Volkswagen Golf 5 - Description of work Page 1 / 10

General
Lifting the vehicle using vehicle hoist and workshop
trolley jack

Safety precautions

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.

Lifting points for lifting platform and trolley jack:

Front:

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- Place support plate, in area of side member marking -

arrow A - , on vertical stiffener of floor plate - arrow B - .

Warning!

Make sure that side member stiffener contacts support

plate of lifting platform at center.

Rear:

- Place support plate, in area of side member marking -

arrow A - , on vertical stiffener of floor plate - arrow B - .

Warning!

Make sure that side member stiffener contacts support

plate of lifting platform at center.

Data stickers

Apply sticker "First service" (at the delivery inspection)

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Appy sticker "Your next service events" 01-3, Data

stickers

"First service" sticker

- Apply sticker on drivers side door jamb (B-pillar); the

sticker is located on an instruction which is attached at
front in the vehicle wallet. Destroy the instruction after
attaching the sticker!

Apply sticker "Next service"

- Service sticker "Next service" : Enter a cross at the

position for oil change service or inspection service (next
service due) and enter date / odometer reading

- Apply sticker on drivers side door beam (B-pillar).

Applying "Data sticker" in service schedule

- Apply the upper of the two data stickers - arrow - .

1 - Planning week

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2 - PR Number

Diagnostic unit, connecting

Special tools, testers and auxiliary items required

„ Vehicle Diagnosis, Testing and Information System

VAS 5051 A

„ Vehicle Diagnosis, Testing and Information System

VAS 5051B

„ Vehicle diagnosis service syst. VAS 5052 or later

testers

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„ Diagnostic system VAS 5053

„ Diagnostic cable VAS 5051/6A

Warning!

„ During a test drive you must always secure

testing and measuring equipment on the back
seat.

„ Drivers must NEVER operate these tools while

driving.

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- Perform the following work procedure:

- Connect diagnosis cable connector to data link

connector.

- Turn on the tester.

- Switch ignition on.

Now follow information given on screen to start the desired

functions.

Vehicle Identification Number (VIN)

Component location engine compartment

Vehicle Identification Number (VIN) is located on extension

of longitudinal member - arrow - .

Meaning of Vehicle Identification Number (VIN):

000 234

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WVW ZZZ 1K1 Z 4 8

1)

Manufacturer Filler Model Filler Model Production Serial

code characters characters year 2004 location number

1) Rabbit/GTI 2006

Vehicle data sticker

The vehicle data sticker - arrow - is located in rear of

vehicle on the left in the spare wheel well under foam
storage tray. The vehicle data sticker can also be found in
the service schedule for the customer.

Sticker contains the following vehicle data:

1 - Production control number

2 - Vehicle Identification Number (VIN)
3 - Model identification number
4 - Model explanation/engine output
5 - Engine and transmission code letters
6 - Paint number/interior equipment identification number
7 - Optional extras identification numbers

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Information on time or distance dependent service

Service Identification

- Check via the vehicle data plate in luggage compartment,

whether the vehicle is equipped with PR number "QG0" or
with PR Number "QG2" . The PR number determines the
service intervals 01-3, Service intervals .

Vehicle data plate is applied at left next to spare wheel

well, component location, see 01-3, Vehicle data
sticker .

Vehicles marked with the following PR-number:

"QG2" indicates time or distance dependent service.

"QG0" means time or distance dependent service.

Engine oils

Approved engine oil norms for vehicles

For information regarding approved oil types please

refer to: Additional Information, Fluid Capacity
Charts for appropriate model and year

Engine code and engine number

Engine code and engine identification are found in:

„ Gasoline engines:

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

Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 00, Technical data, engine number

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„ On vehicle data sticker 01-3, Vehicle data

sticker .

Service intervals

Service intervals

So that each service is performed at the correct point in

time and is not forgotten, a sticker on the door beam or
service reminder indicator in the instrument cluster display
serves to remind customer of the service event.

Information about the sticker can be obtained 01-3, Data

stickers .

Vehicles with PR-number QG0, QG2

Oil change service Page

01-2, Oil change service
- Oil change service at 5,000 miles (8,000 km)

„ (whichever occurs first)

„ (according to service interval display)

Inspection service (oil change service inspection service) every 10,000 Page
miles (15,000 km) or after 1 year
01-2, Oil change
- Oil change service every 10,000 miles (15,000 km) or after 1 service
year

„ (whichever occurs first)

„ (according to service interval display)

Type plate

Note:

„ Vehicles for certain countries have no type plate.

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4-door vehicles

Type plate - arrow 1 - can be seen after opening left front

door, in lower area of B-pillar.

Sticker contains the following vehicle data:

A - Vehicle Identification Number (VIN)

B - Axle loads
C - Model identification number

2-door vehicles

Type plate is visible after opening right door on door beam

at bottom.

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Description of work (part 1 of 2)

Ball joints, visual inspection

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

Automatic transmission, check ATF level, 09G -

transmission

- Work procedure:

Repair Manual, Automatic transmission 09G, Repair

Group 37, ATF level, checking and topping of

Battery, check battery terminals for secure seating

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

Note:

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„ Tight battery connections assure trouble-free battery

function and long service life.

Perform the following work procedure:

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

toward front.

- Check battery terminal clamps are seated securely on

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

Warning!

If the battery clamp is not seated securely on the

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

If the battery clamp on positive terminal is not seated

securely:

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- First disconnect battery clamp - 1 - at battery negative

pole.

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

9 Nm.

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

terminal and tighten to 9 Nm.

If the battery clamp on negative terminal is not seated

securely:

- Tighten ground connection - 1 - on battery to 9 Nm.

- Reinstall cover.

Note:

„ Once the battery is reconnected:

Repair Manual, Electrical Equipment, Repair Group 27,

Battery, check

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Battery: Checking

Repair Manual, Electrical Equipment, Repair Group 27,

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

depth

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

checking .

