MAINTENANCE PROCEDURES

• HEADINGS
  • 01 - Maintenance
    • Engine overview
    • Delivery inspection
      • Delivery inspection
    • Oil change service
      • Oil change service
    • Inspection service
      • Inspection service
    • Description of work
      • All switches, all electrical components, all displays and other operating elements: Checking function
      • Final drive (automatic transmission): Check oil level, add oil if necessary
        • Automatic transmission
        • Continuously Variable Transmission (CVT) transmission
      • Battery: Check
        • Battery with "magic eye"
        • Battery sealing plugs
        • Valve-regulated lead acid battery or absorbed glass mat (AGM) battery
      • Battery: No load voltage, checking before starting engine for the first time
        • Necessary test equipment
      • Battery: Ensure battery cable fits securely
      • Battery: Perform battery load test
        • Special tools, testers, and measuring equipment
        • Perform battery load test
        • Tester display during battery load test
      • Brake system: Visual inspection for leaks and damage
      • Brake pads: Checking thickness
      • Tires: Checking condition, wear pattern and tread depth and adjusting tire pressure.
        • Tires, checking
        • Delivery inspection
        • Inspection service
        • Checking tire wear pattern
        • Check tread depth.
        • Tire pressure, adjusting
        • Spare wheel
      • Brake fluid level, dependent on lining wear: Check
        • Delivery inspection
        • Inspection service
      • Brake fluid: Changing
        • Special tools, testers, and measuring equipment
        • Vehicles with manual transmission:
        • Continued for all vehicles:
        • Table - Sequence / quantity of brake fluid
      • Set digital clock
        • Radio clock
        • Quartz clock
      • Electric windows: Check positioning
      • DTC memory: Retrieving with VAS 5051/ 5052
      • Check vehicle key function
      • Front axle joints: Seal boots, checking play and secure fit.
      • Noise insulation: Removing
        • Vehicles with auxiliary heater:
        • All:
      • Power steering: Check for leaks and fluid level, top off power steering fluid, if necessary
      • Rear lid hinges: Lubricate
      • Calibrate rearview mirror with compass
      • Instrument cluster: Adapt language version
      • A/C system: Check function, set temperature to 72 F (22 C)
      • Cooling system: Check freeze protection, add coolant, if necessary
      • Ribbed belt: Replacing
        • 8-cyl. 5V engines 4.2L
      • Air cleaner: Clean air filter housing and replace filter
        • 4-cyl. 2.0L TFSI engines
        • 4-cyl. 1.8L 5V Turbo engines:
        • 6-cyl. 3.0L engines
        • 6-cyl. 3.2L engines
        • 8-cyl. 4.2L MPI engines
        • 8-cyl. 4.2L engines (RS4)
      • Hood catch: lubricating
      • Engine cover: Removing
      • Engine (from above and below) and engine compartment: Visual inspection for leaks and damage
      • Continuously Variable Transmission (CVT) 01J: Changing ATF
      • Engine oil: Drain/extract, replace oil filter
        • 4-cyl. gasoline engines
        • 4-cyl. TFSI engines
        • 6-cyl. 3.2L FSI gasoline engines
        • 8-cyl. 4.2L MPI gasoline engines
        • 8-cyl. 4.2L FSI gasoline engines, RS4
      • Engine oil: Fill
      • Engine: Oil level, checking
      • Navigation: Eject button, unlocking
      • Test drive: Perform
      • Wheel bolts: Tighten to correct torque setting
        • Center cap
        • Wheel bolts
        • Correct wheel installation
      • Radio: Activate anti-theft coding by entering security code
      • Tire Pressure Monitoring System: Programming tire pressures
      • Tire repair kit: Checking
      • Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary
        • Necessary special tools
        • Windshield spray jet setting
        • Rear window spray jet setting
      • Headlamp washer system: Check spray jet setting.
      • Windshield wiper blades: Checking park position
        • Front windshield wiper blade park position
        • Wiper blade park position, rear window
      • Service interval display: resetting or adapting
        • Service display, resetting
        • Oil quality, adapting
        • Maximum values, adapting
        • Service display, resetting without VAS 5051/5052
      • Windshield/headlamp wiper system: Filling with fluid
      • Vehicle Electrical System Control Module - J519: coding
      • Dust and pollen filter: Replacing
      • Sunroof: Check function, clean guide rails and spray on lubricant spray
      • Manual transmission/final drive: Check oil level, add oil if necessary
      • Headlamps: Check setting, adjust if necessary
        • Check and adjustment conditions
        • Headlamps, checking adjustment (with new test screen without 15 ° setting line)
        • Headlamps, adjusting
        • Fog lights:
      • Deactivate transport mode
      • Door arrester and lock cylinder: Lubricate
      • Plenum chamber cover: Removing
      • Telematics: Emergency battery, replacing
        • Note before disconnecting battery.
      • Transport protection: Remove front and rear strut transportation protection devices
        • Front strut
        • Rear strut
      • Underbody protection: Visual inspection for damage
      • Winter tires from factory
      • Timing belt: Replacing
        • 4-cyl. 5V engines 1.8L Turbo
        • 4-cyl. 5V engines 2.0L
        • 4-cyl. 4V engines 2.0L TFSI
        • 6-cyl. 5V engines 3.0L;
        • Toothed belt change, filling out sticker - all
      • Spark plugs: Replacing
        • Necessary special tools
        • 4-cyl. 5V engines 1.8L Turbo:
        • 4-cyl. 5V engines 2.0L and 2.0L TFSI
        • 6-cyl. engines 3.0L and 3.2L FSI:
        • 8-cyl. engines 4.2L MPI
        • 8-cyl. engines 4.2L (RS4)
      • Headlights: Aiming using Hella Universal Beamsetter IV
      • RAPGARD: Inspection, removal and disposal
    • Type plate / Vehicle Identification Number (VIN)
      • Type plate / Vehicle Identification Number (VIN)
    • Vehicle, lifting
      • Vehicle, lifting
    • Tow starting/towing
      • Tow starting/towing
    • Vehicle checks within inspection and service framework
      • Vehicle checks within inspection and service framework
• FIGURES
  • Fig. 1: Pushing Cover Over Battery Toward Right And Removing It Upward
  • Fig. 2: Identifying The Visual Indicator
  • Fig. 3: Identifying The Visual Indicator
  • Fig. 4: Special Tool - Multimeter V.A.G 1526 A
  • Fig. 5: Locating Battery Terminals On Battery
  • Fig. 6: Locating Battery Terminals On Battery
  • Fig. 7: Battery VAS Tester
  • Fig. 8: Determining Thickness Of Inner Pad By Visual Check
  • Fig. 9: Identifying Thickness Of The Inner Pad
  • Fig. 10: Checking Tire Tread Depth
  • Fig. 11: Identifying Tire Pressure Values For Summer Tires On Sticker
  • Fig. 12: Identifying Fluid Level
  • Fig. 13: Identifying Fluid Level
  • Fig. 14: Identifying Brake Filler And Bleeder Unit VAS 5234
  • Fig. 15: Identifying Brake Filler And Bleeder Unit V.A.G 1869
  • Fig. 16: Identifying Brake Fluid Reservoir Cap
  • Fig. 17: Connecting Suction Hose From VAS 52.4 Or V.A.G 1869 To Tube Of Brake Fluid Reservoir
  • Fig. 18: Connecting Suction Hose From VAS 52.4 Or V.A.G 1869 To Tube Of Brake Fluid Reservoir
  • Fig. 19: Connecting Filler Hose From VAS 52.4 Or V.A.G 1869 To Adapter
  • Fig. 20: Identifying Fluid Level
  • Fig. 21: Connecting Data Link Connector (DLC)
  • Fig. 22: Identifying Lock Nut
  • Fig. 23: Identifying Ball Joint Boots
  • Fig. 24: Identifying Bearing Housing And Control Arm
  • Fig. 25: Identifying Exhaust Pipe Fasteners
  • Fig. 26: Removing Sound Insulation
  • Fig. 27: Checking Fluid Level
  • Fig. 28: Lubricating Hinge Joints
  • Fig. 29: Connecting Data Link Connector (DLC)
  • Fig. 30: Checking Whether 72F (22C ) Is Set In Both Display Fields
  • Fig. 31: Identifying Refractometer T10007
  • Fig. 32: Identifying Refractometer Scales
  • Fig. 33: Checking Coolant Level
  • Fig. 34: Identifying Intake Hose And EVAP Valve Retainer
  • Fig. 35: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 36: Identifying Upper Part Of Air Filter Bolts
  • Fig. 37: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 38: Identifying Hose Clamp And Evaporative Emission (EVAP) Canister Valve
  • Fig. 39: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 40: Identifying Air Duct, Air Intake Hose, Electrical Connector And Mass Air Flow (MAF) Sensor G70
  • Fig. 41: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 42: Identifying Air Duct, Clean Air Tube Clamp, Fuel Line, And Pipe Connection
  • Fig. 43: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 44: Identifying Air Intake Hose, Electrical Connector, And Mass Air Flow (MAF) Sensor G70
  • Fig. 45: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
  • Fig. 46: Identifying Air Duct And Mass Air Flow Sensor G70 Electrical Connector
  • Fig. 47: Identifying Lubrication Points On Hood Safety Catch
  • Fig. 48: Removing Engine Cover
  • Fig. 49: Removing Cover In Engine Compartment (Right Side)
  • Fig. 50: Removing Rear Engine Cover
  • Fig. 51: Removing Rear Engine Cover
  • Fig. 52: Identifying Oil Drain Adapter T 40057 (2.0 TFSI)
  • Fig. 53: Identifying Oil Filter
  • Fig. 54: Identifying Oil Filter Unit And Hoses
  • Fig. 55: Identifying Valve Protection Cap And Oil Filter Housing Bottom
  • Fig. 56: Identifying Remove Oil Drain Adapter T 40057
  • Fig. 57: Identifying Filter Insert And Gasket
  • Fig. 58: Identifying Coolant Reservoir And Oil Filter Cover
  • Fig. 59: Identifying Sealing Ring On Cap
  • Fig. 60: Identifying Oil Filter Housing O-Ring
  • Fig. 61: Identifying Oil Filter Cover
  • Fig. 62: Identifying O-Ring And Oil Filter Insert
  • Fig. 63: Identifying Oil Filter Cover
  • Fig. 64: Identifying Screws And Line
  • Fig. 65: Identifying Oil Filter Cover
  • Fig. 66: Identifying O-Ring And Oil Filter Insert
  • Fig. 67: Identifying Oil Filter Cover
  • Fig. 68: Identifying Markings On Dipstick
  • Fig. 69: Connecting Data Link Connector (DLC)
  • Fig. 70: Identifying Removal Hook
  • Fig. 71: Identifying Radio Controls
  • Fig. 72: Identifying Durability Date In Tire Repair Kit
  • Fig. 73: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
  • Fig. 74: Identifying Windshield Dimensions
  • Fig. 75: Identifying Windshield Wiper Dimensions
  • Fig. 76: Checking Windshield Wiper Blade Tips Position
  • Fig. 77: Identifying Cover
  • Fig. 78: Identifying Spray Jets And Hex Head Nuts
  • Fig. 79: Identifying Dimensions For Wiper Blade On Rear Window
  • Fig. 80: Identifying Service Display
  • Fig. 81: Connecting Data Link Connector (DLC)
  • Fig. 82: Connecting Data Link Connector (DLC)
  • Fig. 83: Connecting Data Link Connector (DLC)
  • Fig. 84: Identifying Service Display
  • Fig. 85: Identifying Plenum Chamber Cover
  • Fig. 86: Connecting Data Link Connector (DLC)
  • Fig. 87: Identifying Headlight Setting Line, Break-Away Point & Center Point
  • Fig. 88: Identifying Adjustment Screws For Main Headlight (Right)
  • Fig. 89: Checking Whether Upper Light-Dark Border Touches Adjusting Line And Runs Across Entire Test Screen Width Horizontally
  • Fig. 90: Identifying Air Duct Grille, Bumper, And Adjustment Screw
  • Fig. 91: Connecting Data Link Connector (DLC)
  • Fig. 92: Identifying Greasing Points For Door Latches
  • Fig. 93: Identifying Plenum Chamber Cover & Removing Rubber Seal
  • Fig. 94: Identifying Plenum Chamber Cover
  • Fig. 95: Identifying Passenger Side Electronics Box Cover
  • Fig. 96: Identifying Screws On Bottom Side Of Telematics Control Module
  • Fig. 97: Identifying Connector And Emergency Battery
  • Fig. 98: Identification Tag Attached At Mirror
  • Fig. 99: Identifying Auxiliary Strut, And Transportation Protection Devices
  • Fig. 100: Identifying Auxiliary Strut, And Transportation Protection Devices
  • Fig. 101: Locating Toothed Belt Change Sticker At Rear Of Engine Compartment
  • Fig. 102: Placing Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils
  • Fig. 103: Identifying Connectors At Spark Plugs
  • Fig. 104: Identifying Bolts And Connectors
  • Fig. 105: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 106: Removing Coolant Hoses
  • Fig. 107: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 108: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 109: Removing Cover Upward
  • Fig. 110: Removing Coolant Hoses
  • Fig. 111: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 112: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 113: Removing Coolant Hoses
  • Fig. 114: Identifying Bolts, Connector, And Ignition Coil
  • Fig. 115: Identifying Floor Surface Specifications For Vehicle
  • Fig. 116: Identifying Specifications For Drivers Side Headlight Beam Angle
  • Fig. 117: Identifying Beamsetter "Scaled Wheel" At 0%
  • Fig. 118: Identifying Hella Universal Beamsetter IV VAS 5107 Scaled Wheel At 1.4%
  • Fig. 119: Identifying Vehicle Data Sticker
  • Fig. 120: Identifying Engine Number Is Located At Left Of Engine/Transmission Connecting Point
  • Fig. 121: Identifying Engine Number On Left Of Cylinder Block
  • Fig. 122: Identifying Engine Number On Left Of Cylinder Block
  • Fig. 123: Identifying Engine Number Stamped On Engine Block
  • Fig. 124: Identifying Engine Code Stamped On Right Inner Side Of Cylinder Block
  • Fig. 125: Identifying Engine Number On Left Front Of Cylinder Block
  • Fig. 126: Identifying Engine Number Stamped On Engine Block
  • Fig. 127: Locating Engine Number
  • Fig. 128: Identifying Front Side Member Vertical Stiffener
  • Fig. 129: Identifying Rear Side Member Vertical Stiffener
  • Fig. 130: Identifying Front Towing Eye
  • Fig. 131: Identifying Rear Towing Eye
• TABLES
  • Tester Evaluations
  • Tank filling

