.

Battery, check battery terminals for secure seating

Special tools, testers and auxiliary items required

Description of work Стр. 6 из 75

„ Torque wrench V.A.G 1331

Note:

„ Tight battery connections assure trouble-free battery

function and long service life.

Perform the following work procedure:

- Operate lock - arrow - , fold up and remove cover

toward front.

- Check battery terminal clamps are seated securely on

the battery terminals by moving the battery Ground (GND)
wire - 1 - and the battery positive wire - 2 - back and forth
by hand.

Warning!

If the battery clamp is not seated securely on the

positive terminal, disconnect battery Ground (GND)
clamp on battery negative terminal first, to prevent
possible accidents.

If the battery clamp on positive terminal is not seated

securely:
Description of work Стр. 7 из 75

- First disconnect battery clamp - 1 - at battery negative

terminal.

- Tighten battery clamp - 2 - on battery positive terminal to

6 Nm.

- Re-connect battery clamp - 1 - on battery negative

terminal and tighten to 9 Nm.

If the battery clamp on negative terminal is not seated

securely:

- Tighten battery ground (GND) connection - 1 - on battery

to 6 Nm.

- Reinstall cover.

Note:

„ Once the battery is reconnected:

Repair Manual, Electrical Equipment, Repair Group 27,

Battery, check

Battery, checking
Description of work Стр. 8 из 75

Repair Manual, Electrical Equipment, Repair Group 27,

Check tires, condition, tire tread design, filling pressure,

tread depth

Checking condition of tires, 01-4, Tire condition,

checking .

Checking tire wear pattern, 01-4, Checking tire wear

pattern .

Depth of tire tread (including spare wheel), checking,

01-4, Depth of tire tread (including spare wheel), check .

General notes, 01-4, General notes .

Check tire inflation pressure using tire inflation device VAS

5216 and correct it if necessary, Eos 2006 , 01-4,
Tire pressures, Eos 2006 .

Special tools, testers and auxiliary items required

„ Tire filling unit VAS 5216

Tire condition, checking

Warning!

If damage is discovered, the tire must be examined to

determine whether a new one must be installed.

Tests during delivery inspection:

- Check tires (tread and side walls) for damage and

remove foreign material for example nails and glass
splinters if necessary.

Tests during inspection service

- Check tires (tread and side walls) for damage and

remove foreign material for example nails and glass
Description of work Стр. 9 из 75

splinters if necessary.

- Check tires for scuffing, one sided wear, porous side

walls, cuts and fractures.

Checking tire wear pattern

The wear pattern of the front wheels can be used to assess

whether a check of the track and camber is necessary:

„ Feathered edges of the treads may indicate faulty

toe adjustment.

„ One-sided tread wear is mainly attributed to

incorrect camber.

When wear of this nature is noticed determine cause by

performing alignment checks (repair measure).

Depth of tire tread (including spare wheel), check

- Check tire tread depth

Minimum depth: 1.6 mm

Note:

„ This value may vary for individual countries due to

different legislative regulations.

„ The minimum tread depth is reached when the tires

have worn down level with the 1.6 mm high tread
wear indicators - arrows - positioned at intervals
around the tire.

„ If the tread depth is approaching the legal minimum

permissible depth, the customer must be informed.

General notes
Description of work Стр. 10 из 75

Warning!

„ For reasons of safety, only tires of same type

and tread pattern should be installed on a
vehicle!

„ On All Wheel Drive (AWD) vehicle tires of the

same type and tread pattern must be used.
Otherwise the center differential may be
damaged.

Note:

„ Tire inflation pressure table applies to normal tires,

for all tire sizes installed at factory.

„ Observe that the inflation pressure specifications

refer to the air pressure of cold tires. Do not reduce
increased pressures on warm tires.

„ Tires pressures for the relevant model are on a

sticker attached to the inside of fuel tank flap.

„ Adapt tire pressure corresponding to load.

„ The spare wheel receives the highest tire pressure

designated for the vehicle.

„ Note that a basic setting should be performed after

every change in pressure in vehicles with tire
pressure control indicator 01-4, Tire pressure
control indicator, performing basic setting .

Winter tires

Note:

„ Important information on the recommended winter

tires can be found in ElsaWin; Technical
Information; Wheels/tires guidebook .

„ For winter tires, tire inflation pressure must be

increased approx. 0.2 bar.

Tire pressures, Eos 2006

Gasoline engines
Description of work Стр. 11 из 75

2.0 L / 200 HP (147 kW), Topic 01-4 .

Gasoline engine

Displacement / output
2.0 L / 200 HP (147
kW) .
Tire sizes half load full load
front rear (bar) front rear
(bar) (bar) (bar)
215/55 R 16 93 V 2.4 2.4 2.6 3.0
205/55 R 16 91 H MS 2.4 2.4 2.6 3.0
235/45 R 17 94 V 2.4 2.4 2.6 3.0
Spare wheel (collapsible spare
wheel)
4.2 4.2 4.2 4.2

Brake fluid, changing

Notes on application and safety, 01-4, Notes on

application and safety precaution .

Specification of brake fluid, 01-4, Specification of brake

fluid .

Work procedure, changing brake fluid, 01-4, Work

procedure, changing brake fluid .

Notes on application and safety precaution

Note:

„ From model year 2006, a new brake fluid is

introduced.

„ The new brake fluid can also be used for older

vehicles.

„ New brake fluid can be mixed with previous brake

fluid.

„ For vehicles from model year 2006, "only" new brake

fluid must be used.

Warning!

„ Brake fluid must never come into contact with

fluids containing mineral oils (oil, gas, cleaning
Description of work Стр. 12 из 75

solutions). Oils containing minerals damage

seals and sleeves on brake systems.

„ Brake fluid is poisonous. Due to its caustic

nature, it must also never be brought into
contact with paint.

„ Brake fluid is hygroscopic, which means that it

absorbs moisture from the air. Always store
brake fluid in air-tight containers.

„ Wash off brake fluid spillage using plenty of

water.

„ Do not reuse, (used) extracted brake fluid.

„ Observe waste disposal regulations!

Specification of brake fluid

Permissible specifications of brake fluid for vehicles

from model year 2006:

„ Brake fluid corresponding to VW standard, VW 501

14 (new brake fluid).

Work procedure, changing brake fluid

Special tools, testers and auxiliary items required

„ Brake charger/bleeder unit VAS 5234

Description of work Стр. 13 из 75

Brake pedal depressor V.A.G 1869/2

- Unscrew brake fluid reservoir cap - 1 - .

- Extract as much brake fluid as possible using intake hose

Brake charger/bleeding unit VAS 5234 .