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

pattern .

Depth of tire tread (including spare wheel): Checking,

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

General notes, 01-4, General notes .

Check tire inflation pressure using tire inflation device VAS

5216 and correct it if necessary, Rabbit/GTI 2006 ,
01-4, Tire pressures, Rabbit/GTI 2006 .

Special tools, testers and auxiliary items required

„ Tire filling unit VAS 5216

Tire condition, checking

Warning!

If damage is discovered, the tire must be examined to

determine whether a new one must be installed.

Tests during delivery inspection:

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

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

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Tests during inspection service

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

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

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

walls, cuts and fractures.

Checking tire wear pattern

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

whether a check of the track and camber is necessary:

„ Feathered edges of the treads may indicate faulty

toe adjustment.

„ One-sided tread wear is mainly attributed to

incorrect camber.

When wear of this nature is noticed determine cause by

performing alignment checks (repair measure).

Depth of tire tread (including spare wheel), check

- Check tire tread depth

Minimum depth: 1.6 mm

Note:

„ This value may vary for individual countries due to

different legislative regulations.

„ The minimum tread depth is reached when the tires

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

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„ If the tread depth is approaching the legal minimum

permissible depth, the customer must be informed.

General notes

Warning!

„ For reasons of safety only tires of same type and

tread pattern should be fitted on a vehicle!

Note:

„ Tire inflation pressure table applies to normal tires,

for all tire sizes installed at factory.

„ Observe that the inflation pressure specifications

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

„ Tires pressures for the relevant model are on a

sticker attached to the inside of fuel tank flap.

„ Adapt tire pressure corresponding to load.

„ The spare wheel receives the highest tire pressure

designated for the vehicle.

„ Note that a basic setting should be performed after

every change in pressure in vehicles with tire
pressure control indicator 01-5, Tire pressure
control indicator, performing basic setting .

Winter tires

Note:

„ Important information on the recommended winter

tires can be found in

Repair Manual, Suspension, Wheels, Brakes, Steering ,

Repair Group 00, Wheels and Tires Guide

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„ For winter tires, tire inflation pressure must be

increased approx. 0.2 bar.

Tire pressures, Rabbit/GTI 2006

Gasoline engine

Displacement / output
2.0L / 147 kW
Tire sizes half load full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 91 W 2.4 2.4 2.6 3.0
225/45 R 17 91 W, Y 2.4 2.4 2.6 3.0
225/40 R 18 92 Y (XL) 2.4 2.4 2.6 3.0
Spare wheel (collapsible spare wheel)
4.2 4.2 4.2 4.2

Brake and clutch systems, changing fluid

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

application and safety precaution .

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

fluid .

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

procedure, changing brake fluid .

Notes on application and safety precaution

Note:

„ From model year 2006, a new brake fluid is

introduced.

„ The new brake fluid can also be used for older

vehicles.

„ New brake fluid can be mixed with previous brake

fluid.

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

fluid must be used.

Warning!

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„ 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.

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

„ Observe waste disposal regulations!

Specification of brake fluid

Permissible specifications of brake fluid for vehicles

up to model year 2005:

„ Brake fluid corresponding to US standard FMVSS

116 DOT 4 (previous brake fluid).

„ Brake fluid corresponding to VW standard, VW 501

14 (new brake fluid).

Permissible specifications of brake fluid for vehicles

from model year 2006:

„ Brake fluid corresponding to VW standard, VW 501

14 (new brake fluid).

Work procedure, changing brake fluid

Special tools, testers and auxiliary items required

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„ Brake charger/bleeder unit VAS 5234

Brake pedal depressor V.A.G 1869/2

- Unscrew brake fluid reservoir cap - 1 - .

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- Extract as much brake fluid as possible using intake hose

Brake charger/bleeding unit VAS 5234 .

Note:

„ The strainer in the brake fluid reservoir must not be

removed.

Warning!

Extracted brake fluid must not be re-used!

- Screw adapter - 1 - onto brake fluid reservoir.

Observe operating instructions for VAS 5234 !

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

drivers seat and brake pedal and apply tension.

- Connect charger hose of brake charger/bleeder unit VAS

5234 to adapter.

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

bleed screws.

- Pull cover caps off bleeder screws of brake calipers.

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

bleed screw.

- Open bleeder screw and let the corresponding amount of

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

Note:

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

bleed screw so that no air can enter brake system.

Repeat work procedure on left side of vehicle at rear.

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

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

Repeat work procedure on left side of vehicle at front.

Table - Sequence / quantity of brake fluid

Sequence: Brake fluid quantity which must flow out of wheel brake cylinders or brake

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brake wheel calipers:

cylinder,
brake caliper
Left front 0.25 liter
Right front 0.25 liter
Left rear 0.25 liter
Right rear 0.25 liter

Total quantity: approx. 1 liter

- Fit cover caps to brake caliper bleed screws.

- Move filler lever on brake charger/bleeder unit VAS

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

- Take filler hose off adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and correct if necessary.

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

- Remove brake pedal depressor.

- Check pedal pressure and brake pedal free play. Free

play: Max. 1 / 3 of pedal travel

Brake fluid level, check

Brake fluid level at delivery inspection:

Brake fluid level at Inspection Service:

Warning!

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

must be checked before brake fluid is added "repair

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measure" .

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

application and safety precaution .

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

fluid .

Work procedure, brake fluid level (depending on brake pad

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

Work procedure, brake fluid level (depending on brake pad

wear), check

Brake fluid level at delivery inspection:

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

MAX mark - 1 - .

Note:

„ To prevent the brake fluid from overflowing from the

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

Brake fluid level at Inspection Service:

The fluid level must always be judged in conjunction with

brake pad wear.

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

due to brake pad wear and automatic adjustment.