Maintenance

Maintenance Procedures

01 - Maintenance

Engine overview

NOTE:

Some engines listed below are applicable to European vehicles.

Gasoline engines

Engine code		ALZ	AVJ	BFB	ALT	AWA	BEX	BKB	BGB	BUL	BWE	BPJ
Emissions category		EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU III	EU IV	EU IV	EU III	EU IV
Number of cylinders/valves per cylinder		4 / 2	4 / 5	4 / 5	4 / 5	4 / 4	4/5	4/5	4/4	4/4	4/4	4/4
Displacement	L	1.6	1.8	1.8	2.0	2.0	1.8	1.8	2.0	2.0	2.0	2.0
Output	kW at RPM	75/5600	110/5700	120/5700	96/5700	110/6000	140/5700	120/5700	147/5700	162/5900	147/5700	125/4300-6000
Torque	Nm at RPM	148/3600	210/ 1750 ... 4600	225/ 1950...4700	195/3300	200/3500	240/ 1980...5400	220/1750	280/2000	300/2200-4000	280/2000	280/1800-4200
Stroke	mm	77.4	86.4	86.4	92.8	92.8	86.4	86.4	92.8	92.8	92.8	92.8
Bore	mm	81.0	81.0	81.0	82.5	82.5	81.0	81.0	82.5	82.5	82.5	82.5
Compression ratio		10.3	9.3	9.5	10.3	11.5	9.5	9.5	10.5	10.3	10.3	10.3
Fuel injection/Ignition		Simos 3.4	ME 7.5 Motronic	ME 7.1 Motronic	ME 7 Motronic	MED 7.1 Motronic	MED 7.1 Motronic	MED 7.1 Motronic	TFSI Motronic	TFSI Motronic	TFSI Motronic	TFSI Motronic
RON	min.	95 (unleaded) 1*)	95 (unleaded) 1*)	95 (unleaded) 1*)	95 (unleaded) 1*)	98 (unleaded) 2*)	98 (unleaded) 2*)	95 (unleaded) 1*)	98 (unleaded) 2*)	98 (unleaded) 2*)	98 (unleaded) 2*)	98 (unleaded) 2*)

1*) 91 RON standard unleaded gasoline is permissible, however with decreased power output.

2*) 95 RON Super unleaded gasoline is permissible, however with decreased power output.

Gasoline engines

Engine code		BDV	AMM	ASN	BBJ	AUK	BBK	BNS
Emissions category		EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV
No. of cylinders		6	6	6	6	6	8	8
Valves per cylinder		5	5	5	5	4	5	4
Displacement	L	2.4	2.4	3.0	3.0	3.2	4.2	4.2
Output	kW at RPM	125/6000	120/6000	162/6300	160/6300	188/6400	253/7000	309/7800
Torque	Nm at RPM	230/3200	230/3200	300/3200	300/3200	320/3400	410/3500	430/5500
Bore	mm	81.0	81.0	82.5	82.5	84.5	84.5	84.5
Stroke	mm	77.4	77.4	92.8	92.8	92.8	92.8	92.8
Compression ratio		10.5	10.5	10.5	10.5	12.5	11.0	12.5
Fuel injection/ Ignition system		Motronic ME 7.1.	Motronic ME 7.1.	Motronic ME 7.1.	Motronic ME 7.1.	FSI Motronic Hitachi	Motronic ME 7.1.1	Motronic MED 9.1
RON	min.	95 (unleaded) 1*)	95 (unleaded) 1*)	98 (unleaded) 2*)	98 (unleaded) 2*)	98 (unleaded) 2*)	98 (unleaded) 2*)	98 (unleaded) 2*)

1*) 91 RON standard unleaded gasoline is permissible, however with decreased power output.

2*) 95 RON Super unleaded gasoline is permissible, however with decreased power output.

Diesel engines

Engine code		AVB	AWX, AVF	AKE	AYM, BCZ, BDG	BFC	BAU, BDH	BSG	BPP	BKN
Emissions category		EU III	EU III	EU III	AYM, BCZ EU III BDG EU III + D4	EU III	BAU EU III BDH EU III + D4	EU IV	EU IV	EU IV
Number of cylinders/valves per cylinder		4 / 2	4 / 2	6 / 4	6 / 4	6/4	6 / 4	6/4	6/4	6/4
Displacement	L	1.9	1.9	2.5	2.5	2.5	2.5	2.7	2.7	3.0
Output	kW at RPM	74/4000	96/4000	132/4000	114/4000	120/4000	132/4000	120/4000	132/4000	150/4000
Torque	Nm at RPM	250/1900	* See footnote 285/ 1750 ...2750	370/ 1500 ... 2500	310/ 1500 ... 2500	310/ 1400 - 3600	370/ 1500... 2500	380/ 1500-3200	380/ 1500-3200	450/ 1500-3000
Bore	mm	79.5	79.5	78,3	78,3	78,3	78,3	83.0	83.0	83.0
Stroke	mm	95.5	95.5	86.4	86.4	86.4	86.4	83,1	83,1	91,5
Compression ratio		18.5	18.5	18.5	18.5	18.5	19.5	17.5:1	17.5:1	19.5
Fuel injection/Ignition		Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)
CZ min.		51	51	51	51	51	51	51	51	51

* Engine code AVF 310 Nm

Diesel engines

Engine code	BKE	BLB	BNA	BPW	BRC	BRF	BVF	BRD	BRE	BVG	BVA	BRB	ASB
Emissions category	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV	EU IV
Number of cylinders/valves per cylinder	4/2	4/4	4/4	4/2	4/2	4/4	4/4	4/4	4/4	4/4	4/4	4/2	6/4
Displacement	1.9	2.0	2.0	2.0	2.0	2.0	2.0	2.0	2.0	2.0	2.0	1.9	3.0
Output kW/rpm	85/4000	103/4000	100/4000	103/4000	100/4000	100/4000	93/4000	125/4000	103/4000	89/4000	120/4000	85/4000	171/4000
Torque	285/1900	320/ 1750-2500	320/ 1750-2500	320/ 1750-2500	320/ 1750-2500	320/ 1750-2500	320/ 1750-2500	350/ 1750-2500	320/ 1750-2500	320/ 1750-2500	350/ 1750-2500	285/1900	450/ 1500-3000
Bore	79.5	81.0	81.0	81.0	81.0	81.0	81.0	81.0	81.0	81.0	81.0	79.5	83.0
Stroke	95.5	95.5	95.5	95.5	95.5	95.5	95.5	95.5	95.5	95.5	95.5	95.5	91,5
Compression ratio	19,0	18.5	18.5	18.5	18.5	18.5	18.5	18.5	18.5	18.5	18.5	19,0	19.5
Fuel injection/Ignition	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)	Diesel (direct injection)
Diesel particle filter	-	-	-	X	X	X	X	X	X	Installation possible	X	Installation possible	X
CZ min.	51	51	51	51	51	51	51	51	51	51	51	51	51

Gasoline engines

Code letters		BPG	BWT
Displacement	ltr.	1.984	1.984
Output	kW at 1/rpm	147/5700	147/5700
Torque	Nm at rpm	280/2000	280/1800
Bore	Dia. mm	82.5	82.5
Stroke	mm	92.8	92.8
Compression ratio		10.5	10,5
RON		98 1)	98 1)
Fuel injection and ignition system		FSI	FSI
Ignition sequence		1-3-4-2	1-3-4-2
Knock control		yes	yes
Charging		yes	yes
Exhaust gas recirculation		no	no
Variable intake manifold		no	no
Variable valve timing		yes	yes
Secondary air injection (AIR)		no	no
1) Unleaded RON 95 is also permissible, although with reduced power.

Delivery inspection

Delivery inspection

--> ServiceNet; Delivery Satisfaction Program; Perfect Delivery Inspection (PDI) Checklists for appropriate model and year

Oil change service

Oil change service

For engine oil specifications and capacities please refer to --> Fluid Capacity Chart for appropriate model and year

Also, for appropriate service intervals refer to --> ServiceNet; Maintenance Schedule for appropriate model year

Inspection service

Inspection service

--> ServiceNet; Delivery Satisfaction Program; Perfect Delivery Inspection (PDI) Checklists for appropriate model and year

Also, for appropriate service intervals refer to --> ServiceNet; Maintenance Schedule for appropriate model year

Description of work

All switches, all electrical components, all displays and other operating elements: Checking function

• Check following:

• Lighting, headlamps, fog lights, turn signals, hazard warning flashers, taillights, rear fog lights, backup lights, brake lights, parking lights
• Interior and reading lights (automatic shutoff on interior lights), illuminated storage compartment, illuminated ashtray, luggage compartment lighting, illuminated ignition
• Warning buzzer for lights and/or radio left on
• All switches in console

• Driver Information System (DIS)
• Instrument unit with all displays, meters and lights
• Two-tone horn
• Windshield/headlamp wipers, headlamp cleaning system

• Cigarette lighter
• Electric exterior mirrors (heated, adjustable)
• Electric windows
• Electric tilt/slide sunroof

• Central locking, remote control operation, comfort closing
• Electric seat
• Heated seat
• Radio

Final drive (automatic transmission): Check oil level, add oil if necessary

Automatic transmission

--> -

• 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V
• 39 FINAL DRIVE - FRONT DIFFERENTIAL for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE

Continuously Variable Transmission (CVT) transmission

--> - 39 - FINAL DRIVE, DIFFERENTIAL

Battery: Check

Battery with "magic eye"

Battery is located in plenum chamber between engine compartment and windshield or in spare wheel well on RS4.

