MAINTENANCE

2004 Volkswagen Touareg
Maintenance Maintenance Procedures
Maintenance
Maintenance Procedures
01 - MAINTENANCE
ENGINE OVERVIEW
Gasoline engines
NOTE:  Some engines listed below are for European vehicles only.
Engines --> Gasoline engine Gasoline engine Gasoline engine

Displacement L 4.2 3.2 3.2
Engine Code AXQ AZZ BAA
Number of cylinders/valves per cylinder 8/5 6/4 6/4
Output kW at RPM 228/6200 162/5400 162/6000
Torque Nm at RPM 410/3000 305/3200 300/4000
Bore mm 84.5 84.0 84.0
Stroke mm 93 95,9 95,9
Compression ratio 11 11.25 11.25
Fuel injection/Ignition Bosch Motronic Motronic ME 7.1.1 Motronic ME 7.1.1
RON min. 98 unleaded * See 98 unleaded * See 98 unleaded * See
footnote footnote footnote
Leak detection system (e.g. USA no no yes

vehicles)
On Board Diagnostic (OBD) yes yes yes

Engine Code BAR BHK BHL
Output kW at RPM 257/6500 206/6200 206/6200
Torque Nm at RPM 440/3500 360/2800 360/2800
Bore mm 84.5 89.0 89.0
Stroke mm 92.8 96.35 96.35
Compression ratio 11.5 12.0 12.0
Fuel injection/Ignition FSI direct injection Bosch Motronic Bosch Motronic
MED 9.1 MED 9.1
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Leak detection system (e.g. USA yes no yes

vehicles)
Engines: --> Gasoline engine Gasoline engine Gasoline engine

Engine Code BHX BJN BKJ
Output kW at RPM 228/6200 331/6200 162/5400
Torque Nm at RPM 410/3200 600/3500 305/3200
Bore mm 84.5 84.0 84.0
Stroke mm 93 90.2 95.9
Fuel injection/Ignition Motronic ME 7.1.1 Bosch Motronic Motronic ME 7.1.1
Leak detection system (e.g. USA no no no

vehicles)
On Board Diagnostic (OBD) yes no no

Engine Code BMV BMX BRJ
Output kW at RPM 177/6000 177/6000 177/6000
Torque Nm at RPM 300/4000 305/3200 310/3200
Bore mm 84.0 84.0 84.0
Stroke mm 95.9 95.9 95.9
Fuel injection/Ignition Motronic ME 7.1.1 Motronic ME 7.1.1 Motronic ME 7.1.1
Leak detection system (e.g. USA no yes no

vehicles)
Diesel engines
Engines --> Diesel engine Diesel engine Diesel engine

Engine Code AYH BAC BKS
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Output kW at RPM 230/3750 128/3500 165/4000
Torque Nm at RPM 750/2000 400/2000 to 2300 450/1400 to 3250
Bore mm 81.0 81.0 83.0
Stroke mm 95.5 95.5 91.4
Fuel injection/Ignition PD TDI PD TDI EDC 16 CP
(Common Rail)
CN min. 51 51 51 * See footnote
Diesel particle filter (DPF) no no Yes
Additive system no no no
vehicles)
Engines --> Diesel engine Diesel engine Diesel engine

Engine Code BKW BLE BLK
Output kW at RPM 230/3750 230/3750 120/3500
Torque Nm at RPM 750/2000 750/2000 400/2000 to 2300
Bore mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Fuel injection/Ignition PD TDI PD TDI PD TDI
CN min. 51 51 * See footnote 51
Diesel particle filter (DPF) no Yes no
Additive system no yes no
vehicles)
Engines: --> Diesel engine Diesel engine Diesel engine

Engine Code BPE BPD BWF
Output kW at RPM 128/3500 120/3500 230/3750
Torque Nm at RPM 400/2000 400/2000 750/2000
Bore mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
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Fuel injection/Ignition PD injection 1.5 PD injection 1.5 PD injection 1.5

CN min. 51 * See footnote 51 * See footnote 51 * See footnote
Diesel particle filter (DPF) yes yes yes
Additive system no no no
vehicles)
*In exceptional circumstances min. 95 RON unleaded, but with reduced performance.
*No RME fuel (biodiesel) permitted
SERVICE WORK
SERVICE WORK
This chapter contains information on the following subjects:
 Service tables --> Service tables