„ Recommended brake fluid level when brake pad

wear limit has almost been reached:

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

TOPPING OFF REQUIRED" .

„ Recommended brake fluid level when brake pads

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

"Between MIN- and MAX-Marking" .

Brake system, visual check for leaks and damage

Check the following components for leaks and damage:

„ Brake master cylinder

„ Brake booster (on anti-lock braking system:

Hydraulic unit)

„ Brake pressure regulator and

„ Brake calipers

- Check that brake hoses are not twisted.

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

operation no brake hose must touch any vehicle
components.

- Check brake hoses are not porous or brittle.

- Check brake hoses and pipes for chafing.

- Check brake connections and methods of securing for

correct seating, leaks and corrosion.

Warning!

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Malfunctions found must be rectified (repair measure).

Brake linings front and rear, checking thickness

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

„ Electric flashlight and mirror

Perform the following work procedure:

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

located in the vehicle tool kit 01-5, Tire repair kit .

Front disc brake pads

- For better judgement of remaining pad thickness remove

the front wheel on the drivers side.

- Pull off wheel bolt covers if necessary 01-5, Wheel

securing bolts, tighten to correct torque setting .

- Mark position of wheel in relation to brake disc.

- Unbolt wheel securing bolts and remove wheel.

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- Measure inner and outer pad thickness.

a - Pad thickness not including backing plate

Wear limit: 2 mm

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

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

Note:

„ When replacing brake pads, it is absolutely

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

- Check brake disc for wear

Repair Manual, Suspension, Wheels, Brakes, Steering,

Repair Group 46, Front brakes, servicing

- Install wheel to marked position.

- Tighten wheel securing bolts, using diagonal sequence to

tightening torque 01-5, Wheel securing bolts, tighten to
correct torque setting .

- Place adapter with vehicle tool kit after completing work.

- Reinstall wheel bolt covers if necessary.

Rear disc brake pads

- Illuminate area behind hole in wheel using an electric

flashlight.

- Determine thickness of outer pad by checking visually.

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- Illuminate inner pad using an electric flashlight and

mirror.

- Determine thickness of inner pad by checking visually.

a - Pad thickness inner and outer, not including backing

plate

Wear limit: 2 mm

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

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

Note:

„ When replacing brake pads, it is absolutely

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

- Check brake disc for wear

Repair Manual, Suspension, Wheels, Brakes, Steering,

Repair Group 46, Rear brakes, servicing

6 speed Direct Shift Gearbox (02E), Oil and filter,

changing

Work procedure:

Repair Manual, 6 Spd. Direct Shift Automatic

Transmission 02E Front Wheel Drive, Repair Group 34,

Electric windows, check positioning

Note:

„ After disconnecting and reconnecting the battery, the

run-up and run-down function of the power window
regulators will not function. Therefore, the electric
windows must be positioned again immediately,
before a new vehicle is delivered. The vehicle
battery must not be disconnected after the electric
windows have been positioned.

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Warning!

After disconnecting and reconnecting the battery,

pinch protection of the power window regulators will
not function. This can cause serious injuries if e.g.
fingers are caught in the window!

Perform the following work sequence to position the

electric windows:

Note:

„ The following work sequence is for the front left

window. The positioning for the remaining windows
is performed in the same manner using the
respective switch in the drivers door.

- Switch ignition on.

- Close all doors and windows completely.

- Hold left front side-window in position "Close" by pulling

and holding switch for longer than 1 second.

- Lift button again for 1 second. Now when the button is

pressed briefly the window will lower fully and when the
button is lifted briefly the window will raise fully.

- Switch off ignition

Vehicle system test, perform

- Connect diagnostic tester 01-3, Diagnostic unit,

connecting .

- Switch ignition on.

- Select operating mode "Guided Fault Finding" on the

display.

- Then perform vehicle identification on tester.

Program now performs a vehicle system test automatically

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

- Press Continue > button.

Now all DTCs will be listed.

Note:

„ At this point it makes sense to switch into operating

mode Guided Functions in order to perform further
work using VAS 5051/5052 and to prevent a second

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vehicle identification on the tester.

„ To do so, press operating mode button and then

Guided Functions.

„ Refer to the corresponding work descriptions for the

continued sequence.

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

operating mode button and then Guided Fault
Finding.

Caution!

In any case, the vehicle must be returned to the

customer with DTC memory erased.

Static malfunction

If one or more static malfunctions are stored in data

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

Sporadic malfunctions

In the event only sporadic malfunctions or notes are stored

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

- Press the Continue > button again to enter the test

plan.

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

End.

All DTC memories will be checked now once more.

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

sporadic DTCs were erased, diagnostic protocol is sent
"online" automatically.

Vehicle system test is completed.

CV joint boots, visual inspection

Perform the following work procedure:

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

leaks and damage.

Ribbed belt, checking condition

Perform the following work procedure:

- Crank engine at vibration damper/belt pulley using a

socket wrench.

Check ribbed belt - 1 - for:

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

sectional breaks)

„ Layer separation (top layer, cord strands)

„ Base break-up

„ Fraying of cord strands

„ Flank wear (material wear, frayed flanks, flank

brittleness -glassy flanks-, surface cracks)

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„ Traces of oil and grease

Note:

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

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

Calibrate compass (USA/Canada)

Note:

„ It should not take more than 30 seconds to calibrate

compass.

„ Vehicle must be standing still during calibration

procedure.

- Switch ignition on.

- Wait 10 seconds.

- Switch on rear window defroster.

- Wait 10 seconds.

- Switch off rear window heater.

- Turn off ignition.

Cooling system, freeze protection and coolant level,

checking

Note:

„ All engines are filled with coolant additive G 12 Plus

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

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

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

„ G 12 Plus increases the boiling point to 275 F

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(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

„ 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).