Fig. 1: Pushing Cover Over Battery Toward Right And Removing It Upward
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Slide cover over battery to right - arrow 1 - and remove upward - arrow 2 -.

Fig. 2: Identifying The Visual Indicator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The visual indicator - arrow - gives information about electrolyte level and battery charge.

• Switch ignition off.

Fig. 3: Identifying The Visual Indicator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check electrolyte level at visual indicator - arrow -.
• Tap lightly on battery housing with a blunt object, air bubbles under the visual indicator can cause a false reading.
• Green --> battery charge is OK.
• Black --> no charge or charge too low

• No color or yellow --> critical electrolyte level has been reached, battery must be replaced --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

NOTE:

Observe before disconnecting battery --> Note before disconnecting battery..

Battery sealing plugs

• On batteries with visible min and max markings, electrolyte level only needs to be checked visually.
• Electrolyte level must be between min. and max. markings.
• On batteries where the outer min. and max. markings are difficult to see or the visibility of the electrolyte level cannot be guaranteed due to the opaque battery housing, the sealing plugs must be removed. Then it is possible to check electrolyte level by a visual inspection of the battery interior.
• The electrolyte level must meet the inner electrolyte level marking (plastic bar). This corresponds to the outer max. mark.

NOTE:

If electrolyte level is too low, battery loses capacity (loses performance) because the cell plates dry out. If the cell plates are not covered by electrolyte, the plates and plate bridges start to corrode causing the function of the battery to diminish. After a while the battery does no longer function. The battery becomes useless.

WARNING:

If the electrolyte level is below them in. marking, the battery must be replaced! --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Valve-regulated lead acid battery or absorbed glass mat (AGM) battery

NOTE:

Valve-regulated lead acid or AGM batteries are sealed, they cannot and must not be opened. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Battery: No load voltage, checking before starting engine for the first time

Necessary test equipment

• Digital multimeter V.A.G 1715

or

• Portable multimeter V.A.G 1526 B

Fig. 4: Special Tool - Multimeter V.A.G 1526 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Portable multimeter

NOTE:

Battery must not be loaded by connected components for at least 12 hours before testing. Battery must not be charged for at least 12 hours before testing. Measure voltage between terminals with engine switched off.

WARNING:

Always follow procedure exactly, otherwise measured values could be incorrect.

Battery: Ensure battery cable fits securely

Fig. 5: Locating Battery Terminals On Battery
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check battery terminals on vehicle battery for secure fit, tighten nuts on -terminal -1- and + terminal - 2 - if necessary.

WARNING:

If the battery clamp is not seated securely on the positive terminal, disconnect battery Ground (GND) strap on battery negative terminal first, to prevent possible accidents.

NOTE:

Observe before disconnecting battery --> Note before disconnecting battery..

Fig. 6: Locating Battery Terminals On Battery
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check battery for secure fit, tighten screws - 4 - on securing bracket - 3 - if necessary.

Tightening torque	Nm
Battery connection to battery terminal	6
Screw to securing bracket	12

Battery: Perform battery load test

Battery load test indicates battery condition.

Special tools, testers, and measuring equipment

Fig. 7: Battery VAS Tester
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Battery tester VAS 5097 A

NOTE:

If battery tester VAS 5097A is used, it is not necessary to remove battery. The battery does not need to be disconnected either.

Perform battery load test

• Switch ignition off.
• Read battery tester operating instructions.
• Connect test lead clamps to battery terminals as shown in battery tester operating instructions.

The clamps must make good contact with battery poles.

• Load current depends on battery capacity and must be adjusted on the tester --> battery tester operating instructions.
• Perform battery load test according to operating instructions.

Tester display during battery load test

Note following tester evaluations:

Tester Evaluations

Display on battery tester	Delivery inspection	Inspection service
Starting output very good	Battery OK	Battery OK
Starting output good	Battery OK	Battery OK
Starting output sufficient	Replace battery	Recharge battery 1)
Starting output poor	Replace battery	Recharge battery 1)
Starting output very poor	Replace battery	Replace battery 2)
Not testable	Replace battery	Replace battery 2)

• Replace battery. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Regarding battery load test:

Because of the high load on the battery during this test (a high current flows) the battery voltage lowers.

If the battery is OK, the voltage only goes down to the minimum voltage specification.

If the battery is malfunctioning or only faintly charged, the battery voltage will drop rapidly to below the displayed minimum voltage.

After the test, this low voltage remains steady over a longer time before the voltage slowly increases.

Brake system: Visual inspection for leaks and damage

• Check the following components for leaks and damage:

• Brake master cylinder
• Brake booster
• ABS Hydraulic unit
• Brake calipers

• Check that brake hoses are not twisted.
• Ensure brake hoses do not come in contact with any vehicle components when steering is at full lock.
• Check brake hoses for porosity, bubbles and cracks.
• Check brake hoses and pipes for chafing.

• Check all brake line connections for secure mounting, leaks, or corrosion.

WARNING:

Malfunctions found must be rectified (repair measure).

Brake pads: Checking thickness

WARNING:

At a pad thickness of 7 mm (including backing plate) the brake pads have reached their wear limit and must be replaced (repair measure). Inform the customer.

Front disc brake pads:

• Determine thickness of outer pads by checking visually (using a flashlight through a hole in wheel).

Fig. 8: Determining Thickness Of Inner Pad By Visual Check
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Determine thickness of the inner pad by visual check (using a flashlight through a hole in the wheel).

Rear disc brake pads:

• Determine thickness of outer pads by checking visually (using a flashlight through a hole in wheel).

Fig. 9: Identifying Thickness Of The Inner Pad
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Determine thickness of the inner pad by visual check (using a flashlight through a hole in the wheel).

Tires: Checking condition, wear pattern and tread depth and adjusting tire pressure.

Tires, checking

NOTE:

For reasons of safety only tires of same type and tread pattern should be fitted on a vehicle! On All Wheel Drive vehicle tires of the same type and tread pattern must be used. Otherwise the center differential may be damaged.

Delivery inspection

• Check running surfaces and side walls for damage, remove foreign bodies, if necessary.

Inspection service

• Check running surfaces and side walls for damage, remove foreign material, if necessary.
• Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.

WARNING:

Report any damage to customer and mark repair order accordingly.

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.

NOTE:

When wear of this nature is noticed determine cause by performing alignment checks (repair measure).

Check tread depth.

• Minimum depth: 1.6 mm

NOTE:

This value may vary for individual countries due to different legislative regulations.

Fig. 10: Checking Tire Tread Depth
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• 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.

Tire pressure, adjusting

Fig. 11: Identifying Tire Pressure Values For Summer Tires On Sticker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tire pressure values for summer tires are on the sticker on the inside of the fuel tank lid.

NOTE:

Observe that the inflation pressure specifications on the sticker refer to the air pressure of cold tires. Do not reduce increased pressures on warm tires. On vehicles with Tire Pressure Monitoring System, changed tire pressures must be stored. --> Tire Pressure Monitoring System: Programming tire pressures When using winter tires, the tire pressure must be increased about 0.2 bar.

Spare wheel

• Spare wheel with standard tire

Keep the highest pressure intended for the vehicle

• Mini spare tire

Pressure is on side of tire

• Tire repair kit

Check --> Tire repair kit: Checking

NOTE:

Tire valves must be sealed with valve caps. Otherwise, dirt can enter valve needle which becomes jammed and can no seal shut.

Brake fluid level, dependent on lining wear: Check

NOTE:

Use only new Original VW / Audi brake fluid, see ETKA

WARNING:

Brake fluid is poisonous. Due to its caustic nature, it must also never be brought into contact with paint. Brake fluid is hygroscopic, meaning that it absorbs moisture from the surrounding air, and must therefore always be stored in air-tight containers.

• Please observe the following:

Delivery inspection

Fig. 12: Identifying Fluid Level
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fluid level must be at MAX mark

NOTE:

To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark.

Inspection service

When driving, fluid level drops slightly from use and automatic brake pad adjustment.

• Always check fluid level in conjunction with brake pad wear:

Fig. 13: Identifying Fluid Level
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When brake pads are new or if there is still enough brake lining left, the brake fluid level must be between MIN and MAX marks.
• With brake fluid at MIN mark or slightly above, topping off brake fluid is not necessary when wear limit of brake pads has been almost reached.

WARNING:

If brake fluid level is below MIN mark, check brake system (repair procedure), before adding brake fluid.

Brake fluid: Changing

Special tools, testers, and measuring equipment

Fig. 14: Identifying Brake Filler And Bleeder Unit VAS 5234
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• VAS 5234 Brake filling and bleeding tool

Fig. 15: Identifying Brake Filler And Bleeder Unit V.A.G 1869
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• V.A.G 1869 Brake filling and bleeding tool with Adapter set V.A.G 1869/4

NOTE:

Use only new Original VW / Audi brake fluid, see ETKA

WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning 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. Observe waste disposal regulations!

Observe operating instructions for VAS 5234 or for V.A.G 1869 !

Fig. 16: Identifying Brake Fluid Reservoir Cap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove brake fluid reservoir cap - 1 -.

WARNING:

The strainer in the brake fluid reservoir must not be removed.

• Remove brake fluid reservoir plug - arrow -.

Fig. 17: Connecting Suction Hose From VAS 52.4 Or V.A.G 1869 To Tube Of Brake Fluid Reservoir
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect suction hose from VAS 5234 or V.A.G 1869 to tube - 1 - of brake fluid reservoir.
• Extract as much brake fluid as possible using suction hose from VAS 5234 or from V.A.G 1869 or with extractor bottle.
• Disconnect suction hose.
• Install brake fluid reservoir plug.

WARNING:

Do not reuse, (used) extracted brake fluid.

Fig. 18: Connecting Suction Hose From VAS 52.4 Or V.A.G 1869 To Tube Of Brake Fluid Reservoir
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install adapter - 1 - to brake fluid reservoir.
• Connect filler hose - 2 - from VAS 5234 or V.A.G 1869 to adapter.

Vehicles with manual transmission:

• Pull cover cap off clutch slave cylinder bleed screw.

Fig. 19: Connecting Filler Hose From VAS 52.4 Or V.A.G 1869 To Adapter
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place extractor bleeder hose - 1 - on clutch slave cylinder bleeder screw, open bleeder screw, and let about 100 ml drain out. Close bleeder screw and install cover cap.
• Operate clutch pedal several times.

Continued for all vehicles:

• Remove caps from the bleeder screws.
• Connect extractor bleeder hose - 1 - to front left bleeder screw, open bleeder screw and allow about 200 ml to flow out. Close bleeder screw.

Repeat work sequence on other side of vehicle at front.

• Connect extractor bleeder hose - 1 - to rear left bleeder screw, open bleeder screw and allow about 200 ml to flow out. Close bleeder screw.

Repeat work sequence on other side of vehicle at rear.

Table - Sequence / quantity of brake fluid

front left	200 ml
front right	200 ml
Left rear	200 ml
Right rear	200 ml
Total amount * See footnote	1,000 ml

* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.

• Fit cover caps to brake caliper bleed screws.
• Move filler lever on VAS 5234 or V.A.G 1869 to position - B - (see operating instructions).
• Take filler hose off adapter.
• Unscrew adapter from brake fluid reservoir.

Fig. 20: Identifying Fluid Level
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check brake fluid level and correct if necessary.
• Install cap to brake fluid reservoir.
• Check pedal pressure and brake pedal free play. Free play: Max. 1 / ₃ of pedal travel

Set digital clock

Vehicle is equipped with a radio or quartz clock.

Radio clock

If an acceptable radio clock signal is received, clock automatically switches to "radio-controlled quartz clock" operating mode. The radio clock reception symbol (radio tower radiating waves) appears in display. If the clock does not receive a valid signal, it automatically switches to "quartz clock" mode after 3 days and radio clock reception symbol goes out.