Note:

„ The strainer in the brake fluid reservoir must not be

removed.
Description of work Стр. 14 из 75

Warning!

Extracted brake fluid must not be re-used!

- Screw adapter - 1 - onto brake fluid reservoir.

Observe operating instructions for VAS 5234 !

- Install brake pedal depressor V.A.G 1869/2 between

drivers seat and brake pedal and apply tension.

- Connect charger hose of brake charger/bleeder unit VAS

5234 to adapter.

- Unscrew both wheels at rear axle in order to reach the

bleed screws.

- Pull cover caps off bleeder screws of brake calipers.

- Connect collector bottle bleeder hose - 1 - to right rear

bleed screw.

- Open bleeder screw and let the corresponding amount of

brake fluid (see table) flow out. Close bleeder screw.

Note:

„ Use a suitable bleed hose. It must seat tightly on

bleed screw so that no air can enter brake system.
Description of work Стр. 15 из 75

Repeat work procedure on left side of vehicle at rear.

- Connect collector bottle bleeder hose - 1 - to right front

bleeder screw, open bleed screw and allow the
corresponding quantity to flow out (see table). Close
bleeder screw.

Repeat work procedure on left side of vehicle at front.

Table - Sequence / quantity of brake fluid

Sequence: Brake fluid quantity which must flow out of wheel brake cylinders or brake
brake wheel calipers:
cylinder,
brake caliper
Left front 0.25 liter
Right front 0.25 liter
Left rear 0.25 liter
Right rear 0.25 liter

Total quantity: approx. 1 liter

- Install cover caps to brake caliper bleed screws.

- Move filler lever on brake charger/bleeder unit VAS

5234 to position "B" (see operating instructions).

- Take filler hose off adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and correct if necessary.

Description of work Стр. 16 из 75

- Screw in cap - 1 - for brake fluid reservoir.

- Remove brake pedal depressor.

- Check pedal pressure and brake pedal free play. Free

play: Max. 1 / 3 of pedal travel

Brake fluid level, check

Brake fluid level at delivery inspection

Brake fluid level at Inspection Service

Warning!

If fluid level is below MIN. marking - 2 - , brake system

must be checked before brake fluid is added "repair
measure" .

Notes on application and safety, 01-4, Notes on

application and safety precaution .

Specification of brake fluid, 01-4, Specification of brake

fluid .

Work procedure, brake fluid level (depending on brake pad

wear): Checking, 01-4, Work procedure, brake fluid level
(depending on brake pad wear), check .

Work procedure, brake fluid level (depending on brake pad

wear), check

Brake fluid level at delivery inspection:

Description of work Стр. 17 из 75

- At time of delivery inspection, brake fluid level must be at

MAX mark - 1 - .

Note:

„ To prevent the brake fluid from overflowing from the

reservoir, the level must not be over the MAX mark -
1 - .

Brake fluid level at Inspection Service:

The fluid level must always be judged in conjunction with

brake pad wear.

When vehicle is in use, the fluid level tends to drop slightly

due to brake pad wear and automatic adjustment.

„ Recommended brake fluid level when brake pad

wear limit has almost been reached:

"At MIN-marking and slightly above it" - 2 - , "NO

TOPPING OFF REQUIRED" .

„ Recommended brake fluid level when brake pads

are new or are far removed from the brake pad wear
limit:

"Between MIN- and MAX-Marking" .

Description of work Стр. 18 из 75

Brake system, visual check for leaks and damage

Check the following components for leaks and damage:

„ Brake master cylinder

„ Brake booster (on anti-lock braking system:

Hydraulic unit)

„ Brake pressure regulator and

„ Brake calipers

- Check that brake hoses are not twisted.

- Turn steering to left stop and to right stop. During this

operation no brake hose must touch any vehicle
components.

- Check brake hoses are not porous or brittle.

- Check brake hoses and pipes for chafing.

- Check brake connections and methods of securing for

correct seating, leaks and corrosion.

Warning!

Malfunctions found must be rectified (repair measure).

Brake linings front and rear, thickness, checking

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

„ Electric flashlight and mirror

Perform the following work procedure:

Description of work Стр. 19 из 75

The adapter to loosen/tighten the anti-theft wheel bolts is

located in the vehicle tool kit 01-4, Wheel securing bolts,
tighten to correct torque setting .

Front disc brake pads:

- For better judgment of remaining pad thickness remove

the front wheel on the drivers side.

- Pull off wheel bolt covers if necessary 01-4, Wheel

securing bolts, tighten to correct torque setting .

- Mark position of wheel in relation to brake disc.

- Unbolt wheel securing bolts and remove wheel.

- Measure inner and outer pad thickness.

a - Pad thickness without backing plate

Wear limit: 2 mm

With pad thickness (not including backing plate) of 2 mm,

the brake pads have reached their wear limit and must be
replaced (repair procedure). Inform customer!

Note:

„ When replacing brake pads, it is absolutely

necessary to check brake discs for wear! Checking
and if necessary replacing brake discs is a repair
measure.

- Check brake disc for wear

Repair Manual, Brake System, Repair Group 46,

- Install wheel to marked position.

- Tighten wheel securing bolts, using diagonal sequence to

tightening torque 01-4, Wheel securing bolts, tighten to
Description of work Стр. 20 из 75

correct torque setting .

- Place adapter with vehicle tool kit after completing work.

- Reinstall wheel bolt covers if necessary.

Rear disc brake pads:

- Illuminate area behind hole in wheel using an electric

flashlight.

- Determine thickness of outer pad by checking visually.

- Illuminate inner pad using an electric flashlight and

mirror.

- Determine thickness of inner pad by checking visually.

a - Pad thickness inner and outer, not including backing

plate

Wear limit: 2 mm

With pad thickness (not including backing plate) of 2 mm,

the brake pads have reached their wear limit and must be
replaced (repair procedure). Inform customer!

Note:

„ When replacing brake pads, it is absolutely

necessary to check brake discs for wear! Checking
and if necessary replacing brake discs is a repair
measure.

- Check brake disc for wear

Repair Manual, Brake System, Repair Group 46,

Electric windows, 1-touch down/up, resetting

Note:
Description of work Стр. 21 из 75

„ 1-touch down/up feature reduces the need to hold

buttons in control elements in vehicle door.

1-touch down/up, checking

- Switch ignition on.

All windows can be operated via control elements in drivers

door.

- Briefly press front button for all windows down to second

level. Windows open completely.

- Pull front button to close all windows.

After switching ignition off, windows can still be operated

for approx. 10 minutes as long as drivers or passengers
door is not opened.

1-touch down does not work after switching ignition off.