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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
0 -25 3,5
-35 4,0
-5 -25 3,0
-35 3,5
-10 -25 2,0
-35 3,0
-15 -25 1,5

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-35 2,0
-20 -25 1,0
-35 1,5
-25 -35 1,0
-30 -35 0,5
-35 -40 0,5

- Check coolant additive concentration after test drive

again.

Checking coolant level and adding coolant if necessary

- Check coolant level in expansion tank with engine cold.

Note:

„ Check coolant level and top off if necessary. With

engine at operating temperature, coolant level must
be at top marking, with engine cold, it must be in
center of hatched area.

„ 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).

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Mixture ratio:

Freeze protection to Coolant additive G 12 Plus / Water

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

-35 C approx. 50 % approx. 50 %

-40 F approx. 60 % approx. 40%

Note:

„ Coolant additive G 12 Plus conforming to TL VW

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

„ Especially in countries with tropical climates or when

vehicle is driven under heavy load, the coolant
improves the engine reliability by its increased
boiling point.

„ The coolant concentration must not be reduced by

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

Air cleaner, clean housing and replace filter element

Removing and installing air filter element (2.0 L TFSI engines)

Removing

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

removing and installing .

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

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prevent damage to chrome applications.

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

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

part - 3 - .

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

housing - 1 - .

Installing

Note:

„ Self-locking bolts are equipped for fastening the

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

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

the following prerequisites are met:

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

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

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

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

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

- Tighten bolts - arrows - to maximum 3 Nm.

Upper engine cover, removing and installing

Caution!

„ Be sure to not strike the engine cover with a fist

or a tool when installing it and engaging the
fastening points. There is a risk of damage.

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Removing and installing engine cover, 2.0 L TFSI gasoline

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

Removing and installing engine cover (2.0L TFSI gasoline

engines)

Special tools, testers and auxiliary items required

„ Spring type clip pliers VAS 5024A

Removing

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

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

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

sensor and set connector aside.

- Release both fastening clips - arrows A - .

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

4 - and raise.

Installing

Installation is the reverse of removal.

Lower engine compartment cover (noise insulation),

removing and installing

Special tools, testers and auxiliary items required

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„ Torque wrench V.A.G 1783

Removing

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

Nm.
„ Combi-screws, Qty. 3, torque specification 6 Nm.

- Remove bolts - arrows - .

- Remove noise insulation rearward.

Installing

- Slide noise insulation - 3 - as shown into lower lock

carrier - 2 - .

- The narrow latches - arrow a - must be slid below or

wide latches - arrow b - slid above the lock carrier edge -
3- .

- Retaining tabs must engange over wide tabs in lock

carrier holes when doing so.

- Tighten screws - arrows - to correct torque

specification.

Engine and components in engine compartment (from

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above and below), visual check for leaks and damage

Perform visual check as follows:

- Check engine and components in engine compartment

for leaks and damage.

- Check hoses, lines and connections of

„ Fuel system

„ Cooling and heating system

„ and brake system

for leaks, abrasions, porosity and brittleness.

Note:

„ Ensure that all malfunctions detected are rectified

within repair measures.

„ If fluid losses are greater than can be reasonably

expected, determine cause and repair (repair
measure)

Engine oil level, check

Note:

„ Observe waste disposal regulations!

„ After stopping engine, wait at least 3 minutes to

allow oil to flow back into oil pan.

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

- Pull out dipstick again and read oil level.

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If the dipstick appears as illustrated:

A - Oil must not be topped off.

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

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

be damaged.

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

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

Engine oil, draining or extracting; changing oil filter and

filling engine oil

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

draining or extracting .

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

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

Engine oil, draining or extracting

Special tools, testers and auxiliary items required

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„ Oil extractor V.A.G 1782

„ Oil absorbent towel VAS 6204/1

Engine oil, draining or extracting

Perform the following work procedure:

Note:

„ In engines with standing oil filter module, oil filter

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

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

extraction unit, replace oil drain plug. This prevents
leaks.

„ Observe waste disposal regulations!

- Extract engine oil using old oil collecting and extracting

unit V.A.G 1782 .

or

- Remove oil drain plug

- Drain engine oil.

Note:

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

therefore the oil drain plug must always be replaced.

„ Observe waste disposal regulations!

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

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

Engine oil capacity,

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

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

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Torque specifications for oil drain plug:

„ Gasoline engines: 30 Nm

Warning!

„ Torque settings must not be exceeded

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

or even damage the oil pan.

Oil filter, replacing

Replacing oil filter, 2.0L TFSI engines

Special tools, testers and auxiliary items required

„ Oil drain adapter T40057

„ Oil filter wrench VAS 3417

„ Torque wrench V.A.G 1331/

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Perform the following work procedure:

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

Oil filter housing must be drained before it is removed.

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

Note:

„ When screwing in oil drain adapter T40057 , a valve

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

- Allow engine oil to drain.

- Unscrew oil drain adapter T40057 again.

- Oil filter housing can now be unscrewed using oil filter

wrench VAS 3417 .

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

Note:

„ Observe waste disposal regulations!

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

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

.

Filling engine oil

Oil specifications 01-3, Engine oils .

Engine oil capacities,

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

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

General notes

Note:

„ Observe waste disposal regulations!

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

check oil level.

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

- Pull out dipstick again and read oil level.

If the dipstick appears as illustrated:

A - Oil must not be topped off.

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

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

be damaged.

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

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

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Description of work (part 2 of 2)

Perform test drive

To what extent the following can be checked is dependent

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

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

- Engine: Output, misfiring, idling speed, acceleration

- Clutch: Pulling away, pedal pressure, odors

- Gear selection: Ease of operation, shift lever position

- Automatic transmission: Selector lever position, shiftlock /

ignition key interlock, shift behavior, display in instrument
cluster

- Foot and parking brake: Function, free travel and

effectiveness, pulling to one side, juddering, squeal

- ABS function: When braking with activated ABS, the

brake pedal must pulse noticeably.