Quartz clock

Set hour

• Press "MODE" button; hour display blinks.
• Press "+" button to advance hour display.
• Press "-" button to reverse hour display.

Set minute

• Press "MODE" button until minute display blinks.
• Press "+" button to advance minute display.
• Press "-" button to reverse minute display.

Set date

• Press "MODE" button until date display blinks.
• Press "+" or "-" button to set day.
• Press "MODE" button again, month display blinks.
• Press "+" or "-" button to set month.

• Press "MODE" button again, year display blinks.
• Press "+" or "-" button to set year.

Electric windows: Check positioning

Electric windows forget current position and automatic lowering and raising function when battery is disconnected.

Activate automatic lowering/raising function as follows:

• Switch ignition on.
• Raise windows with electric window regulators up to stop.
• Then operate all window switches again for at least 1 second in "close" position to activate automatic lowering/raising.
• Press switch down. Window must lower to stop by itself.

DTC memory: Retrieving with VAS 5051/ 5052

• Follow these steps in sequential order.

Fig. 21: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Vehicle - Self-diagnosis
• Gateway - Installation list

• Read control module with stored DTC memory.
• Correct relevant malfunctions with customers approval.

Check vehicle key function

• Separate keys so that each can be checked individually for function.
• Mechanically lock and unlock drivers door with each key.
• Remove radio operation (press a remote control operation button)
• Insert each key in ignition and switch ignition on. Immobilizer key symbol in instrument cluster must go out after two seconds. If key symbol blinks, key is not programmed to immobilizer. Guided Fault Finding; Program vehicle key

• Remove radio operation (press a remote control operation button)

NOTE:

Enter number of keys checked and delivered to customer in delivery protocol.

Front axle joints: Seal boots, checking play and secure fit.

NOTE:

Perform this test with vehicle on lift (wheels hanging freely).

Tie rod ends

• Check play by moving tie rods and wheels.

• You should not feel or see any play.

• Check all around ball joint boots - arrow - for damage and correct seating. Use a mirror, if necessary.

• Ball joint boots can usually be recognized by leaking lubrication.

Fig. 22: Identifying Lock Nut
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make sure lock nut - 1 - is tightened to 40 Nm.

All control arms

Fig. 23: Identifying Ball Joint Boots
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check all around ball joint boots - arrows - for damage and correct seating. Use a mirror, if necessary.

• Ball joint boots can usually be recognized by leaking lubrication.
• You should not feel or see any play.

Control arm

Fig. 24: Identifying Bearing Housing And Control Arm
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• With unloaded wheels, check relative movement of wheel bearing housing to control arm.
• By raising and lowers the wheels several times by hand - arrow - the relative movement between wheel bearing housing and control arm can be observed.
• If relative movement when lifting or lowering gives evidence of play that can be felt or seen, control arm must be replaced.

Drive shaft boot

• Check all around interior and exterior drive shaft boot for damage and correct seating. Turn wheel, if necessary.

• By turning the front wheels, tears can be found in their early stages.
• Drive shaft boot damage can usually be recognized by leaking lubrication.

Noise insulation: Removing

Vehicles with auxiliary heater:

Fig. 25: Identifying Exhaust Pipe Fasteners
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove parking/auxiliary heater exhaust pipe screws - arrows - on noise insulation.

All:

Fig. 26: Removing Sound Insulation
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove quick-release screws - arrows -.

Power steering: Check for leaks and fluid level, top off power steering fluid, if necessary

• With engine not running, move front wheels in straight-ahead position.

Cold fluid (exterior temperature approx +20 ° C)

• Remove cover.
• Clean dipstick with clean cloth.
• Screw cap on hand-tight and remove again.

Screw cap fully in to get an accurate fluid level reading.

Fig. 27: Checking Fluid Level
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check fluid level: Fluid level must be in area of "MAX" marking.

Warm fluid (engine fluid temperature +80 ° C)

• Check fluid level: Fluid level must be 10 mm above "MAX" marking.

NOTE:

If fluid level is above specified range, fluid must be extracted off. If the fluid level is below the specified level, check the hydraulic system for leaks. It is not enough to simply top off with fluid. Do not use power steering fluid that has drained out.

Rear lid hinges: Lubricate

• Open rear lid
• Remove left/right lid hinge cover if present.

Fig. 28: Lubricating Hinge Joints
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lubricate each of the four hinge joints on both rear lid hinges - arrows -.

• Lubricant: "G 000 115 A2"

NOTE:

Included spray tube must be inserted in sprayer head to aim spray. Shake spray can about five times. Spray must not be shaken too long or hard because otherwise spray oil will foam up and its lubricating ability is reduced. Clean excess fluid from body and joints.

Calibrate rearview mirror with compass

--> - 68 - INTERIOR EQUIPMENT

Instrument cluster: Adapt language version

• Follow these steps in sequential order.

Fig. 29: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Guided Fault Finding or Guided Functions
• Go to - function/component selection

• Service work
• Language adaptation
• Now follow guided program

NOTE:

Please follow guided program function description K-lead adapter VAS 6017B must be used.

A/C system: Check function, set temperature to 72 F (22 C)

• Check all climate control functions: Owners manual

Fig. 30: Checking Whether 72F (22C ) Is Set In Both Display Fields
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check whether 72 ° F (22 ° C ) is set in both display fields.
• Set temperature as follows, if necessary:
• Press the "AUTO" button.
• Set temperature on drivers and passengers side to 72 ° F (22 ° C) with "+" and "-" buttons.

Cooling system: Check freeze protection, add coolant, if necessary

NOTE:

All new engines are filled with coolant additive G 12 Plus according to TL VW 774 F (purple color). 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 freezing, 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

Special tools, testers and auxiliary items required

Fig. 31: Identifying Refractometer T10007
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• 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).

Fig. 32: Identifying Refractometer Scales
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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, 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	6-cylinder engines	8-cylinder engines
0	-25	3,5	5,0	5,0
	-35	4,0	6,0	6,0
-5	-25	3.0	4,5	4,5
	-35	3,5	5,5	5,5
-10	-25	2.0	3,5	3,5
	-35	3.0	4,5	4,5
-15	-25	1,5	2.5	2.5
	-35	2.0	3,5	3,5
-20	-25	1,0	1,5	1,5
	-35	1,5	2.5	2.5
-25	-35	1,0	1,5	1,5
-30	-35	0,5	1,0	1,0
-35	-40	0,5	0,5	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.

Fig. 33: Checking Coolant Level
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• 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 / TL VW 774 F	Water
-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. The coolant concentration must not be reduced by adding water, even during the warmer season. The coolant additive ratio must be at least 40%.

Ribbed belt: Replacing

8-cyl. 5V engines 4.2L

• Ribbed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

Air cleaner: Clean air filter housing and replace filter

Fig. 34: Identifying Intake Hose And EVAP Valve Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

In various engine versions, a snow screen is located in intake hose - A -. Snow screen must be removed and cleaned.

4-cyl. 1.8L 5V Turbo engines --> 4-cyl. 1.8L 5V Turbo engines:

4-cyl. 2.0L Turbo FSI engines --> 4-cyl. 2.0L TFSI engines

6-cyl. 3.0L engines --> 6-cyl. 3.0L engines

6-cyl. 3.2L engines --> 6-cyl. 3.2L engines

8-cyl. 4.2L MPI engines --> 8-cyl. 4.2L MPI engines

8-cyl. 4.2L engines (RS4) --> 8-cyl. 4.2L engines (RS4)

4-cyl. 2.0L TFSI engines

Fig. 35: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.

Fig. 36: Identifying Upper Part Of Air Filter Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air duct - 2 -.
• Disconnect electrical connector from Mass Air Flow (MAF) Sensor G70.
• Open clamp from air guide hose to turbocharger and remove this at Mass Air Flow (MAF) Sensor G70.
• Remove both screws - 1 - at upper part of air filter and remove upward.

• Remove old air filter element.
• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See footnote}

4-cyl. 1.8L 5V Turbo engines:

Fig. 37: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.
• Remove air duct - 2 -.

Fig. 38: Identifying Hose Clamp And Evaporative Emission (EVAP) Canister Valve
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Open hose clamp - 1 - and remove line from Evaporative Emission (EVAP) canister valve.
• Remove line - 3 - and remove both screws - 2 -.
• Remove upper part of air filter from bracket and pivot toward engine side.
• Remove old air filter element.

• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See footnote}

6-cyl. 3.0L engines

Fig. 39: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at air duct.
• Remove bolts - arrows -.

Fig. 40: Identifying Air Duct, Air Intake Hose, Electrical Connector And Mass Air Flow (MAF) Sensor G70
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air duct - 2 -.
• Remove air intake hose - 4 - and disconnect electrical connector - 3 - from Mass Air Flow (MAF) Sensor G70.
• Remove both fuel lines from bracket on upper part of air filter housing.
• Disconnect pipe connection - 1 -.

• Remove both screws - 2 - at upper part of air filter and remove upward.
• Remove old air filter element.
• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See footnote}

6-cyl. 3.2L engines

Fig. 41: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows -.

Fig. 42: Identifying Air Duct, Clean Air Tube Clamp, Fuel Line, And Pipe Connection
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air duct - 2 -.
• Open clean air tube clamp - 4 - and remove from air filter housing.
• Unclip fuel line - 3 -.
• Disconnect pipe connection - 1 -.

• Remove both screws - 2 - at upper part of air filter and remove upward.
• Remove old air filter element.
• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See footnote}

8-cyl. 4.2L MPI engines

Fig. 43: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at air duct.
• Remove bolts - arrows -.
• Remove air duct - 2 -.

Fig. 44: Identifying Air Intake Hose, Electrical Connector, And Mass Air Flow (MAF) Sensor G70
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air intake hose - 4 - and disconnect electrical connector - 3 - from Mass Air Flow (MAF) Sensor G70.
• Remove line -1- and remove both screws - 2 -.
• Remove both fuel lines from bracket on upper part of air filter and remove this upward.
• Remove old air filter element.

• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See footnote}

8-cyl. 4.2L engines (RS4)

Fig. 45: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disengage fuel line - 1 - at upper part of air filter housing.
• Remove bolts - arrows -.

Fig. 46: Identifying Air Duct And Mass Air Flow Sensor G70 Electrical Connector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air duct - 2 -.
• Loosen hose clamp - 2 - and remove air intake hose from upper part of air filter.
• Disconnect electrical connector - 1 - from Mass Air Flow Sensor G70.
• Remove hoses - 6 - , - 4 - and - 3 - from bracket.

• Now remove screws - 5 - and remove upper part of air filter housing upward.
• Remove old air filter element.
• Clean filter housing and install new air filter element.
• Further assembly occurs in reverse order.

• Follow notes ^{* See note}

NOTE:

If the air filter insert is heavily soiled or soaked, dirt particles or moisture can reach the Mass Air Flow Sensor G70 and cause an incorrect air flow reading. This causes lack of performance because a lower injection amount is calculated. Always use an original air filter insert. Hose supports and charge air system hoses must be free of oil and grease before installation. Do not use any lubricant containing silicone when installing. Air filter housing must be clean. Secure all hose connections with hose clamps that match current standard production. When cleaning air filter housing with compressed air, observe the following: To avoid malfunctions, cover critical air carrying engine components such as Mass Air Flow (MAF) sensor, air inlet tube, etc. with a clean cloth. Check drain hose in bottom side of air filter or dirt and adhesion (clean, if necessary). Check mass air flow sensor and air guide hose (clean air side) for salt residue, dirt and leaves. Check air duct from lock carrier to air filter housing for dirt and leaves. When installing air filter insert, ensure it is centered in mount on bottom of air filter. Carefully and gently place upper part of air filter on lower part. Ensure upper part of air filter is not sitting crooked on air filter insert (note air filter insert sealing lip). Ensure secure fit from air guide hose to Mass Air Flow (MAF) Sensor G70. Observe waste disposal regulations!

Hood catch: lubricating

Fig. 47: Identifying Lubrication Points On Hood Safety Catch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lubricate hood safety catch only on lubrication places indicated - arrows -.