1-touch down/up, resetting

Note:

„ If the vehicle battery was disconnected or

discharged, 1-touch down/up does not function and
must be reset.

„ Before delivering a new vehicle, 1-touch down/up

feature must be reset.

„ The vehicle battery must not be disconnected after

resetting.

Work procedure

- Close all doors and windows completely.

- Place vehicle key in door lock and hold key in lock

position at least one second.

Window regulator positioning is now initialized.

Vehicle system test, perform

- Connect diagnostic tester 01-3, Diagnostic testing unit,

connecting .

- Switch ignition on.

- Select operating mode "Guided Fault Finding" on the

display.
Description of work Стр. 22 из 75

- Then perform vehicle identification on tester.

Program now performs a vehicle system test automatically

and checks for all possible control modules for this vehicle
type.

- Press Continue > button.

Now all DTCs will be listed.

Note:

„ At this point it makes sense to switch into operating

mode Guided Functions in order to perform further
work using VAS 5051 and to prevent a second
vehicle identification on the tester.

„ To do so, press operating mode button and then

Guided Functions.

„ Refer to the corresponding work descriptions for the

continued sequence.

„ In order to return to Guided Fault Finding, press the

operating mode button and then Guided Fault
Finding.

Caution!

In any case, the vehicle must be returned to the

customer with DTC memory erased.

Static malfunction

If one or more static malfunctions are stored in data

memory, it is recommended to arrange with the customer
to repair this malfunction via Guided Fault Finding.

Sporadic malfunctions

In the event only sporadic malfunctions or notes are stored

in DTC memory and the customer has made registered no
complaint in conjunction with an electronic vehicle system,
erase DTC memory.

- Press the Continue > button again to enter the test

plan.

- Now end Guided Fault Finding via Go to button and then

End.

All DTC memories will be checked now once more.

In the window now appearing, it will be confirmed that all

Description of work Стр. 23 из 75

sporadic DTCs were erased, diagnostic protocol is sent

"online" automatically.

Vehicle system test is completed.

CV (Constant Velocity) joint boots, visual inspection

Perform the following work procedure:

- Check outer and inner CV joint boots - arrows - for

leaks and damage.

Ribbed belt, checking condition

Perform the following work procedure:

- Crank engine at vibration damper/belt pulley using a

socket wrench.

Check ribbed belt - 1 - for:

„ Sub-surface cracks (cracks, core ruptures, cross

sectional breaks)

„ Layer separation (top layer, cord strands)

„ Base break-up
Description of work Стр. 24 из 75

„ Fraying of cord strands

„ Flank wear (material wear, frayed flanks, flank

brittleness -glassy flanks-, surface cracks)

„ Traces of oil and grease

Note:

„ Replace the belt if any damage is found. This will

avoid possible break-downs or operating problems.
The replacement of a ribbed belt is a repair
measure.

Cooling system, freeze protection and coolant level,

checking

Note:

„ All engines are filled with coolant additive G 12 Plus

according to TL VW 774 F (color purple). G 12 Plus
can be mixed with the previous coolant additives G
11 and G 12 (red). Ensure that the system is
replenished only with G12 Plus (due to its positive
properties).

„ G 12 Plus is suitable as a filled-for-life filling for cast

iron and all-aluminum engines and gives optimum
protection against freeze, corrosion damage, scaling
and over-heating.

„ G 12 Plus increases the boiling point to 275 F

(135 C) and ensures for a better heat dissipation.

„ The coolant portion of the mixture must amount to at

least 40% (freeze protection to -13 F [-25 C])
and should not exceed 60% (freeze protection to -40
F [-40 C]). Otherwise the freeze protection will
be reduced and the cooling efficiency will be
worsened.

„ The freeze protection must be ensured to

approximately -13 F (-25 C).

Checking freeze protection and adding coolant additive if

necessary
Description of work Стр. 25 из 75

Special tools, testers and auxiliary items required

„ Refractometer T10007

Note:

„ Read the bright/dark boundary to obtain an accurate

reading for the following tests. Place a drop of water
on the glass to improve the readability of the
bright/dark boundary. The bright/dark boundary can
be clearly recognized on the "WATERLINE" .

- Check the concentration of the coolant additive using

refractometer T10007 (operating instructions).

The scale - 1 - of the refractometer is designed for coolant

additives G 12; G12 Plus and G11.

Scale - 2 - refers only to coolant additive G 13. (previously

L80)

Note:

„ The freeze protection must be ensured to

approximately -13 F [-25 C].

„ If for climatic reasons greater freeze protection is

required, the amount of G 12 Plus can be increased,
Description of work Стр. 26 из 75

but only up to 60% (freeze protection to about -40

F [-40 C]), otherwise freeze protection and cooling
effectiveness will be reduced.

- If freeze protection is insufficient, drain off required

quantity shown in freeze protection table and add coolant
additive G 12 Plus.

Note:

„ Observe waste disposal regulations!

Freeze protection to C Difference amount in liters

Actual value Specified value 4-cylinder engines
0 -25 3.5
-35 4.0
-5 -25 3.0
-35 3.5
-10 -25 2.0
-35 3.0
-15 -25 1.5
-35 2.0
-20 -25 1.0
-35 1.5
-25 -35 1.0
-30 -35 0.5
-35 -40 0.5

- Check coolant additive concentration after test drive

again.

Checking coolant level and adding coolant if necessary

- Check coolant level in expansion tank with engine cold.

Description of work Стр. 27 из 75

„ Delivery inspection: Coolant level above the "MIN

marking" - arrow - .

„ Inspection service: Coolant level above the "MIN

marking" - arrow - .

- If coolant is too low, add required amount according to

mixture ratio.

Note:

„ Determine cause of fluid loss which cannot be

attributed to normal use and rectify (repair
measure).

Mixture ratio:

Freeze protection to Coolant additive G 12 Plus / Water

TL VW 774 F
-25 C approx. 40% approx. 60 %

-35 C approx. 50 % approx. 50 %

-40 F approx. 60 % approx. 40%

Note:

„ Coolant additive G 12 Plus conforming to TL VW

774 F prevents freeze and corrosion damage,
scaling, and raises the boiling point. For these
reasons, the cooling system must be filled with
radiator freeze and corrosion protection fluid all year
round.

„ Especially in countries with tropical climates or when

vehicle is driven under heavy load, the coolant
improves the engine reliability by its increased
boiling point.
Description of work Стр. 28 из 75

„ The coolant concentration must not be reduced by

adding water, even during the warmer season. The
coolant additive ratio must be at least 40%.

Air cleaner, cleaning housing and replacing filter element

Removing and installing air filter element, 2.0L TFSI

engines, 01-4, Removing and installing air filter element,
2.0 L TFSI engine .