- Steering: Function, steering free play, steering wheel

centralized when wheels are in straight ahead position

- Sunroof: Function

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

GALA, interference

- Multifunction indicator (MFI): Functions

- A/C system: Function

- Vehicle: Moving off line when traveling straight ahead

(level road)

- Imbalance: Wheels, drive shafts, prop shafts

- Wheel bearings: Noises

- Engine: Hot starting behavior

Wheel securing bolts, tighten to correct torque setting

Removing and installing wheel bolt covers

Note:

„ Depending on vehicle equipment, wheel bolts can be

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covered by the following components:

„ Covers for wheel bolts

„ Wheel center cover

„ Full wheel cover

- If present, remove respective wheel bolt cover

Note:

„ The pulling hook for removing the cover caps or

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

Removing wheel center cover (example)

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

center cap and pull in - direction of arrow - .

Installation notes

Note:

„ The covers protect the wheel bolts and should be

reinstalled after retightening the wheel mounting
bolts.

„ Note that on some rims, the center wheel cover tab

must engage in rim cut-out.

„ After completing work, place adapter and pulling

hook with vehicle tool kit.

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

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

Loosen anti-theft wheel bolts and tighten

Note:

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

bolts is located with the vehicle tool kit.

„ If there is no adapter installed in the vehicle for

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

„ In case of losing the adapter, a replacement adapter

can only be obtained via the code number.

„ The adapters code number for loosening/tightening

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

Special tools, testers and auxiliary items required

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„ Master wheel bolt key set T10101

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

- Slide wheel wrench onto adapter until it stops.

- Retighten wheel securing bolts to the correct tightening

torque.

Retighten wheel securing bolts

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

Note:

„ Ensure wheel bolts are retightened alternately.

Tightening torque: 120 Nm

Radio/navigation system, activating anti-theft coding

Volkswagen Radio and Navigation units

Radio units / radio-navigation systems are shipped with a

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security code.

Security code means that every unit with anti-theft coding

has been programmed with its own code.

This code is not active from the factory.

Note:

„ Security code is located on card for the unit.

„ Code number together with serial number is printed

on card for the unit, located at front in owner
information packet.

„ If SAFE appears continuously in display after

switching on the radio, the radio is locked! Radio
must remain switched on one hour, then the lock is
deactivated. Now it is possible to enter the code
anew.

To activate radio/navigation system anti-theft coding refer

to

Repair Manual, Communication, Repair Group 91,

Radio, Telephone, Navigation, Trip computer

Tire pressure control indicator, performing basic setting

Note:

„ Basic setting of Tire Pressure Monitoring Display

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

„ If no pressure loss and no tire damage is detected

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

Tire Pressure Monitory System display is a component of

ABS Control Module -J104- software.

ABS Control Module compares speed and rolling

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

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„ Tire inflation pressure is too low.

„ Tires have structural damage.

„ Vehicle is loaded on one side.

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

towing trailer or driving uphill and downhill).

„ Snow chains are installed.

„ Spare wheel is installed.

„ One wheel per axle was replaced.

Tire Pressure Monitoring Display Indicator Lamp K220 has

a yellow indicator light in instrument cluster - arrow - .

„ "BLINKING LIGHT" means that no "INITIAL BASIC

SETTING" was performed yet.

„ "STEADY LIGHT" , in conjunction with warning

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

Performing "INITIAL" basic setting

- Switch ignition on.

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- Simultaneously press the ESP - 1 - button and SET

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

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

Beginning of basic setting is confirm by a notifying tone.

On next new ignition start, warning does not appear.

Performing basic setting

- Switch ignition on.

- After changing tire pressures or changing one or more

tires, tire pressure display SET button, item - 2 - in
illustration, must be pressed until a confirmation tone is
heard.

Warning will no longer appear next time engine is switched

on.

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Tire repair kit

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

arrow -

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

tire inflation cylinder with sealant.

Note:

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

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

- is displayed.

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

and the bottle must then be replaced.

- Check the expiration date and enter in maintenance

tables.

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

Caution!

„ Tire sealant must not be older than 4 years.

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

must also be replaced.

Note:

„ Residual tire sealant or full bottles, which have

expired, must be disposed of.

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

with other fluids and must be disposed of.

Observe disposal regulations.

Dust and pollen filter, clean housing and replace filter

element

Note:

„ Clean the surrounding area of the dust and pollen

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

- Perform the following work procedure:

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

- .

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

C - and - D - .

- Remove bolts - A - if necessary.

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

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

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

cover.

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

conditioner or heater.

Note:

„ Observe waste disposal regulations!

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

unit or heater.

- Install in reverse order of removal.

Headlight adjustment, check

Adjusting gas discharge headlights 01-5, Adjusting

headlights with gas discharge lamps .

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Adjusting halogen headlights 01-5, Adjusting headlights

with halogen lamps .

Adjusting fog lights and other auxiliary headlights 01-5,

Adjusting fog lights and other auxiliary lights .

Test requirements:

Special tools, testers and auxiliary items required

„ Head light adjusting unit VAS 5046 or

„ Headlight adjuster VAS 5047

Test- and adjustment requirements:

„ Tire pressure must be OK.

„ Lenses must not be damaged or dirty.

„ Reflectors and bulbs OK.

„ Vehicle must be properly loaded.

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

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

„ Vehicle and headlight adjuster must be on a level

surface. Operating instructions of headlight
adjuster VAS 5046 or operating instructions of
headlight adjuster VAS 5047

„ Vehicle and headlight adjuster must be aligned.

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„ Inclination must be set.

- Following headlamp adjusting device operating

instructions!

In the trim above the headlight, inclination measurements

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

Applies to vehicles with halogen headlights with

manual headlight range control:

„ The headlight range adjuster thumb wheel must be

in basic setting - 0 - .