• Lubricant: "G 052 778 A2"

Engine cover: Removing

Fig. 48: Removing Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

4-cyl. Gasoline engines

• Remove bolts or nuts - arrows - and remove engine cover(s).

Fig. 49: Removing Cover In Engine Compartment (Right Side)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

6-cyl. 5V engines 3.0L

Remove cover - 1 - at right in engine compartment.

Fig. 50: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear engine cover upward.

Fig. 51: Removing Rear Engine Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

V8 4.2 gasoline engines

Remove rear engine cover upward.

Engine (from above and below) and engine compartment: Visual inspection for leaks and damage

Perform visual check as follows:

• Remove engine cover --> Engine cover: Removing.
• Check engine and engine compartment for leaks and damage.
• Check lines, hoses and connections on following systems for leaks, chafing, porosity and cracks:

• Fuel system
• Cooling and heating system
• Brake system

• Perform visual inspection from below using same viewpoints as when vehicle was on lift and noise insulation removed.

WARNING:

Malfunctions found must be rectified (repair measure).

Continuously Variable Transmission (CVT) 01J: Changing ATF

• Continuously Variable Transmission (CVT) 01J: Change ATF --> - 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

Engine oil: Drain/extract, replace oil filter

WARNING:

Oil extraction not permitted with various engine types! See maintenance table.

NOTE:

Perform oil change at operating temperature.

Special tools, testers and auxiliary items required

• Hazet tension band 2171-1
• or
• Oil filter wrench 3417
• Oil extractor V.A.G 1782

Fig. 52: Identifying Oil Drain Adapter T 40057 (2.0 TFSI)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Oil Drain Adapter T 40057 (2.0 TFSI)

NOTE:

Observe waste disposal regulations!

4-cyl. gasoline engines --> 4-cyl. gasoline engines

4-cyl. TFSI engines --> 4-cyl. TFSI engines

6-cyl. 3.2L FSI gasoline engines --> 6-cyl. 3.2L FSI gasoline engines

8-cyl. 4.2L MPI gasoline engines --> 8-cyl. 4.2L MPI gasoline engines

8-cyl. 4.2L FSI gasoline engines, RS4 --> 8-cyl. 4.2L FSI gasoline engines, RS4

4-cyl. gasoline engines

Fig. 53: Identifying Oil Filter
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen oil filter - arrow - using oil filter wrench 3417 or tension band Hazet 2171-1.
• Remove oil filter.

NOTE:

Observe waste disposal regulations! Observe installation note on oil filter. Open oil drain plug or extract engine oil. Clean oil filter sealing surface on engine. Lubricate rubber seal lightly with oil.

Fig. 54: Identifying Oil Filter Unit And Hoses
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install new filter and tighten.

WARNING:

After changing oil filter unit, check clearance of hoses - arrows - going from oil cooler to adjacent components. Correct the position of the oil cooler, if necessary.

• Install oil drain plug with new gasket.
• Fill up with engine oil, specifications --> Engine oil: Fill.

Tightening torque	Nm
Oil drain plug 4-cyl. gasoline engines	30

NOTE:

Engines with turbocharger: After the engine oil and oil filter have been replaced, observe the following when first starting the engine: As long as the oil pressure warning light in the instrument panel insert flashes, the engine is only to run at idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or destroy it completely. The full oil pressure achieved and the engine can be accelerated only when the warning light extinguishes Check for cleanliness.

4-cyl. TFSI engines

• Remove noise insulation --> Noise insulation: Removing.

NOTE:

Before removing oil filter, motor oil must be drained from filter so that it does not drain onto engine and attached parts.

Fig. 55: Identifying Valve Protection Cap And Oil Filter Housing Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bottom valve protective cap - 1 -.
• Remove ball head hose from Oil Drain Adapter T 40057 and turn threaded bolt in bottom oil filter housing bottom valve - 2 - under a slight resistance is felt.
• Now place ball head hose on threaded bolts and turn Oil Drain Adapter T 40057 to stop - a clear snap of the drain valve will be heard.
• Allow oil filter to run empty.

WARNING:

Hot engine oil

• Open oil drain plug or extract engine oil.

Fig. 56: Identifying Remove Oil Drain Adapter T 40057
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove Oil Drain Adapter T 40057.
• Check whether bottom valve - 1 - is flush and not crooked, as in illustration (A02-0423).
• Remove protective cap.
• Open oil filter housing - 2 - with Oil Filter Wrench 3417 or with socket AF 36, e.g. Socket AF 36 T10125 and remove oil filter.

Fig. 57: Identifying Filter Insert And Gasket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace filter insert - 4 - and gasket - 3 -.
• Note position of service flag on sealing ring (see arrow)

NOTE:

Observe waste disposal regulations! Clean sealing surface on oil filter housing. Lubricate rubber seal lightly with oil. Smooth side of sealing ring must face toward outside Screw on filter housing and tighten. Install oil drain plug with new gasket. Fill up with engine oil, specifications --> Engine oil: Fill.

Tightening torque	Nm
Oil filter	25+5
Oil drain plug	30

NOTE:

Engines with turbocharger: After the engine oil and oil filter have been replaced, observe the following when first starting the engine: As long as the oil pressure warning light in the instrument panel insert flashes, the engine is only to run at idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or destroy it completely. The full oil pressure achieved and the engine can be accelerated only when the warning light extinguishes Check for cleanliness.

6-cyl. 3.2L FSI gasoline engines

NOTE:

Loosen the cap before draining / extracting, so that the engine oil can run out of the oil filter housing.

Fig. 58: Identifying Coolant Reservoir And Oil Filter Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant reservoir - 1 - and lay aside.
• Remove oil filter cover with socket wrench SW 36 - 2 -.
• Clean sealing surfaces oil filter cover and at oil filter housing.
• Replace oil filter insert..

Fig. 59: Identifying Sealing Ring On Cap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Sealing ring on cap, replacing

• Remove sealing ring at pull tab - arrow A - from cap - 1 -.
• Insert new sealing ring - 2 - with semicircular profile in groove - arrow B - on cap.

• The pull tab - arrow A - must face upward.
• Smooth side of sealing ring - 2 - must face toward outside

Fig. 60: Identifying Oil Filter Housing O-Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

O-ring, inserting in oil filter housing

• Insert O-ring - 2 - in groove - arrow - on oil filter housing - 1 -.

NOTE:

Observe waste disposal regulations! Engage new oil filter insert in oil filter cover. Install oil filter cover. Install coolant reservoir. Remove noise insulation. Open oil drain plug on oil pan or extract engine oil. Install oil drain plug.

NOTE:

Oil drain plug is installed without seal. Check for cleanliness.

Tightening torque	Nm
Oil filter cover	25
Oil drain plug on oil pan	30

• Fill motor oil. --> Engine oil: Fill

8-cyl. 4.2L MPI gasoline engines

• Remove engine cover upward.

Fig. 61: Identifying Oil Filter Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oil filter cover - arrow - using socket wrench SW24.
• Filter element, removing

NOTE:

Removing the filter element will open a valve and oil in the filter housing will flow automatically into the crankshaft housing.

Fig. 62: Identifying O-Ring And Oil Filter Insert
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace O-ring - 2 - as well as oil filter insert - 3 -.

Fig. 63: Identifying Oil Filter Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten cover - arrow -.
• Open oil drain plug or extract engine oil.
• Install oil drain plug with new gasket.
• Fill up with engine oil, specifications --> Engine oil: Fill.

Tightening torque	Nm
Oil filter cover	25
Oil drain plug	50

NOTE:

Check for cleanliness.

8-cyl. 4.2L FSI gasoline engines, RS4

• Remove engine cover upward.

Fig. 64: Identifying Screws And Line
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Loosen screws - 1 - and unclip line - 2 -.
• Lay aside bracket.

Fig. 65: Identifying Oil Filter Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove oil filter cover - arrow - using socket wrench SW32.
• Filter element, removing

NOTE:

Removing the filter element will open a valve and oil in the filter housing will flow automatically into the crankshaft housing.

Fig. 66: Identifying O-Ring And Oil Filter Insert
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace O-ring - 2 - as well as oil filter insert - 3 -.

Fig. 67: Identifying Oil Filter Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten cover - arrow -.
• Open oil drain plug and drain engine oil.
• Install oil drain plug with new gasket.
• Fill up with engine oil, specifications --> Engine oil: Fill.

Tightening torque	Nm
Oil filter cover	25
Oil drain plug	25

NOTE:

Check for cleanliness. Do not extract engine oil!

Engine oil: Fill

NOTE:

Please follow specified engine oil capacity and oil standards in the ELSA maintenance table.

Engines with turbocharger:

• After the engine oil and oil filter have been replaced, observe the following when first starting the engine:

• As long as the oil pressure warning light in the instrument panel insert flashes, the engine is only to run at idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or destroy it completely
• The full oil pressure achieved and the engine can be accelerated only when the warning light extinguishes

All:

• Check engine oil level --> Engine: Oil level, checking.

Engine: Oil level, checking

NOTE:

Oil temperature at least 140 ° F (60 ° C). Vehicle must be in level position. After stopping engine, wait a few minutes to allow oil to flow back into oil pan. Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop. Pull out dipstick again and read oil level.

Fig. 68: Identifying Markings On Dipstick
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Markings on dipstick:

NOTE:

Oil level must not exceed - a - mark on dipstick.

Navigation: Eject button, unlocking

• Follow these steps in sequential order.

Fig. 69: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Guided functions
• Go to - function/component selection
• Service work

• J401 - Navigation, Eject button, locking/unlocking
• Now follow guided program

Test drive: Perform

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 removal lock, shift behavior, instrument panel insert display

• Foot and parking brake: Function, free travel and effectiveness, pulling to one side, juddering, squeal
• ABS function: A pulsing at the brake pedal must be felt when performing ABS controlled braking
• Steering: Function, steering free play, steering wheel centralized when wheels are in straight ahead position
• Tilt/slide sunroof: Function

• Cruise Control System (CCS): Function
• Radio: reception, SCV, interference
• Driver Information System (DIS): Functions
• A/C system: Function

• Vehicle: Moving off line when traveling straight ahead (level road)
• Imbalance: Wheels, drive shafts
• Wheel bearings: Noises
• Engine: Hot starting behavior

Wheel bolts: Tighten to correct torque setting

Center cap

Fig. 70: Identifying Removal Hook
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The removal hook - A - for removing the center cap is located in the vehicles tool kit.

Wheel bolts

The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.

Place adapter with vehicle tool kit after completing work.

NOTE:

Be sure to tighten wheel bolts in diagonal sequence to the following specified torque:

Tightening torque	Nm
Wheel bolts	120

Correct wheel installation

• When installing wheels, you must observe the following points to ensure wheels fit securely:

• Always tighten wheel bolts to the specified torque so the wheel bolt seats in rim are not deformed.
• When installing a wheel, do not tighten first wheel bolt immediately (for example, with an impact wrench). This would prevent other bolts from centering rim properly when they are screwed in. Rim could then become loose, even if tightened to specified torque.
• Before installing wheels, check for rust/corrosion in wheel bolt seats and contact surfaces between rims and hubs, removing if necessary. Otherwise, the wheel bolts can lose tension after installation and the rim can come loose.

WARNING:

If the above points are not observed, wheels can come loose and the wheel bolt seats in rim can be deformed. The deformity could be so small that you can't see it. But even small deformities in the wheel bolt seats can prevent the wheel from fitting securely, so that it becomes looser and looser.

Radio: Activate anti-theft coding by entering security code

Radio units are shipped with a fixed code. Fixed code means that every radio unit with anti-theft coding has been programmed with its own code. This code is not active from the factory. To increase anti-theft protection, there is no longer a radio card in the radio and navigation system owners manual. The entry of the radio code is no longer described in the owners manual.

The Anti-theft coding on a unit that is ready to play is activated by entering the fixed code.