Removing and installing air filter element, 2.0 L TFSI engine

Removing

- Remove engine cover 01-4, Upper engine cover,

removing and installing .

- Place engine cover with upper side on a soft surface,

prevent damage to chrome applications.

- Unscrew bolts - arrows - on lower side of engine cover.

- Separate lower part of air filter housing - 1 - from upper

part - 3 - .

- Remove air filter insert - 2 - from lower part of air filter

housing - 1 - .

Installing
Description of work Стр. 29 из 75

Note:

„ Self-locking bolts are equipped for fastening the

upper part of the air filter housing to the lower part of
air filter housing as well as the intake supports. If
these bolts are loosened of tightened using a drill
motor, the threads in the upper part of air filter
housing can be damaged.

„ For this reason, a drill motor may only be used when

the following prerequisites are met:

„ The drill motor RPM is max. 200 / min.

„ The torque must be adjustable to max. 3 Nm.

- Engage upper part of air filter housing - 1 - on retaining

tabs - arrows - on upper part of air filter housing - 2 - and
pivot in - direction of arrow - , then lightly press on.

- Both housing halves must fit together flush, - arrows - .

Description of work Стр. 30 из 75

- Tighten bolts - arrows - to maximum 3 Nm.

Upper engine cover, removing and installing

Caution!

„ To install engine cover or to engage at mounting

points, be sure not to strike the engine cover
with a fist or tool, danger of damage.

Removing and installing engine cover, 2.0 L TFSI gasoline

Direct Fuel Injection engines, 01-4, Removing and
installing engine cover, 2.0L TFSI gasoline Direct Fuel
Injection engines .

Removing and installing engine cover, 2.0L TFSI gasoline

Direct Fuel Injection engines

Special tools, testers and auxiliary items required

„ Spring type clip pliers VAS 5024A

Removing
Description of work Стр. 31 из 75

- Release spring clip - A - using spring-type clip pliers

VAS 5024A and slide air intake - B - from engine
compartment cover - C - .

- Disconnect connector - 1 - from Mass Air Flow (MAF)

sensor and set connector aside.

- Release both fastening clips - arrows A - .

- First release engine cover at - arrow 3 - , then - arrow

4 - and raise.

Installing

Installation is the reverse of removal.

Lower engine compartment cover (noise insulation),

removing and installing
Description of work Стр. 32 из 75

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1783

Work procedure

„ Self-tapping screws, Qty. 8, torque specification 2

Nm.
„ Combi-screws, Qty. 10, torque specification 6 Nm.

- Remove bolts - arrows - .

- Remove noise insulation rearward.

- Tighten screws - arrows - to correct torque

specification.

Engine and components in engine compartment (from

above and below), visual check for leaks and damage

Perform visual check as follows:

- Check engine and components in engine compartment

for leaks and damage.

- Check hoses, pipes and connections of

„ Fuel system
Description of work Стр. 33 из 75

„ Cooling and heating system

„ and brake system

for leaks, abrasions, porosity and brittleness.

Note:

„ Ensure that all malfunctions detected are rectified

within repair measures.

„ If fluid losses are greater than can be reasonably

expected, determine cause and repair (repair
measure)

Engine oil level, check

Note the following:

- After stopping engine, wait at least 3 minutes to allow oil

to flow back into oil pan.

- Pull out dipstick, wipe off with a clean cloth and re-insert
dipstick again up to stop.

Note:

„ Observe waste disposal regulations!

- Pull out dipstick again and read oil level.

If the dipstick appears as illustrated:

A - Oil must not be topped off.

B - Oil can be topped off. This will cause the oil level to be
in area A .
C - Oil must be topped off. It is sufficient when oil level is
in area B (grooved field).
Description of work Стр. 34 из 75

If oil level is above area - A - , the catalytic converter can

be damaged.

- When oil level is below marking - C - , top off with oil to

marking - A - . Oil specification 01-3, Engine oils .

Engine oil, draining or extracting; changing oil filter and

filling engine oil

Engine oil: Drain or extract and fill, 01-4, Engine oil,

draining or extracting .

Replace oil filter 01-4, Oil filter, replacing .

Filling with engine oil 01-4, Filling engine oil .

Engine oil, draining or extracting

Special tools, testers and auxiliary items required

„ Oil extractor V.A.G 1782

„ Oil absorbent towel VAS 6204/1

Engine oil, draining or extracting

Perform the following work procedure:

Note:

„ In engines with standing oil filter module, oil filter

should be changed before changing engine oil 01-
4, Oil filter, replacing . Removing the filter element
will open a valve and oil in the filter housing will flow
automatically into the crankshaft housing.

„ If engine oil is drained and not extracted using old oil

extraction unit, replace oil drain plug. This prevents
leaks.
Description of work Стр. 35 из 75

„ Observe waste disposal regulations!

- Extract engine oil using old oil collecting and extracting

unit V.A.G 1782 .

or

- Remove oil drain plug

- Drain engine oil.

Note:

„ The oil drain plug is equipped with a permanent seal,

therefore the oil drain plug must always be replaced.

„ Observe waste disposal regulations!

- Screw in new oil drain plug with sealing ring hand-tight.

- Fill up with engine oil, specification 01-3, Engine oils .

Engine oil capacity,

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 17,

Torque specifications for oil drain plug:

„ Gasoline engines: 30 Nm

Warning!

„ Torque settings must not be exceeded

„ A torque figure that is too high may lead to leaks

or even damage the oil pan.

Oil filter, replacing

Replacing oil filter, 2.0L TFSI engines, 01-4, Replacing

oil filter, 2.0L TFSI engines .

Replacing oil filter, 2.0L TFSI engines

Special tools, testers and auxiliary items required

Description of work Стр. 36 из 75

„ Oil drain adapter T40057

„ Oil filter wrench VAS 3417

„ Torque wrench V.A.G 1331/

Perform the following work procedure:

- Unscrew dust cap - arrow - from oil filter housing.

Oil filter housing must be drained before it is removed.

Description of work Стр. 37 из 75

- Screw oil drain adapter T40057 into oil filter housing and
hold hose into an oil collecting pan.

Note:

„ When screwing in oil drain adapter T40057 , a valve

in the oil filter housing is opened. If oil drain adapter
T40057 is unscrewed again, the valve closes
automatically again.

- Allow engine oil to drain.

- Unscrew oil drain adapter T40057 again.

- Oil filter housing can now be unscrewed using oil filter

wrench VAS 3417 .

- Replace oil filter element - 4 - and sealing ring - 3 - .