Load: Vehicle must be loaded with one person on the

drivers seat, weighing 165 lbs (75 kg), otherwise vehicle
must be empty (curb weight).

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

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

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

- Read fuel level from fuel gauge. Calculate additional

weight needed using the following table. Place extra weight
in luggage compartment.

Tank filling table

Fuel level according Additional weight

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

Example:

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

Note:

„ For additional weight use containers filled with water.

A container filled with 5 liters of water weighs

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approx. 11 lbs (5 kg).

Applies to vehicles with gas discharge lamps with

dynamic headlight range control:

Note:

„ On vehicles with gas discharge headlights, DTC

memory should be checked and erased using
vehicle diagnosis, test and information system VAS
5051 or vehicle diagnosis and service system VAS
5052 and headlight range adjuster brought into
Basic Setting before every headlight adjustment.

Checking headlight setting (with new test screen without 15 -

setting line)

Headlights:

Check the following:

- With the low beam switched on check whether the

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

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

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

Note:

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

cover and uncover left half of headlight (as viewed
when looking forward) a few times. Then check low
beam again.

„ After correct adjustment of low beams the center

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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.

Fog lights:

- Check whether the upper light-dark border touches the

setting line horizontally over the complete test screen
width.

Other additional headlights:

Accessory auxiliary light systems must be checked and

adjusted according to the guidelines valid for them.

Adjusting headlights with gas discharge lamps

Perform basic setting:

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- Connect diagnostic tester 01-3, Diagnostic unit,

connecting .

- Switch ignition on.

- Select "Guided Fault Finding"

Enter vehicle information; all control modules are

interrogated.

- Press the following selections in the order shown:

„ Go To

„ Functions and component selection

„ Body

„ Electrical Equipment

„ 01 - On Board Diagnostic (OBD) capable systems

„ 55-Dynamic Headlamp Range Control

„ J 431-Dynamic Headlamp Range Control, Functions

„ J 431-Headlamp Range Control Module, basic

setting

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„ Press -button.

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

J431 - Headlamp Range Control Module, basic setting

„ Press -button.

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

J431 - Headlamp Range Control Module, basic setting

- Follow procedure on tester.

- Check headlight adjustment and adjust headlights if

necessary.

- Complete function program for J431 - Headlamp Range

Control Module, basic setting.

Note:

„ Also check whether both headlights work evenly

when operating the manual headlight range control.

Adjust left headlight (Rabbit/GTI 2004 ):

Adjustment screws for right headlight are arranged

symmetrically

„ Adjustment screw - 1 - for vertical adjustment

„ Adjustment screw - 2 - for height/lateral adjustment

- To adjust the height, turn the adjustment screws - 1 -

and - 2 - with the same number of revolutions.

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- To adjust laterally, turn only the adjustment screw - 2 - .

Adjusting headlights with halogen lamps

Left headlight (Rabbit/GTI 2004 ):

Adjustment screws for right headlight are arranged

symmetrically

„ Adjustment screw - 1 - for vertical adjustment

„ Adjustment screw - 2 - for height/lateral adjustment

- To adjust the height, turn the adjustment screws - 1 -

and - 2 - with the same number of revolutions.

- To adjust laterally, turn only the adjustment screw - 2 - .

Adjusting fog lights and other auxiliary lights

Fog lights in headlights:

Note:

„ The adjustment of fog lights is performed

automatically when adjusting headlights.

Fog lights in bumper, right (Rabbit 2004 ):

Adjusting screw on left fog light is arranged symmetrically.

Inclination figures:

„ Fog lights 20 cm

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- Unclip retaining tabs - arrows - and remove cover on

lower part of bumper.

- To adjust the lamp range, turn the adjustment screw -

arrow - .

Lateral adjustment is not possible.

Fog lights in bumper, right (GTI)

Adjusting screw on left fog light is arranged symmetrically.

Inclination figures:

„ Fog lights 20 cm

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- Remove screw - 1 - .

- Unclip retaining tabs - 2 - and remove cover on lower

part of bumper.

Note:

„ Retaining tabs are partially seated very securely.

Therefore, be very careful when removing cover to
avoid breaking retaining tabs.

To adjust the lamp range, turn the adjustment screw -

arrow - .

- Secure cover in reversed sequence.

Other auxiliary lights

Accessory auxiliary light systems must be checked and

adjusted according to the guidelines valid for them.

Service interval display, reset

Service Reminder Indicator must for

„ Vehicle release inspection

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„ Every service

(adapted)!

- Connect diagnostic tester 01-3, Diagnostic unit,

connecting .

- Switch ignition on.

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

screen.

If display does not appear as in work sequence: see

Vehicle Diagnostic, Testing and Information System
operating instructions.

- Press > button to confirm.

- Select in succession:

„ Brand

„ Model

„ Model year

„ Engine code

- Confirm vehicle identification.

- Select in succession:

„ "Instrument cluster" - ARROW - .

„ "Resetting Service Reminder Indicator (SRI)" .

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- Perform adaptation according to instructions of "GUIDED

FUNCTIONS" .

End Adaptation

Indicated on display:

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

Indicated on display:

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

- Press "exit" button in exit menu.

- Turn off ignition and disconnect diagnostic connection.

- Switch ignition on.

After switching on the ignition, service event is no longer

indicated in the odometer display in the instrument panel
insert.

Service interval display, recoding

- Connect diagnostic tester 01-3, Diagnostic unit,

connecting .

- Switch ignition on.

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

screen.

If display does not appear as in work sequence: see

Vehicle Diagnostic, Testing and Information System
operating instructions.

- Select in succession:

„ Brand

„ Model

„ Model year

„ Engine Code

- Confirm vehicle identification.

If the vehicle identification procedure was performed

correctly, press > button for confirmation.

- Select in succession:

„ "Instrument cluster" - ARROW - .