On chorus II+, concert II+ and symphony II+ radio systems, enter the radio code as follows

• Switch on radio. "Code 1000" appears in the display.
• Press upper left control button "X___" -arrow- until first digit of radio code appears in display.
• Enter remaining three radio code digits with other three control buttons
• Press "ENTER" control button. The radio is coded.

Fig. 71: Identifying Radio Controls
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dispose of sticker with radio code.

If the radio code is entered incorrectly two times and "Code Safe 2" appeared in the display, use the following procedure

Leave radio switched on approx. 60 minutes. After 60 min., "Code Safe / Code 1000" appears in the display and the radio is switched off

Enter radio code again.

On navigation system BNS 5.0, enter radio code as follows

• Switch on navigation system
• Enter PIN using Speller
• Confirm entry with "OK"
• Dispose of sticker with radio code.

NOTE:

Please inform the customer that he can only learn the anti-theft radio code from the service advisor That way, thieves really cannot use the radio!

Tire Pressure Monitoring System: Programming tire pressures

Specified values should also be saved with every tire pressure adaptation, e.g. when vehicle load condition changes, so that Tire Pressure Monitoring System can be as useful as possible. Do this as follows:

• Press Reset button on windshield washer lever.
• Select Tire Pressure Monitoring System.
• Select Save tire pressures.

NOTE:

Saving of tire pressures must be started after each deliberate change to specified values.

Tire repair kit: Checking

Fig. 72: Identifying Durability Date In Tire Repair Kit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles with a tire repair kit, check durability date - arrow -.

NOTE:

If expiration date has passed, replace bottle.

Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary

Necessary special tools

Special tools, testers and auxiliary items required

Fig. 73: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Windshield washer aiming tool T10127 equipped with replacement tip 3125/5A.

NOTE:

Never use a needle or a similar object, since it may damage the water hoses in the spray nozzle!

Windshield spray jet setting

• Mark four points on windshield using water-soluble pen.

Fig. 74: Identifying Windshield Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjusting dimension:

• Dimension - a - = 250 to 275 mm
• Dimension - b - = 465 to 490 mm
• Dimension - c - = 270 to 415 mm
• Dimension - d - = 140 to 225 mm

NOTE:

Adjusting dimensions are calculated from outer edge of windshield. Locate individual spray jet points using windshield washer aiming tool T10127 with replacement tip 3125/5A.

NOTE:

If the spray field is uneven or does not adjust to the aforementioned specifications, replace the washer jet (repair measures).

Rear window spray jet setting

Fig. 75: Identifying Windshield Wiper Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjust spray jets with Washer Jet Adjuster T10127 so fluid sprays over the wiper onto the rear window at the places shown.

• Dimension - a - = approx. 125 mm
• Dimension - b - = approx. 295 mm
• Dimension - c - = approx. 5 mm

Headlamp washer system: Check spray jet setting.

Headlamp cleaner spray jets are set at the factory and do not need to be adjusted.

Windshield wiper blades: Checking park position

Front windshield wiper blade park position

• Switch windshield wipers on and off and allow to run to end position.

Fig. 76: Checking Windshield Wiper Blade Tips Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check whether wiper blades rest again front window in indicated position.

• Dimension - a - = 24 mm
• Dimension - b - = 44 mm

NOTE:

Dimensions indicate distance of wiper blades to plenum chamber cowl panel grille on lower window edge. If necessary, unscrew wiper arm, align and tighten nuts. Activate mist wipe and check adjustment.

Tightening torque	Nm
Wiper arm to wiper shaft	21

Wiper blade park position, rear window

• Let wiper motor run to end position.
• Switch ignition off and remove ignition key.

Fig. 77: Identifying Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully spread cover - arrows - and lift.

Fig. 78: Identifying Spray Jets And Hex Head Nuts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Carefully remove spray jets - 2 -.
• Loosen hex head nuts - 1 - a few turns.
• Loosen wiper arms by tilting wiper shaft slightly.

Fig. 79: Identifying Dimensions For Wiper Blade On Rear Window
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place wiper blade on rear window and adjust as follows:

• Dimension - a - = 15 to 20 mm

NOTE:

Dimension gives distance of wiper blade point to lower edge of window. Tighten wiper arm nut to 12 Nm. Activate wiper. Adjust wiper arm again, if necessary, and tighten nut. Check spray jet adjustment --> Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary.

Service interval display: resetting or adapting

NOTE:

Service display serves to remind the driver of service needed. The display appears in the center display. Service indicators appears 1 month or 2.000 km before reaching service interval. It disappears after 100 km. Example display: After a total driving distance of 28,700 km, "SERVICE IN 1300 KM" appears.

Fig. 80: Identifying Service Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The distance remaining to the service interval can be viewed via the center display menu by press button - 1 - once.
• When a service interval arrives, the text information appears in the center display for 5 seconds after switching ignition on. It is shown after automatic transmission message and a possible navigation system destination. Display: "SERVICE!".

Service display, resetting

• Follow these steps in sequential order.

Fig. 81: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Guided Fault Finding or Guided Functions
• Go to - function/component selection

• Service work
• Combination Processor, reset WIV
• Now follow guided program

NOTE:

Please follow guided program function description WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension)

Oil quality, adapting

• Follow these steps in sequential order.

Fig. 82: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Guided Fault Finding or Guided Functions
• Go to - function/component selection

• Service work
• Combination Processor, changing oil quality
• Now follow guided program

NOTE:

It is necessary to change oil quality if changed between inspection. Inspection Service = Oil quality 1 WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension) Please follow guided program function description

Maximum values, adapting

• Follow these steps in sequential order.

Fig. 83: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Guided Fault Finding or Guided Functions
• Go to - function/component selection

• Service work
• Combination Processor, adjusting maximum WIV value
• Now follow guided program

Fixed interval maximum values

Minimum mileage in Km	15000
Maximum mileage in Km	15000
Maximum time interval in days	365

NOTE:

WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension) Please follow guided program function description

Service display, resetting without VAS 5051/5052

NOTE:

If reset without VAS 5051 or VAS 5052 , service display is automatically set to fixed interval (15,000 km).

Resetting can be carried out using tester VAS 5051 or VAS 5052 in "Adaptation" function --> Service interval display: resetting or adapting.

Service display can also be reset using the following procedure:

• Turn off ignition.

Fig. 84: Identifying Service Display
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press Taste button - 1 - and switch on ignition at the same time.

After releasing button, display shows: "SERVICE IN ????Km" or "SERVICE!".

• Hold down button Taste - 2 - until text is reset to "SERVICE IN ????Km" or "SERVICE!".
• Turn off ignition.

Windshield/headlamp wiper system: Filling with fluid

• Fill washer fluid fully.

NOTE:

Always add a neutral pH window cleaner to washer fluid (freeze protection in winter).

Vehicle Electrical System Control Module - J519: coding

• Connect VAS 5051 --> DTC memory: Retrieving with VAS 5051/ 5052.
• 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
• Electrical system (Highline or Lowline depending on vehicle equipment)
• Electrical system function
• J519 Vehicle Electrical System Control Module, coding

• Press button

Follow tester steps and confirm entry until following text appears:

OK J519 Vehicle Electrical System Control Module, coding

• Press the following selections in the order shown:

• Go To
• End

Dust and pollen filter: Replacing

NOTE:

Filter insert is available in different versions (with and without activated charcoal insert as integrated odor Parts catalog. The filter is located beneath the fresh air plenum cover on the right side. Remove plenum chamber cover --> Plenum chamber cover: Removing.

Fig. 85: Identifying Plenum Chamber Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unclip cover - B - and remove forward.
• Remove dust and pollen filter - C - from housing.

NOTE:

When inserting filter in filter frame, observe flow-through direction - arrow D - When installing, ensure cover - B - is seated correctly. It must be clipped in at both catches - A - , otherwise water will run on dust and pollen filter and into A/C unit.

Sunroof: Check function, clean guide rails and spray on lubricant spray

• Check sunroof for leaks.
• Clean guide rails.
• Spray guide rails.

• Lubricant: "G 052 778 A2"

• Check sunroof function.

Manual transmission/final drive: Check oil level, add oil if necessary

--> -

• 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
• 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
• 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
• 34 - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING
• 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
• 34 CONTROLS, HOUSING 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
• 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

Headlamps: Check setting, adjust if necessary

The following test- and adjustment instructions are applicable to all countries. National guidelines or regulations of the country must be observed.

Check and adjustment conditions

• Tire pressure OK.
• Lenses must not be damaged or dirty.
• Reflectors and bulbs OK.
• Vehicle must be properly loaded.

Load: Vehicle must be loaded with one person on the drivers seat, weighing 75 kg, otherwise vehicle must be empty (curb weight).

The curb weight is the weight of the vehicle ready for operation with completely filled fuel tank (at least 90%), including the weight of all equipment items carried for operation (e.g. spare wheel, tool, vehicle jack, fire extinguisher etc.).

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

Fuel level according to fuel gauge	Additional weight in kg
1/4	52
1/2	35
3/4	17
Full	0

Example:

If the fuel tank is half full, place a weight of 35 kg in the luggage compartment.

NOTE:

For additional weight use containers filled with water. A container filled with 5 liters of water weighs approx. 5kg.

Vehicle must be rolled for several meters or the front and rear suspension must be bounced several times so that the springs settle.

• Vehicle and headlamp adjuster must be on a level surface operating instructions for headlamp adjuster.
• Vehicle and headlamp adjuster must be aligned.

Ensure headlight adjuster is about 30 cm in front of headlight.

• Inclination must be set.

Inclination measurements are stamped in "%" at top of headlamp. The headlamps 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.

Vehicles with manual headlight range adjuster:

• The headlight range adjuster thumb wheel must be in basic setting - 0 -.

Vehicles with automatic headlight range adjusting

NOTE:

To check/adjust headlights, they must always be placed in the basic setting with the VAS 5051. Performing basic setting with VAS 5051 : connect VAS 5051 with ignition switched off.

Fig. 86: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Use K-lead adapter VAS 6017B.
• 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 Headlamp Range Control
• J 431-Dynamic Headlamp Range Control, Functions
• J 431-Headlamp Range Control Module, basic setting

• Press button

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

J 431-Headlamp Range Control Module, basic setting

• Press button
• Follow test sequence

Headlamps, checking adjustment (with new test screen without 15 ° setting line)

• Switch ignition and low beams on

Fig. 87: Identifying Headlight Setting Line, Break-Away Point & Center Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Horizontal light-dark border must contact hyphenated line - 1 - on test surface.
• Break-away point - 2 - between left horizontal part and rising part on right of light-dark border must run vertically through central 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 headlamp (as viewed when looking forward) a few times. Next, check low beam again. After correct adjustment of dipped 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. If headlight adjustment is not OK: Adjust headlights:

Headlamps, adjusting

Fig. 88: Identifying Adjustment Screws For Main Headlight (Right)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Main headlight (right)

Adjusting screw on right headlight:

Placement on left headlight is similar.

• To adjust height, turn adjustment screws - 1 - and - 2 - with same number of revolutions.
• To adjust laterally, turn only adjustment screw - 2 -.

Fog lights:

Inclination figures:

• Fog lights 20 cm

Fig. 89: Checking Whether Upper Light-Dark Border Touches Adjusting Line And Runs Across Entire Test Screen Width Horizontally
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check whether upper light-dark border touches adjusting line and runs across entire test screen width horizontally.

Fig. 90: Identifying Air Duct Grille, Bumper, And Adjustment Screw
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove air duct grille on inner side of bumper - arrow -.
• To change lamp range, turn adjustment screw - arrow -. Lateral adjustment is not possible.

NOTE:

Right fog light is shown in illustration. Adjusting screw on left fog light is arranged symmetrically.

Other additional headlamps:

Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.

Deactivate transport mode

Transport mode can be activated in instrument panel insert and in radio.

Transport mode activated in instrument cluster has the following effects in comfort system central module.

• SAFE LED in doors is no longer controlled
• Interior light, footwell lights and luggage compartment lights can no longer be switched on at terminal 15.
• At terminal 15, interior light is switched on for a maximum of 30 seconds when a door is opened.
• Anti-theft system (DWA) can no longer be armed. If anti-theft system is already armed, transport mode is ignored and only accepted after anti-theft system is deactivated.