Note:

„ Observe waste disposal regulations!

Description of work Стр. 38 из 75

- Tighten oil filter housing - 2 - to 25 Nm.

- Screw dust cap - 1 - hand-tight into oil filter housing - 2 -

.

Filling engine oil

Oil specifications 01-3, Engine oils .

Engine oil capacities,

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 17,

General notes

Note:

„ Observe waste disposal regulations!

- After topping off with oil wait at least 3 minutes then

check oil level.

- Pull out oil dipstick and wipe with clean rag. Replace
dipstick and push down to stop.

- Pull out dipstick again and read oil level.

If the dipstick appears as illustrated:

A - Oil must not be topped off.

B - Oil can be topped off. After topping off, oil may be in
range A .
C - Oil must be topped off. It is sufficient when oil level is
in area B (grooved field).

If oil level is above area - A - , the catalytic converter can

Description of work Стр. 39 из 75

be damaged.

- When oil level is below marking - C - , top off with oil to

marking - A - . Oil specification 01-3, Engine oils .

Perform test drive

To what extent the following can be checked is dependent

upon the vehicle equipment and local conditions
(urban/country).

The following should be checked by means of a road test:

- Engine: Output, misfiring, idling speed, acceleration

- Clutch: Pulling away, pedal pressure, odors

- Gear selection: Ease of operation, shift lever position

- Automatic transmission: Selector lever position, shift

lock / ignition key interlock, shift behavior, display in
instrument cluster

- Foot and parking brake: Function, free travel and

effectiveness, pulling to one side, juddering, squeal

- ABS function: When braking with activated ABS, the

brake pedal must pulse noticeably.

- Steering: Function, steering free play, steering wheel

centralized when wheels are in straight ahead position

- Sunroof: Function

- Radio, Radio/Navigation system: Function, Reception,

GALA, interference

- Multifunction indicator (MFI): Functions

- A/C system: Function

- Vehicle: Moving off line when traveling straight ahead

(level road)

- Imbalance: Wheels, drive shafts, prop shafts

- Wheel bearings: Noises

- Engine: Hot starting behavior

Wheel securing bolts, tighten to correct torque setting

Removing and installing wheel bolt covers

Note:

„ Depending on vehicle equipment, wheel bolts can be

covered by the following components:
Description of work Стр. 40 из 75

„ Covers for wheel bolts

„ Wheel center cover

„ Full wheel cover

- If present, remove respective wheel bolt cover

Note:

„ The pulling hook for removing the cover caps or

wheel center cap can be found in the vehicle tool kit.

Removing wheel center cover (example)

- Insert removal hook into one of the holes of the wheel

center cap and pull in - direction of arrow - .

Installation notes

Note:

„ The covers protect the wheel bolts and should be

reinstalled after retightening the wheel mounting
bolts.

„ Note that the center wheel cover tab must engage

into rim recess for some rims.

„ After completing work, place adapter and pulling

hook with vehicle tool kit.
Description of work Стр. 41 из 75

- On vehicles with full wheel cover, install cover so that tire

inflating valve is guided through the designated recess -
arrow - .

Loosen anti-theft wheel bolts and tighten

Note:

„ The adapter to loosen/tighten the anti-theft wheel

bolts is located with the vehicle tool kit.

„ If there is no adapter installed in the vehicle for

loosening/tightening the anti-theft wheel bolts, use
master wheel bolt key set T10101 .

„ In case of losing the adapter, a replacement adapter

can only be obtained via the code number.

„ The adapters code number for loosening/tightening

the anti-theft wheel bolts is stamped at the face of
the adapter.

Special tools, testers and auxiliary items required

Description of work Стр. 42 из 75

„ Master wheel bolt key set T10101

- Slide adapter into anti-theft wheel bolt until it stops.

- Slide wheel wrench onto adapter until it stops.

- Retighten wheel securing bolts to the correct tightening

torque.

Retighten wheel securing bolts

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

Note:

„ Ensure wheel bolts are retightened alternately.

Tightening torque: 120 Nm

Radio/navigation system, activating anti-theft coding

Refer to

Repair Manual, Communication, Repair Group 91,

Description of work Стр. 43 из 75

Tire pressure control indicator, performing basic setting

Note:

„ Basic setting of Tire Pressure Monitoring Display

Indicator Lamp K220 should always only be
performed, "after" tire inflation pressure values have
first been corrected to the proper values.

„ If no pressure loss and no tire damage is detected

after a tire pressure warning, the erroneous warning
can be eliminated by a basic setting.

Tire Pressure Monitory System display is a component of

ABS Control Module -J104- software.

ABS Control Module compares speed and rolling

circumference of individual wheels with help of ABS
sensors. If rolling circumference of a wheel changes, this is
displayed via tire pressure control indicator. Rolling
circumference of tire may be change if:

„ Tire inflation pressure is too low.

„ Tires have structural damage.

„ Vehicle is loaded on one side.

„ Wheels of one axle are are loaded higher (e.g. when

towing trailer or driving uphill and downhill).

„ Snow chains are installed.

„ Spare wheel is installed.

„ One wheel per axle was replaced.

Description of work Стр. 44 из 75

Tire Pressure Monitoring Display Indicator Lamp K220 has

a yellow indicator light in instrument cluster - arrow - .

„ "BLINKING LIGHT" means that no "INITIAL BASIC

SETTING" was performed yet.

„ "STEADY LIGHT" , in conjunction with warning

buzzer, means "WARNING" , a loss of pressure was
detected, check tire inflation pressures, perform
system basic setting.

Performing "INITIAL" basic setting

- Switch ignition on.

- Simultaneously press the ESP - 1 - button and SET

- 2 - button in the center console for longer than 2
seconds.

If ESP is not installed, press the button for ASR .

Beginning of basic setting is confirm by a notifying tone.

On next new ignition start, warning does not appear.

Performing basic setting

- Switch ignition on.

- After changing tire pressures or changing one or more

Description of work Стр. 45 из 75

tires, tire pressure display SET button, item - 2 - in

illustration, must be pressed until a confirmation tone is
heard.

Warning will no longer appear next time engine is switched

on.

Tire repair kit

The tire repair kit is located in the spare wheel well -

arrow -

In addition to the compressor, the tire repair kit contains a

tire inflation cylinder with sealant.

Note:

„ The tire sealant in the bottle has a limited shelf-life.

„ Therefore, on the bottle, the expiration date - arrow

- is displayed.

In this example, the expiration date 05/2003 has passed,

and the bottle must then be replaced.

- Check the expiration date and enter in maintenance

tables.

- Replace tire sealant, if expiration date has been reached.

Description of work Стр. 46 из 75

Caution!