„ "Adapt service interval extension" .

- Perform adaptation according to instructions of "GUIDED

FUNCTIONS" .

End Adaptation

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Indicated on display:

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

Indicated on display:

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

- Press "exit" button in exit menu.

- Turn off ignition and disconnect diagnostic connection.

Sunroof, checking function, cleaning and lubricating

guide rails

Perform the following work procedure:

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- Check function of sunroof.

- Clean guide rails - arrows - and lubricate with special

grease.

Windshield wash/wipe system and headlight wash

system, check function

Check freeze protection content of windshield cleanser

concentrate G 052 164 , fill with fluid 01-5, Checking
freeze protection content of fluid, if necessary top off with
fluid .

Windshield wipe-/wash system: Check spray nozzle

adjustment, adjust if necessary 01-5, Windshield wipe-
/wash system, check spray nozzle adjustment, adjust if
necessary .

Headlight wash system: Check spray nozzle adjustment,

adjust if necessary 01-5, Headlight wash system: Spray
nozzle adjustment, checking, adjusting if necessary
(Rabbit/GTI 2006 ) .

Checking freeze protection content of fluid, if necessary top off

with fluid

Special tools, testers and auxiliary items required

„ Refractometer T10007

Read the bright/dark boundary to obtain an accurate

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

- Check the concentration of the anti-freeze additive using

refractometer T10007 (operating instructions).

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Scale - 1 - of refractometer applies to windshield cleanser

concentrate G 052 164 .

The scale - 2 - is designed for commercially available

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

Mixture ratio:

Freeze protection to W/screen clear Water

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

-22/-23 C 1 part 2 parts

-37/-38 C 1 part 1 part

Filling-up with fluid:

The windshield wash/wipe system fluid reservoir must be

filled up fully.

Use only windshield cleanser concentrate G 052 164 all-

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

Note:

„ Windshield cleanser concentrate G 052 164 protects

the spray nozzles, fluid reservoir and hoses from
freezing.

„ All vehicles with fan type spray jets must be filled

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

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low temperatures.

„ Fill with windshield cleanser concentrate G 052 164

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

„ Freeze protection (anti-freeze) must be guaranteed

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

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

adjust if necessary

Note:

„ In the event contamination in spray nozzle produces

an uneven spray pattern, remove spray nozzle

Repair Manual, Electrical Equipment, Repair Group 92,

, and rinse it with water in the opposite direction of

spray.

„ Subsequently blowing through in the opposite

direction of the spray flow with compressed air is
permitted.

Caution!

„ Do not use solid objects to clean the spray

nozzles!

„ Do not use a needle or similar under any

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

Windshield washer system spray jets, Topic 01-5 .

Rear window washer nozzle adjustment: Topic 01-5 .

Special tools, testers and auxiliary items required

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„ Adjustment tool T10127 equipped with needle 3125/

5A

Windshield washer system spray jets:

The washer nozzles are preset. Small height adjustments

can be made.

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

direction upward or downward as follows:

- Adjust the spray stream by turning at the adjuster -

arrow - with a screwdriver.

„ "Clockwise" deeper adjustment.

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„ "Counterclockwise" higher adjustment.

Rear window washer nozzle adjustment:

Note:

„ It is only possible to adjust spray nozzles diagonally,

that is, in direction of rear window or opposite. A
lateral adjustment in direction of wiper arm rotation is
not possible. Spray nozzles are secured in this
direction at the factory.

- Adjust nozzle with adjustment tool T10127 so that fluid

sprays onto upper third of rear window, as shown.

Headlight wash system: Spray nozzle adjustment, checking,

adjusting if necessary (Rabbit/GTI 2006 )

Note:

„ In the event contamination in spray nozzle produces

an uneven spray pattern, remove spray nozzle

Repair Manual, Electrical Equipment, Repair Group 92,

, and rinse it with water in the opposite direction of

spray.

„ Subsequently blowing through in the opposite

direction of the spray flow with compressed air is
permitted.

Caution!

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„ Do not use solid objects to clean the spray

nozzles!

„ Do not use a needle or similar under any

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

Special tools, testers and auxiliary items required

„ Adjustment device T10167

Spray jet adjustment for left headlight (right headlight is

identical but reversed)

Check spray jet setting.

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.

Spray pattern should encounter headlight lamps at center,

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see - B - and - C - .

Adjusting nozzles

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.

Spray nozzles - arrow - are driven outward.

- Perform the following work procedure:

- Direct the spray direction of respective nozzle using

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

Windshield wiper blades, park position, checking

Front windshield wiper blades, check park position (Rabbit/GTI

2006 )

- Deactivate APS function,

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Repair Manual, Electrical Equipment, Repair Group 92,

Deactivate APS wiper motor function.

- Check if the windshield wiper blade tips are positioned

with the following distances to the plenum chamber cover
at the bottom of the windshield:

„ Dimension - a - = 0 to 10 mm

„ Dimension - b - = 0 to 10 mm

- If necessary, adjust wiper arm:

Adjust windshield wiper blades

Repair Manual, Electrical Equipment, Repair Group 92,

Windshield wiper blades - Parked position

Note:

„ For right-hand drive vehicles, the placement is a

mirror image!

Rear windshield wiper blades, park position, checking

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- Switch rear windshield wipers on and off and allow to run

to end position.

- Check whether blade points rest in with the following

distance to lower edge of window.

„ Dimension - a - = 15 + 5 mm

- If necessary, adjust wiper arm:

Repair Manual, Electrical Equipment, Repair Group 92,

Windshield wiper blades - park position

Tie rod ends, check play, security and joint boots

Perform the following work procedure:

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

moving tie rods and wheels. Play: zero play

- Check mountings.

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

proper seating.

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Door arrester, lubricate

Perform the following work procedure:

- Grease door arrester at points shown - arrows - .