Transport mode activated in Chorus, Concert, Symphony and Navigation Plus (RNSD with CD) radio has the following effects.

• Device does not draw any current and cannot be operated.

NOTE:

K-lead adapter VAS 6017B must be used. Transport mode can be reset in Navigation Plus (RNSE with DVD).

Deactivate transport mode using guided fault finding or guided functions.

• Follow these steps in sequential order.

Fig. 91: Connecting Data Link Connector (DLC)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Connect VAS 5051/5052
• Use auxiliary K-lead adapter VAS 6017B
• Guided Fault Finding or Guided Functions
• Go to - function/component selection

• Service work
• Transport mode, activating/deactivating
• Now follow guided program

Door arrester and lock cylinder: Lubricate

Fig. 92: Identifying Greasing Points For Door Latches
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• lubricate door latches only at lubrication points shown - arrows -.

• Lubricant: "G 052 778 A2"

• Lubricate lock cylinder.

• Lubricant: "G 052 778 A2"

Plenum chamber cover: Removing

Fig. 93: Identifying Plenum Chamber Cover & Removing Rubber Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove plenum chamber cover rubber seal in direction of - arrow -.
• Remove plenum chamber cover - 1 - forward.

Fig. 94: Identifying Plenum Chamber Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles from VIN >8E Z 5 A 400 001

• Remove plenum chamber cover rubber seal in direction of - arrow -.
• Remove plenum chamber cover - 1 - forward.

Telematics: Emergency battery, replacing

NOTE:

Emergency battery should be replaced very 4 years on vehicles with Telematics.

Telematics control module is located in right footwell E-box (passenger side, below floor covering).

• Lower A-pillar trim, removing and installing; Floor covering, raising: --> - 70 - INTERIOR TRIM

Fig. 95: Identifying Passenger Side Electronics Box Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Release passenger side electronics box cover - arrows -.
• Remove Telematics control module from E-box (do not disconnect control module).

Fig. 96: Identifying Screws On Bottom Side Of Telematics Control Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both screws - arrows - on bottom side of Telematics control module and remove cover.

Fig. 97: Identifying Connector And Emergency Battery
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect connector - 1 - and remove emergency battery - 2 -.
• Perform installation in reverse order of removal.

Note before disconnecting battery.

WARNING:

Activate Telematics control module Service Mode before disconnecting battery.

Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation; Telephone/Telematics

NOTE:

Retrieve radio/navigation unit anti-theft coding before disconnecting battery. If battery is reconnected, activate vehicle equipment (radio/navigation, clock, electric windows, engine) according to operating instructions and deactivate Telematics control module service mode. Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation; Telephone/Telematics

Transport protection: Remove front and rear strut transportation protection devices

Fig. 98: Identification Tag Attached At Mirror
Courtesy of VOLKSWAGEN UNITED STATES, INC.

For some models the front and rear suspension struts have transportation protection devices installed. These models can be identified by a tag attached at the mirror - arrow -.

• Release coil spring (for example, put vehicle on lift)

NOTE:

It is not necessary to remove the wheels. Be careful not to damage surface of coil springs.

Remove transportation protection devices --> Front strut

Front strut

Fig. 99: Identifying Auxiliary Strut, And Transportation Protection Devices
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull auxiliary strut - 2 - downward.
• Remove 2 transportation protection devices at each strut - 1 -.
• Install auxiliary strut - 2 - by sliding up in spring retainer.

Rear strut

Fig. 100: Identifying Auxiliary Strut, And Transportation Protection Devices
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pull auxiliary strut - 2 - downward.
• Remove 2 transportation protection devices at each strut - 1 -.
• Install auxiliary strut - 2 - by sliding up in spring retainer.

Underbody protection: Visual inspection for damage

• When inspecting visually, observe underbody, wheel housings and sills!

WARNING:

Malfunctions found must be rectified (repair measure).

Winter tires from factory

On vehicles that were delivered from factory with winter tires, check for correct pressure during delivery inspection.

The excessive speed warning sticker should be placed in drivers field of vision.

Timing belt: Replacing

4-cyl. 5V engines 1.8L Turbo

• Toothed belt, removing and installing --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

4-cyl. 5V engines 2.0L

• Toothed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

4-cyl. 4V engines 2.0L TFSI

• Toothed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

6-cyl. 5V engines 3.0L;

• Toothed belt, removing and installing: --> - 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK

Toothed belt change, filling out sticker - all

Fig. 101: Locating Toothed Belt Change Sticker At Rear Of Engine Compartment
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Fill out toothed belt change sticker - 2 - at rear of engine compartment, attach new sticker if necessary.

Spark plugs: Replacing

Necessary special tools

• Spark plug wrench 3122 B

Fig. 102: Placing Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Ignition Coil Puller T40039

WARNING:

Place Ignition Coil Puller T40039 on top rib - arrow - of ignition coil and pull this from spark plug. Placing on bottom rib can cause damage.

NOTE:

Plug designation --> - 28 IGNITION/GLOW PLUG SYSTEM for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB 28 - IGNITION/GLOW PLUG SYSTEM for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT 28 IGNITION/GLOW PLUG SYSTEM for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN 28 - IGNITION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH 28 - IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS 28 IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF Observe waste disposal regulations!

4-cyl. 5V engines 1.8L Turbo --> 4-cyl. 5V engines 1.8L Turbo:

4-cyl. 5V engines 2.0L and 2.0L TFSI --> 4-cyl. 5V engines 2.0L and 2.0L TFSI

6-cyl. 3.0L and 3.2L FSI 5V engines --> 6-cyl. engines 3.0L and 3.2L FSI:.

8-cyl. 4.2L MPI 5V engines --> 8-cyl. engines 4.2L MPI.

8-cyl. 4.2L 5V engines (RS4) --> 8-cyl. engines 4.2L (RS4)

4-cyl. 5V engines 1.8L Turbo:

• Remove engine cover --> Engine cover: Removing.
• Switch ignition off.

Fig. 103: Identifying Connectors At Spark Plugs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove connector - 1 - at spark plugs.
• Push connector - 1 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

4-cyl. 5V engines 2.0L and 2.0L TFSI

• Switch ignition off.
• Remove engine cover (if present) --> Engine cover: Removing

Fig. 104: Identifying Bolts And Connectors
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

6-cyl. engines 3.0L and 3.2L FSI:

• Switch ignition off.
• Remove engine cover (if present) --> Engine cover: Removing.

Right cylinder bank

• Remove upper part of air filter --> 4-cyl. 1.8L 5V Turbo engines:.

Fig. 105: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

Left cylinder bank

Fig. 106: Removing Coolant Hoses
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant reservoir -arrow-.
• Tie aside coolant reservoir with coolant hoses 1 to 3 connected.

Fig. 107: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

8-cyl. engines 4.2L MPI

• Switch ignition off.

Right cylinder bank

• Remove upper part of air filter --> Air cleaner: Clean air filter housing and replace filter.

Fig. 108: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

Left cylinder bank

Fig. 109: Removing Cover Upward
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover upward.

Fig. 110: Removing Coolant Hoses
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant reservoir -arrow-.
• Tie aside coolant reservoir with coolant hoses 1 to 3 connected.

Fig. 111: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

8-cyl. engines 4.2L (RS4)

• Switch ignition off.

Right cylinder bank

• Remove upper part of air filter --> Air cleaner: Clean air filter housing and replace filter.

Fig. 112: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

Left cylinder bank

Fig. 113: Removing Coolant Hoses
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove coolant reservoir -arrow-.
• Tie aside coolant reservoir with coolant hoses 1 to 3 connected.

Fig. 114: Identifying Bolts, Connector, And Ignition Coil
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove both bolts - 1 -.
• Push connector - 2 - toward ignition coil, press on catch with hand and remove connector.
• Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
• Remove spark plugs using spark plug wrench T40039.

• Install new spark plugs.

Tightening torque	Nm
Spark plugs in cylinder head	30

NOTE:

Push ignition coils by hand into intended resources in cylinder head cover.

Headlights: Aiming using Hella Universal Beamsetter IV

Service

Align vehicle headlights using the Hella Universal Beamsetter IV VAS 5107 and the following procedure:

Additional instructions and diagrams Instruction Manual for the Hella Beamsetter Series IV

Fig. 115: Identifying Floor Surface Specifications For Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications:

• 0.5mm or less slant from front wheel to back wheel of the Hella Universal Beamsetter IV VAS 5107 - A -.
• 1mm or less slant per meter for the length of the vehicle - B -.

• Clean headlight lenses.
• Adjust vehicle tire pressure to specifications.

Have a second technician sit in the drivers seat while aligning the headlights.

• Bounce front and rear of vehicle up and down several times to settle vehicle suspension.

Setting low beam alignment of drivers side headlight

• Move Hella Universal Beamsetter IV VAS 5107 into position in front of the vehicle so it is aligned with the vehicle and Hella Universal Beamsetter IV VAS 5107 is 30 to 70cm (12 to 28 in.) from the drivers side headlight.
• Switch headlights ON in low beam position.
• Align Hella Universal Beamsetter IV VAS 5107 so it is centered on the headlight (align vertically then horizontally).

NOTE:

Use the arrows on the Hella Universal Beamsetter IV VAS 5107 housing as a guide. You may want to use a straight edge or tape measure, because alignment must be within 3cm (1.2 in.) of the center of the headlight. Without moving the Hella Universal Beamsetter IV VAS 5107 , slide Broad-band sight toward center of vehicle (Broad-band sight can also be moved up and down for a better position).

Use Broad-band sight to make final alignment of Hella Universal Beamsetter IV VAS 5107 to vehicle by:

• Loosening hand-wheel that locks column in place.
• Sighting down through the slit in the Broad-band sight and rotating Hella Universal Beamsetter IV VAS 5107 and column until two similar points on vehicle are aligned

NOTE:

Try using corners of the headlight housings or two screws that are the same height and as far apart as possible on the vehicle. Carefully tighten hand wheel without changing Hella Universal Beamsetter IV VAS 5107 position. Set Inclination to 1.0 %. Set Hella Universal Beamsetter IV VAS 5107 "Scaled wheel" to the proper low beam inclination %. Adjust height (vertical) alignment first. Turn headlight height adjuster screw to align the upper edge of the flat portion of the beam with the center horizontal line of the grid on the Hella Universal Beamsetter IV VAS 5107 pattern screen.

NOTE:

VOL is the correct beam pattern for both right and left headlights.

Fig. 116: Identifying Specifications For Drivers Side Headlight Beam Angle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adjust lateral (horizontal) alignment of drivers side headlight so that the peak (highest point) of the headlight beam pattern aligns with the right edge of the target box of the grid on the pattern screen (it should match the VOL pattern shown on the Hella Universal Beamsetter IV VAS 5107 ).

NOTE:

If the height alignment changed, readjust.

Checking drivers side headlight high beam alignment

• Switch headlights ON in high beam position.
• Realign Hella Universal Beamsetter IV VAS 5107 with the high beam headlight if necessary.

Fig. 117: Identifying Beamsetter "Scaled Wheel" At 0%
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set Beamsetter "Scaled wheel" to 0%.
• Cover low beam lamp (use hand or small piece of cardboard) and check that the "hot spot" of high beam pattern is centered on the square target box of the pattern screen.

NOTE:

High beam pattern is built into the reflector design and cannot be adjusted separately.

If high beam pattern is way out of adjustment:

• Inspect for reflector damage.
• Replace reflector if needed.

NOTE:

Always align headlight in the low beam position.

Aligning fog lamp

• Switch fog lamps ON.
• Align Hella Universal Beamsetter IV VAS 5107 with fog lamp (make sure it is between 30 and 70cm from the fog lamp lens).

Fig. 118: Identifying Hella Universal Beamsetter IV VAS 5107 Scaled Wheel At 1.4%
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set Hella Universal Beamsetter IV VAS 5107 scaled wheel to 1.4%.