„ Tire sealant must not be older than 4 years.

„ If the bottle was opened, e.g. for a flat tire, it

must also be replaced.

Note:

„ Residual tire sealant or full bottles, which have

expired, must be disposed of.

„ Old tire sealant or remainder of it must not be mixed

with other fluids and must be disposed of.

Dust and pollen filter, cleaning housing and replacing

filter element

Note:

„ Clean the surrounding area of the dust and pollen

filter in air conditioner shaft or heating before
installing a new filter.

- Perform the following work procedure:

- Remove screw clips - A - and remove insulation mat - B

- .
Description of work Стр. 47 из 75

Screw clips - A - are available in different versions, e.g. -

C - and - D - .

- Remove bolts - A - if necessary.

Bolt - A - is not installed on all vehicles. Bolts secure the

cover - B - in the event the catches - D - no longer hold.

- Push cover - B - in - direction of arrow C - and

remove cover.

- Remove filter element - A - from shaft - B - of air

conditioner or heater.

Note:

„ Observe waste disposal regulations!

- Using e.g. a vacuum cleaner, clean shaft - B - of A/C

unit or heater.

- Install in reverse order of removal.

Headlight adjustment, check and adjust if necessary

Check headlight adjustment, 01-4, Check headlight

adjustment .

Adjusting gas discharge headlights, 01-4, Adjusting

headlights with gas discharge lamps .
Description of work Стр. 48 из 75

Adjusting halogen headlights, 01-4, Adjusting headlights

with halogen lamps .

Adjusting fog lights and other auxiliary headlights, 01-4,

Adjusting fog lights and other auxiliary lights .

Check headlight adjustment

Special tools, testers and auxiliary items required

„ Head light adjusting unit VAS 5046 or

„ or

„ Headlight adjuster VAS 5047

„ or

„ Headlight adjuster VAS 5209

Test- and adjustment requirements:

„ Tire pressure must be OK.

„ Lenses must not be damaged or dirty.

„ Reflectors and bulbs OK.

„ Move vehicle back and forth for 1 meter (3 to 4 feet)

or bounce front and rear of vehicle several times up
and down to settle suspension.

„ Vehicle and headlight adjuster must be on a level

surface Headlight adjuster operating instructions.
Description of work Стр. 49 из 75

„ Vehicle and headlight adjuster must be aligned.

„ Inclination must be set.

„ Vehicle must be loaded, e.g. with one person or 165

lbs (75 kg) on drivers seat in unloaded vehicle (curb
weight), Topic 01-4 .

Note:

„ The curb weight is the weight of the vehicle ready to

be operated with filled fuel tank (at least 90% filled),
including the weight of all equipment usually carried
in the car such as spare wheel, tools, car jack, fire
extinguisher, etc.)

Establish vehicle curb weight:

- If the fuel tank is not at least 90% full, adjust the weight
as follows:

„ Read fuel level from fuel gauge.

„ Calculate additional weight needed using the

following table. Place extra weight in luggage
compartment.

Tank filling table

Fuel level according Additional weight

to fuel gauge in luggage compartment in Lbs (Kg)
1/4 66 (30)
1/2 44 (20)
3/4 22 (10)
Full 0

Example:

If the fuel tank is half full, place a weight of 44 lbs (20 kg) in
the luggage compartment.

Note:

„ For additional weight use containers filled with water.

A container filled with 5 liters of water weighs
approx. 12 lbs (5kg).

Adjustment notes
Description of work Стр. 50 из 75

„ In the trim above the headlight, inclination

measurements are stamped in "%" . The headlights
must be adjusted according to these measurements.
Percentage information is based on a projection
distance of 10 meters. For example: inclination of
1.0 % converts to approx. 10 cm.

„ Applies to vehicles with halogen headlights with

manual headlight range control: The headlight range
adjuster thumb wheel must be in basic setting - 0 -
.

„ Applies to vehicles with gas discharge lamps with

dynamic headlight range control: DTC memory
should be checked and erased using Vehicle
Diagnosis, Testing and Information System VAS
5051 and or Vehicle Diagnosis Service Syst. VAS
5052 , and headlight range control brought into
Basic Setting before every headlight adjustment.

Check headlight adjustment, headlights:

Check the following:

- With the low beam switched on check whether the

horizontal light-dark border of the setting line - 1 - contacts
the test surface.

- Check whether the break-away point - 2 - between the

left horizontal part and the rising part on the right of the
light-dark border runs vertically through the center point - 3
- . The bright core of the light beam must be on the right of
the vertical line.

Note:

„ To make it easier to find break-away point - 2 -

cover and uncover left half of headlight (as viewed
when looking forward) a few times. Then check low
beam again.
Description of work Стр. 51 из 75

„ After correct adjustment of low beams the center

point of the main beam must lie on the center mark -
3 - .

„ For the previous test screen with 15 -setting line,

adjust as for new test screen. To avoid incorrect
settings, ignore 15 setting line.

Checking headlight adjustment, fog lights:

- Check whether the upper light-dark border touches the

setting line horizontally over the complete test screen
width.

Other additional headlights:

Accessory auxiliary headlight systems must be checked

and adjusted according to the guidelines valid for them.

Adjusting headlights with gas discharge lamps

Perform basic setting:

Description of work Стр. 52 из 75

- Connect diagnostic tester 01-3, Diagnostic testing unit,

connecting .

- Switch ignition on.

- Select "Guided Fault Finding"

Enter vehicle information; all control modules are

interrogated.

- Press the following selections in the order shown:

„ Go To

„ Functions and component selection

„ Body

„ Electrical Equipment

„ 01 - On Board Diagnostic (OBD) capable systems

„ 55 - Dynamic headlight range control

„ J431 - Headlamp Range Control Module, functions

„ J431 - Headlamp Range Control Module, basic

setting

„ Press -button.
Description of work Стр. 53 из 75

- Follow the steps of the tester and confirm the entry until
the following text appears:

J431 - Headlamp Range Control Module, basic setting

„ Press -button.

- Follow the steps of the tester and confirm the entry until
the following text appears:

J431 - Headlamp Range Control Module, basic setting

- Follow procedure on tester.

- Check headlight adjustment and adjust headlights if

necessary.

- Complete function program for J431 - Headlamp Range

Control Module, basic setting.

Note:

„ Also check whether both headlights work evenly

when operating the manual headlight range control.