Use solid lubricant G 000 150 .

Transportation mode, deactivating

- Connect diagnostic tester 01-3, Diagnostic unit,

connecting .

- Switch ignition on.

Indicated on display:

Select mode of operation:

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

Note:

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„ If the displays indicated in the work procedure are

not indicated on display: Operating instructions for
Vehicle Diagnosis, Testing and Information System
VAS 5051 or Vehicle Diagnosis Service Syst VAS
5052

Indicated on display:

- Press "Grouped services" on display.

Indicated on display:

- Press "Switch off transport mode" on display.

End procedure

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Indicated on display:

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

Indicated on display:

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

- Press "exit" button in exit menu.

- Turn off ignition.

Note:

„ Diagnostic operation system VAS 5051 or Vehicle

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

Transport protection, removing locking pieces from front

axle struts

In vehicles with sport suspension, locking pieces are

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

Note:

„ Locking pieces should prevent vehicle from

bouncing when being driven on to an automobile

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transport or railroad car and thereby become

damaged.

Warning!

Locking pieces must always be removed before

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

Perform the following work procedure:

Note:

„ It is not necessary to remove the wheels.

„ Be careful not to damage surface of coil springs.

- Relieve load on coil spring by raising vehicle on lifting

platform.

- Press locking piece - arrow - from coil spring.

Underbody protection, perform visual check for damage

During visual check, observe floor pan, wheel housings

and sills!

Note:

„ Malfunctions found must be rectified (repair

measure). This inhibits corrosion and rusting
through.

Clock, setting

Set clock with buttons below tachometer

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Adjustment buttons are located at left under tachometer.

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

only briefly to advance by one hour.

- Press the right button - 2 - to set the minutes. Press

button only briefly to advance by one minute.

Set hour and date with buttons on windshield wiper

lever

- Switch ignition on.

- Press button - 2 - for 2 seconds to go to main menu.

- Select "Settings" menu with button - 2 - and confirm with

button - 1 - .

- Select "Clock" menu with button - 2 - and confirm with

button - 1 - .

- Now mark menu time "Hours" by pressing button - 1 - ,

set correct hour with button - 2 - and then confirm with
button - 1 - .

- Do the same with menu item "Minutes" .

- You can leave the "Settings" menu using menu item

"back" .

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- Now select "MFD" as actual display and confirm with

button - 1 - .

- Switch ignition off.

Set hour and date with buttons on multi-function

steering wheel

- Switch ignition on.

- Press button - 1 - until "Settings" menu appears.

- Then select menu item "Clock" with buttons - 2 - and - 4

- .

- Confirm selection with button - 3 - .

- If "Hour" is marked, marked menu item is located

between both horizontal lines, confirm again with button -
3 - and set correct hour with buttons - 2 - and - 4 - .

- Confirm again with button - 3 - and change to minute

setting which is done the same as when setting the hour.

- You can leave the menu again with button - 1 - .

- Switch ignition off.

Toothed belt for camshaft drive: Replacing (2.0 L TFSI

only)

Note:

„ Generally, it is not necessary to replace the belt

before reaching the next replacement interval. In
particular, cracks on the back side of the belt do not
affect service life and cannot be claimed as goodwill
or warranty measures.

- Toothed belt, removing and installing

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

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

Airbag for driver and passenger, visual inspection of

airbag components

Driver side airbag

Identification of airbag is embossed as "AIRBAG" on

upholstered cover of steering wheel.

- Perform a visual inspection for any damages to

upholstered cover - 1 -

Warning!

„ Adhesive from tape, stickers, etc. and other

residues or unauthorized work on airbag units
can affect airbag function. So that future airbag
function is ensured. make certain the customer
is aware of this.

„ Upholstered cover of steering wheel may only be

cleaned with a dry or damp cloth.

Front passenger side airbag

Identification of airbag is embossed as "AIRBAG" on right

side of instrument panel.

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- Perform a visual inspection for any damages to surface

of instrument panel - 2 - .

Warning!

„ Adhesive from tape, stickers, etc. and other

residues or unauthorized work on airbag units
can affect airbag function. So that future airbag
function is ensured. make certain the customer
is aware of this.

„ Upholstered cover of steering wheel may only be

cleaned with a dry or damp cloth.

Spark plugs, replacing

Replacing spark plugs, 2.0 L TFSI engine 01-5,

Replacing spark plugs (2.0 L TFSI engine) .

Special tools, testers and auxiliary items required

„ Spark plug wrench 3122 B

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„ Torque wrench V.A.G 1331

„ Puller T40039

„ Puller T10094

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„ Puller T10095

„ Removal/installation tool T10029

„ Puller T10112

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„ Removal/installation tool T10118

Replacing spark plugs (2.0 L TFSI engine)

Removing:

Perform the following work procedure:

Note:

„ To pull off spark plugs, place ignition coil puller

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

„ If lower ribs are used, these can be damaged

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

removing and installing .

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Spark plugs are located under ignition coils with power

output stages - 2 - .

Note:

„ Note installation position of ignition coils with power

output stages!

- Remove both bolts - 1 - .

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

in direction of arrow using ignition coil puller T40039 .

- Push connector in direction of ignition coils with power

output stages, press catch down by hand and disconnect

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connectors - arrows - .

- Remove spark plugs using spark plug wrench 3122 B .

Note:

„ Spark plug identification and tightening torque,

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

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

„ Observe waste disposal regulations!

Installing

- Install new spark plugs using spark plug wrench 3122

B .

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- Guide ignition coils with power output stages into cylinder

head.

- Align ignition coils with power output stages into

designated recesses of cylinder head cover.

- Connect all connectors to ignition coils - arrows - .

- Press ignition coils with power output stages onto spark

plugs by hand until stop. They must engage audibly.

- Secure wiring using bolts - 1 - .

- Install engine cover.

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