Adjust fog lamp so the top of the beam pattern aligns with the centerline of the target grid on the beam pattern screen.

Passengers side headlight, alignment

• Move Hella Universal Beamsetter IV VAS 5107 to the passenger side of the vehicle and follow the same procedures to align the Hella Universal Beamsetter IV VAS 5107 to the headlamp.
• Align headlight low beam, check high beam and align fog lamp.

NOTE:

Make sure to reset the Hella Universal Beamsetter IV VAS 5107 "Scaled wheel" to the proper setting each time you change from low beam to high beam or to fog lamp. Ensure that headlights and vehicle body are clean and free of fingerprints.

RAPGARD: Inspection, removal and disposal

From my 2002

Service

Within 48 Hours after arrival at Dealer:

Inspection

• Inspect RAPGARD for damage or peeling.

If RAPGARD is disturbed (dented, scratched, etc.):

• You must note the damage on the Carrier Delivery Receipt, including damage type, extent and location. Failure to note damage on the Carrier Delivery Receipt will result in non-payment of the repair.

NOTE:

RAPGARD must be removed from the vehicle no later than six months after application. See sticker (location on vehicle body varies) for detailed information.

Within 72 Hours prior to delivery to the Customer:

• Remove RAPGARD from vehicle.
• Wash vehicle exterior.
• Inspect paint surfaces, moldings and glass.
• Protect the paint surface of all new vehicles by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or equivalent.

Removal

• Vehicle must be at room temperature.
• The ideal body surface temperature for RAPGARD removal is 60 ° F (15.5 ° C) to 80 ° F (26.6 ° C).

If body surface temperatures are below 60 ° F (15.5 ° C) or above 80 ° F (26.6 ° C) then:

• Removal procedure should be performed indoors after surface temperatures have been allowed to stabilize within the given range.

• Rinse vehicle thoroughly with water to remove surface dirt or dust and to help stabilize body surface temperatures.
• Starting at the corners of each panel, carefully remove RAPGARD from vehicle.

RAPGARD, paint inspection after removal

• Inspect painted surfaces under one of the following lighting conditions:

• Indoors under fluorescent lighting.
• Outdoors under bright sunlight.

Important!

If any defects on the exterior have been identified (scratches, dings, dents and other types of body damage):

• Contact your Service Manager and arrange to repair defects immediately.

NOTE:

After removal of RAPGARD, some vehicles may exhibit temporary paint discoloration or paint swelling (caused by trapped moisture under the RAPGARD). This temporary swelling is caused by the paint finish absorbing moisture trapped under the RAPGARD film. This swelling will disappear with exposure to the sun or heat lamps within 2 - 3 hours. Severe Paint swelling may require 2 - 3 days to recover.

DO NOT buff or refinish paint for this condition!

Adhesive residue removal

WARNING:

Always read and follow manufacturer Cautions and Warnings regarding use of product.

If RAPGARD adhesive residue remains on paint finish, remove with a non-abrasive polishing product such as, (3M Part No. 5995) light colors or (3M Part No. 5996) dark colors or equivalent.

Thick lines of adhesive residue can be removed with general purpose adhesive cleaner (3M Part No. 08987-aerosol, or Part No, 08984-qt. can) or equivalent.

NOTE:

Paint discoloration (looks like shaded or dark magic marker lines) can be removed with a heat gun using the following procedure: Hold heat gun approximately 3 in. away from affected paint surfaces and apply heat using slow oscillating motions until discoloration is gone. If discoloration remains, wipe the heated area with Isopropyl alcohol and repeat procedure to increase surface drying.

Important!

After inspecting and removing RAPGARD, washing vehicle, inspecting and repairing any defects in paint surfaces, moldings and glass:

• Protect the vehicle paint surface by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or equivalent.

RAPGARD Disposal

RAPGARD can be disposed as normal paper waste. If unsure about proper disposal procedures in your area, check local regulations.

Type plate / Vehicle Identification Number (VIN)

Type plate / Vehicle Identification Number (VIN)

Meaning of Vehicle Identification Number (VIN):

WAU	ZZZ	8E	Z	1	A	000 520
Manufacturer- code	Filler characters	Model	Filler characters	Model year 2001	Production location	Serial number

Vehicle data sticker

The vehicle data sticker is in the customers service schedule and in the vehicle in the spare wheel recess or on the luggage compartment floor.

NOTE:

Service plan vehicle data plate is located in spare wheel well on "Avant vehicles". Vehicle data plate that remains in vehicle is located under rear seat bench.

Fig. 119: Identifying Vehicle Data Sticker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Sticker contains the following vehicle data:

Engine code and engine identification

NOTE:

The "engine code" is on the vehicle data sticker in the service schedule and in the spare wheel recess or on the luggage compartment floor.

4-cyl. - 2V gasoline engine:

Fig. 120: Identifying Engine Number Is Located At Left Of Engine/Transmission Connecting Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is located at left of engine/transmission connecting point.

A sticker with "engine code" and "serial number" is also attached to toothed belt guard.

4-cyl. - 5V gasoline engine 1.8L Turbo:

Fig. 121: Identifying Engine Number On Left Of Cylinder Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is located at left of cylinder block.

A sticker with "engine code" and "serial number" is also attached to toothed belt guard.

4-cyl. - 5V gasoline engines 2.0L:

Fig. 122: Identifying Engine Number On Left Of Cylinder Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is located at left of cylinder block.

A sticker with "engine code" and "serial number" is also attached to toothed belt guard.

4-cyl. - 2.0 TFSI engines:

Fig. 123: Identifying Engine Number Stamped On Engine Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is stamped onto engine block - arrow -

A sticker with "engine code" and "serial number" is also attached to toothed belt guard.

V6 3.0 gasoline engines:

Fig. 124: Identifying Engine Code Stamped On Right Inner Side Of Cylinder Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is stamped on right inner side of cylinder block between cylinder head and hydraulic pump.

A sticker with "engine code" and "serial number" is also attached to toothed belt guard.

V6 3.2 gasoline engines:

Fig. 125: Identifying Engine Number On Left Front Of Cylinder Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is located at left front of cylinder block - arrow -.

V8 gasoline engines:

Fig. 126: Identifying Engine Number Stamped On Engine Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is stamped onto engine block - arrow -

V8 gasoline engines RS4

Fig. 127: Locating Engine Number
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine number ( "engine code" and "serial number" ) is stamped onto engine block - arrow -

Vehicle, lifting

Vehicle, lifting

WARNING:

Before driving on to a hoist ensure there is sufficient clearance between low lying vehicle components and hoist. Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the permissible lifting capacity of the platform. Vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent vehicle from tipping. Never start engine and engage a gear with vehicle lifted so long as even one wheel has contact with the floor. There is a risk of an accident if this is not observed! If work is to be performed under vehicle it must be supported by suitable stands.

Floor jack

Always use a suitable rubber or wooden block between the jack and the vehicle.

A floor jack must be attached only at the mounting points depicted in the illustration.

Do not lift the vehicle at the engine oil pan, transmission, or on front or rear axles as serious damage may result.

Lifting points for lifting platform and floor jack

Fig. 128: Identifying Front Side Member Vertical Stiffener
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Front:

At side member vertical stiffener in area of marking for onboard vehicle jack.

Fig. 129: Identifying Rear Side Member Vertical Stiffener
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear:

At side member vertical stiffener in area of marking for onboard vehicle jack.

Tow starting/towing

Tow starting/towing

• Attach tow rope or bar only at following eyes:

Front towing eye

Fig. 130: Identifying Front Towing Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover from right bumper.
• Remove towing eye from vehicle tool kit compartment.
• Screw in towing eye until stop and tighten eye with wheel bolt wrench.

Rear towing eye

Fig. 131: Identifying Rear Towing Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove cover from right bumper.
• Remove towing eye from vehicle tool kit compartment.
• Screw in towing eye until stop and tighten eye with wheel bolt wrench.

Remove towing eye after use and return to vehicle tool kit storage compartment. Towing eye must always be in vehicle.

NOTE:

The tow-rope should be able to stretch to reduce the risk of damage to both vehicles. It is advisable to use synthetic fiber ropes or ropes of similar elastic material only. However, it is safer to use a tow-bar! Avoid excessive towing effort and do not jerk. During towing operations on unsurfaced roads there is always a danger that the attachment points will be overstressed and damaged. Vehicle towing should only be done if it is not possible to start the engine with the starting assist cable.

If the vehicle must ever tow or be towed, observe the following:

• Regulations concerning towing must be observed.
• Both drivers must be familiar with the specifics of towing procedures. Inexperienced drivers should not attempt to tow start or tow.
• When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
• The driver of the vehicle being towed must ensure that the tow rope is always taut.

• The emergency lights must be switched on both vehicles - unless local regulations differ.
• The ignition must be switched on, so that the steering wheel is not locked and the turn signals, horn, windshield wipers, and windshield washer system can be operated.
• Since the brake booster only works with the engine running, the brake pedal must be stepped on with substantially more force when the engine is switched off.
• With the engine switched off, the power steering also does not work, increasing the amount of steering effort.

• Without lubricants in the manual transmission and/or automatic transmissions the car may only be towed with raised drive wheels.

When towing vehicles with manual transmission, observe the following:

• Before tow starting, push in clutch pedal and hold, and select gear 2 or 3.
• Switch ignition on.
• When both vehicles are moving, release clutch pedal.
• As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing vehicle.

NOTE:

Vehicles with catalytic converter (gasoline engine only) must not be started when the catalytic converter is at operating temperature and pulling the vehicle over a longer distance of more than 50 m. Otherwise unburned fuel may pass into the catalytic converter and cause damage. Tow starting vehicles with an automatic transmission is for technical reasons not possible.

When towing vehicles with front wheel drive and automatic transmission, observe the following:

• Selector lever must be in the "N" position.
• Do not tow vehicle faster than 50 km/h (30 mph).
• Do not tow further than 50 km (30 miles).

For longer distances, the front end of the vehicle must be raised.

Reason: When the engine is not running the transmission oil pump is not working and the transmission is not adequately lubricated for high speeds or long distances.

Using a breakdown vehicle, the vehicle may only be towed suspended at the front.

Reason: If given a rear suspended tow, the drive shafts turn backward. This would cause the planetary gears in the automatic transmission to achieve such high RPM that the transmission would be heavily damaged within a very short time.

When towing vehicles with all wheel drive and manual transmission, also observe the following:

• Do not tow vehicle faster than 50 km/h (30 mph).
• Do not tow further than 50 km (30 miles).

Using a breakdown vehicle the vehicle may be towed suspended at front or rear.

NOTE:

If normal towing of the vehicle is not possible, the vehicle must be transported with a special transporter or trailer. This is also valid for distances greater than 50 km (30 miles).

When towing vehicles with all wheel drive and automatic transmission, also observe the following:

• Selector lever must be in the "N" position.
• Do not tow vehicle faster than 50 km/h (30 mph).
• Do not tow further than 50 km (30 miles).

The vehicle must not be towed by a tow truck with front or rear axle raised.

NOTE:

If normal towing of the vehicle is not possible, the vehicle must be transported with a special transporter or trailer. This is also valid for distances greater than 50 km (30 miles).

Vehicle checks within inspection and service framework

Vehicle checks within inspection and service framework

For vehicle checks, we recommend interactive acceptance VAS 5000 and performance test stand V.A.G 1858.

Brake check

Information for checking brakes on front and all wheel drive vehicles is in the corresponding brake system repair manual.

Performance check

Perform performance check on performance test stand recommended by Audi. The corresponding correction factors for automatic transmissions and all wheel drive are provided in these test stands. Vehicles with all wheel drive may only be tested on a four-wheel performance test stand. The four-wheel performance test stand V.A.G 1858 has movable rollers in order to be able to test vehicles with different axle spacing.

Tachometer check

With the tachometer test, the vehicle wheels are driven. Vehicles with all wheel drive may only be tested on a four-wheel test stand.

Shock absorber check

Information on testing shock absorbers can be found in the suspension repair manual.

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