Adjusting headlights:

Adjustment screws for right headlight are arranged

symmetrically

„ Adjustment screw - A - - vertical adjustment

„ - B - - horizontal adjustment

Adjusting headlights with halogen lamps

Description of work Стр. 54 из 75

Adjustment screws for right headlight are arranged

symmetrically

„ Vertical adjustment screw - A - (low beam and high

beam headlight)

„ Horizontal adjustment screw - B - (high beam

headlights)

„ Horizontal adjustment screw - C - (low beam

headlights)

Adjusting fog lights and other auxiliary lights

Fog lights in headlights:

Note:

„ The adjustment of fog lights is performed

automatically when adjusting headlights.

Left fog lamp in bumper:

Adjusting screw on right fog light is arranged

symmetrically.

- You can pull the cover - 1 - out of catches. e.g. with wire
Description of work Стр. 55 из 75

bracket from vehicle tool kit - 2 - .

- Engage wire bracket in cover hole and pull cover in -

direction of arrow - out of catches.

- To adjust light range, turn adjusting screw - arrow - .

Lateral adjustment is not possible.

Other auxiliary lights

Accessory auxiliary light systems must be checked and

adjusted according to the guidelines valid for them.

Service interval display, reset

Service Reminder Indicator must for

„ Vehicle release inspection

„ Every service

(adapted)!

- Connect diagnostic tester 01-3, Diagnostic testing unit,

connecting .

- Switch ignition on.

- Touch button/field on screen. "GUIDED FUNCTIONS" on

screen.

If the displays indicated in the work procedure are not

indicated on display: Operating instructions for Vehicle
Diagnosis, Testing and Information System 5051 or
Vehicle Diagnosis Service Syst VAS 5052

- Press > button to confirm.

- Select in succession:

„ Brand
Description of work Стр. 56 из 75

„ Model

„ Model year

„ Engine Code

- Confirm vehicle identification.

- Select in succession:

„ "Instrument cluster" - ARROW - .

„ "Resetting Service Reminder Indicator (SRI)" .

- Perform adaptation according to instructions of "GUIDED

FUNCTIONS" .

End Adaptation

Indicated on display:

- Press the "Go to" button - arrow - on display.

Description of work Стр. 57 из 75

Indicated on display:

- Press "exit" button - arrow - on display.

- Press "exit" button in exit menu.

- Turn off ignition and disconnect diagnostic connection.

- Switch ignition on.

After switching on the ignition, service event is no longer

indicated in the odometer display in the instrument panel
insert.

Service interval display, recoding

- Connect diagnostic tester 01-3, Diagnostic testing unit,

connecting .

- Switch ignition on.

- Touch button/field on screen. "GUIDED FUNCTIONS" on

screen.

Note:

„ If the displays indicated in the work procedure are

not indicated on display: Operating instructions for
Vehicle diagnosis, testing and information system
VAS 5051 or Vehicle diagnosis and service system
VAS 5052 .

- Select in succession:

„ Brand

„ Model

„ Model year

„ Engine Code
Description of work Стр. 58 из 75

- Confirm vehicle identification.

If the vehicle identification procedure was performed

correctly, press > button for confirmation.

- Select in succession:

„ "Instrument cluster" - arrow - .

„ "Adapt service interval extension" .

- Perform adaptation according to instructions of "GUIDED

FUNCTIONS" .

End Adaptation

Indicated on display:

- Press the "Go to" button - arrow - on display.

Description of work Стр. 59 из 75

Indicated on display:

- Press "exit" button - arrow - on display.

- Press "exit" button in exit menu.

- Turn off ignition and disconnect diagnostic connection.

Windshield wash/wipe system and headlight wash

system, checking function

Check freeze protection content of windshield cleaner

concentrate G 052 164 , fill with fluid 01-4, Checking
freeze protection content of fluid, if necessary top off with
fluid .

Windshield wipe-/wash system, check spray nozzle

adjustment, adjust if necessary 01-4, Windshield wipe-
/wash system, check spray nozzle adjustment, adjust if
necessary .

Headlight wash system, check spray nozzle adjustment,

adjust if necessary 01-4, Headlight wash system, check
spray nozzle adjustment, adjust if necessary .

Checking freeze protection content of fluid, if necessary top off

with fluid

Special tools, testers and auxiliary items required

„ Refractometer T10007
Description of work Стр. 60 из 75

Read the bright/dark boundary to obtain an accurate

reading for the following tests. Place a drop of water on the
glass to improve the readability of the bright/dark
boundary. The bright/dark boundary can be clearly
recognized on the "WATERLINE" .

- Check the concentration of the anti-freeze additive using

refractometer T10007 (operating instructions).

Scale - 1 - of refractometer applies to windshield cleaner

concentrate G 052 164 .

The scale - 2 - is designed for commercially available

windshield cleaner as well as a mixture of commercially
available windshield cleaner and windshield cleaner
concentrate G 052 164 .

Mixture ratio:

Freeze protection to W/screen clear Water

G 052 164
-17/-18 C 1 part 3 parts

-22/-23 C 1 part 2 parts

-37/-38 C 1 part 1 part

Filling-up with fluid:

The windshield wash/wipe system fluid reservoir must be

filled up fully.

Use only windshield cleaner concentrate G 052 164 all-

year-round when topping-off the windshield wash/wipe
system.

Note:

„ Windshield cleaner concentrate G 052 164 protects

the spray nozzles, fluid reservoir and hoses from
freezing.
Description of work Стр. 61 из 75

„ All vehicles with fan type spray jets must be filled

with windshield cleaner concentrate G 052 164 as
this fluid has a low viscosity at minus temperatures.
The complicated spray jet system could otherwise
become blocked due to crystallized washer fluid and
adversely affect the fan pattern of the spray jet.
Windshield cleaner concentrate G 052 164 assures
that the fan type spray jets remain functional even at
low temperatures.

„ Fill with windshield cleaner concentrate G 052 164

in the warmer season also. The powerful cleaner
removes wax and oil deposits from the windows.

„ Freeze protection (anti-freeze) must be guaranteed

to approx. -25 C (approx. -35 C in countries with an
arctic climate) in the washer system.

Windshield wipe-/wash system, check spray nozzle adjustment,

adjust if necessary

Note:

„ In the event contamination in spray nozzle produces

an uneven spray pattern, remove spray nozzle

Repair Manual, Electrical Equipment, Repair Group 92,

, and rinse it with water in the opposite direction of

spray.

„ Subsequently blowing through in the opposite

direction of the spray flow with compressed air is
permitted.

Caution!

„ Do not use solid objects to clean the spray

nozzles!

„ Do not use a needle or similar under any

circumstance to adjust spray nozzles, otherwise
the water hoses in the spray nozzles may be
damaged!

Windshield washer system spray jets, Topic 01-4 .

Special tools, testers and auxiliary items required

Description of work Стр. 62 из 75

„ Adjustment tool T10127 equipped with needle 3125/

5A

Windshield washer system spray jets:

The washer nozzles are preset. Small height adjustments

can be made.

- If both spray fields are not at same height, adjust spray

direction upward or downward as follows:

- Adjust the spray stream by turning at the adjuster -

arrow - with a screwdriver.

„ "Clockwise" deeper adjustment.

Description of work Стр. 63 из 75

„ "Counterclockwise" higher adjustment.

Headlight wash system, check spray nozzle adjustment, adjust

if necessary

Note:

„ In the event contamination in spray nozzle produces

an uneven spray pattern, remove spray nozzle

Repair Manual, Electrical Equipment, Repair Group 92,

, and rinse it with water in the opposite direction of

spray.

„ Subsequently blowing through in the opposite

direction of the spray flow with compressed air is
permitted.

Caution!

„ Do not use solid objects to clean the spray

nozzles!

„ Do not use a needle or similar under any

circumstance to adjust spray nozzles, otherwise
the water hoses in the spray nozzles may be
damaged!

Special tools, testers and auxiliary items required

„ Adjustment device T10167

Description of work Стр. 64 из 75

Spray jet adjustment for left headlight (right headlight is

identical but reversed)

Check spray jet setting

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.

Spray from windshield washer nozzles - A - should spray

onto center of head lights, see - B - , - C - , - D - and - E
- .

Adjusting nozzles

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.

Spray nozzles - arrow - are driven outward.

Description of work Стр. 65 из 75

- Perform the following work procedure:

- Align spray direction of corresponding nozzle using

adjustment tool T10167 or adjustment tool 3019A at
upper edge of headlight, see - B - , - C - , - D - and - E -
.

Windshield wiper blades, end position, checking

Windshield wiper blades, checking end position and

adjusting if necessary

Repair Manual, Electrical Equipment, Repair Group 92,

Tie rod ends, check play, security and joint boots

Perform the following work procedure:

- With vehicle raised (wheels hanging free), check play by

moving track rods and wheels. Play: zero play

- Check mountings.

- Check track rod joint boots - arrow - for damage and

proper seating.
Description of work Стр. 66 из 75

Door arrester, lubricate

Perform the following work procedure:

- Lubricate door arrester at points shown - arrows - .

Use solid lubricant G 000 150 .

Transportation mode, deactivating

- Connect diagnostic tester 01-3, Diagnostic testing unit,

connecting .

- Switch ignition on.

Indicated on display:

Select mode of operation:

- Press button for "Vehicle Self-Diagnosis" on display.

Note:

„ If the displays indicated in the work procedure are

not indicated on display: Operating instructions for
Description of work Стр. 67 из 75

Vehicle Diagnosis, Testing and Information System

VAS 5051 or Vehicle Diagnosis Service Syst VAS
5052

Indicated on display:

- Press "Collecting services" on display.

Indicated on display:

- Press "Switch off transport mode" on display.

End procedure

Indicated on display:

- Press the "Go to" button - arrow - on display.

Description of work Стр. 68 из 75

Indicated on display:

- Press "exit" button - arrow - on display.

- Press "exit" button in exit menu.

- Turn off ignition.

Note:

„ Diagnostic operation system VAS 5051 or Vehicle

Diagnosis and Service System VAS 5052 must
possibly remain connected for various tests.

Transport protection, removing locking pieces from front

axle struts

In vehicles with sport suspension, locking pieces are

installed in springs of front axle. These models can be
identified by a tag attached at the mirror - arrow - .

Note:

„ Locking pieces should prevent vehicle from

bouncing when being driven on to an automobile
transport or railroad car and thereby become
damaged.

Warning!
Description of work Стр. 69 из 75

Locking pieces must always be removed before

delivering the vehicle! An "Attention!" hanging tag is
secured to interior mirror to make this point absolutely
clear.

Perform the following work procedure:

Note:

„ It is not necessary to remove the wheels.

„ Be careful not to damage surface of coil springs.

- Relieve load on coil spring by raising vehicle on lifting

platform.

- Press locking piece - arrow - from coil spring.

Underbody protection, perform visual check for damage

During visual check, observe floor pan, wheel housings

and sills!

Note:

„ Malfunctions found must be rectified (repair

measure). This inhibits corrosion and rusting
through.

Clock, setting
Description of work Стр. 70 из 75

Clock is at lower left in instrument cluster display.

Items - 1 - and - 2 - show clock setting buttons.

- Press the left button - 1 - to set the hour.

- Hold button down to quickly scroll through hours.

- Briefly press right button - 2 - to scroll through one

minute at a time.

- Hold button down to quickly scroll through minutes.

Toothed belt for camshaft drive, replacing (2.0 L TFSI

only)

- Toothed belt, removing and installing

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 15,

Spark plugs, replacing

Replacing spark plugs, 2.0 L TFSI engine 01-4,

Replacing spark plugs, 2.0 L TFSI gasoline Direct Fuel
Injection engines .

Special tools, testers and auxiliary items required

Description of work Стр. 71 из 75

„ Spark plug wrench 3122 B

„ Torque wrench V.A.G 1331

„ Puller T40039
Description of work Стр. 72 из 75

Replacing spark plugs, 2.0 L TFSI gasoline Direct Fuel Injection

engines

Removing:

Perform the following work procedure:

Note:

„ To pull off spark plugs, place ignition coil puller

T40039 on uppermost thick rib - arrow - of ignition
coils with power output stages.

„ If lower ribs are used, these can be damaged

- Remove engine covers 01-4, Upper engine cover,

removing and installing .

Spark plugs are located under ignition coils with power

output stages - 2 - .

Note:

„ Note installation position of ignition coils with power

output stages!
Description of work Стр. 73 из 75

- Remove both bolts - 1 - .

- Pull all ignition coils approx. 30 mm out of cylinder head

in - direction of arrow - using ignition coil puller
T40039 .

- Push connector in direction of ignition coils with power

output stages, press catch down by hand and disconnect
connectors - arrows - .

- Remove spark plugs using spark plug wrench 3122 B .

Note:

„ Spark plug identification and tightening torque,

Description of work Стр. 74 из 75

Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 28,

„ Observe waste disposal regulations!

Installing

- Install new spark plugs using spark plug wrench 3122

B .

- Guide ignition coils with power output stages into cylinder

head.

- Align ignition coils with power output stages into

designated recesses of cylinder head cover.

- Connect all connectors to ignition coils - arrows - .

Description of work Стр. 75 из 75

- Press ignition coils with power output stages onto spark

plugs by hand until stop. They must engage audibly.

- Secure wiring using bolts - 1 - .

- Install engine cover.