 Oil change service --> Oil change service
 Inspection service --> 2004 --> Inspection service 2004
 Service interval 2005 --> --> Service interval 2005
 Service inspection interval 2005 --> --> Service inspection interval 2005
 Time- and/or distance-dependent additional work --> Time and/or distance dependent additional work
 Delivery inspection --> Delivery inspection
SERVICE TABLES
VW engine oil standards
WARNING: Only oils approved by VW must be used; Fluid Capacity Charts.
Filter change interval
For information on filter change intervals please refer to: --> Maintenance Schedule for appropriate
model and year
Toothed belt change interval
For information on toothed belt service intervals please refer to: --> Maintenance Schedule for
appropriate model and year
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OIL CHANGE SERVICE
NOTE:  Inform the customer of the repair measures required if a problem is

detected during service work.
For information on oil change service please refer to: --> Maintenance Schedule for appropriate model
and year
Also, for information on oil specifications please refer to: --> Fluid Capacity Charts for appropriate
model and year
INSPECTION SERVICE 2004
For information regarding service intervals please refer to: --> Maintenance Schedule for appropriate
model and year.
SERVICE INTERVAL 2005
model and year.
SERVICE INSPECTION INTERVAL 2005
The sequence of the individual service positions has been tested and optimized. Therefore they should be
adhered to, to prevent unnecessary work interruptions.
NOTE:  Inform the customer of the repair measures required if a problem is

detected during service work.
 Ask the customer if he or she would like:
 New wiper blades,

 Washer fluid G 052 164 (cleaner and freeze protection) filled up.
model and year.
TIME AND/OR DISTANCE DEPENDENT ADDITIONAL WORK
In addition to the service, depending on the operating conditions and the vehicle equipment, additional
maintenance work must be performed.
It is also possible to perform this additional work outside the service interval, taking into account entries in the
service plan (or sticker: Your Next Service).
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Refer to --> Maintenance Schedule for appropriate model and year.
DELIVERY INSPECTION
For information regarding delivery inspection please refer to: --> Maintenance Schedule for appropriate
model and year.
GENERAL
GENERAL
 Raise vehicle with hoist and floor jack --> Raising vehicle with hoist and floor jack
 Service sticker --> Service Sticker
 Diagnostic unit, connecting --> Diagnostic unit, connecting
 Vehicle Identification Number (VIN) --> Vehicle Identification Number (VIN)
 Vehicle data sticker --> Vehicle data sticker

 Information on time or distance dependent service --> Information on time or distance dependent
service
 Engine code and engine number --> Engine code and engine number
 RME fuel (biodiesel) --> RME - fuel (Biodiesel)
 Type plate --> Type plate

 Vehicle lifting mode: Level control system, switching on and off --> Vehicle lifting mode: Switching
level control system on and off
RAISING VEHICLE WITH HOIST AND FLOOR JACK
NOTE:  When lifting the vehicle, the vehicle lift mode must be active so that the
vehicle level control is automatically switched off.
Refer to vehicle lifting mode, switching level control system on and off --> Vehicle lifting mode: Switching
level control system on and off.
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
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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.
Hoist and floor jack lifting points:
Front:
Fig. 1: Hoist And Floor Jack Lifting Points (Front)

Courtesy of VOLKSWAGEN UNITED STATES, INC.
 Position the support plate on the longitudinal reinforcement - Arrow - of the floor plate.
WARNING: On no account must front of vehicle be raised on side member vertical

stiffener.
Rear:
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Fig. 2: Hoist And Floor Jack Lifting Points (Rear)

 Position the support plate on reinforcement - arrow - of the floor plate in area of rear axle.
WARNING: Ensure that the lifting platform support plate is positioned centrally on
reinforcement
SERVICE STICKER
Apply sticker "First service" (at the delivery inspection):
Fig. 3: Identifying "First Service" Sticker

Affix sticker "Your next service events" --> Service Sticker
"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" : Indicate what is due next and enter date and mileage
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Fig. 4: Identifying Service Sticker "Next Service"

 Apply sticker to drivers side door jamb (B Pillar).
Applying "data sticker" in service schedule
Fig. 5: Locating Data Sticker

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

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1 - Planning week
2 - PR number
DIAGNOSTIC UNIT, CONNECTING
Vehicle diagnostic, test and information system VAS 5051/or Vehicle diagnosis and service system VAS 5052 ,
connecting and selecting functions
Special tools, testers and auxiliary items required
Fig. 6: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
 Vehicle Diagnosis, Testing and Information System VAS 5051 B
Fig. 7: Diagnostic Cable - VAS 5051/6A

 Diagnostic cable VAS 5051/6A
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Fig. 8: VAS 5052 Vehicle Diagnostic And Service Information System

 Vehicle diagnosis service syst. VAS 5052 or later testers
Fig. 9: Diagnostic Cable VAS 5052/3

 Diag. Cable For VAS5052 (2 meter) VAS 5052/3 A
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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Fig. 10: Connecting Connector Of Diagnosis Cable VAS 5051/1 Or VAS 5051/3 To Data Link Connector
 Perform the following work procedure:
Fig. 11: Location Of Data Link Connector (DLC)

Open cover - 1 - of On Board Diagnostic (OBD) connection and connect connector of diagnostic cable Vehicle
Diagnosis, Testing and Information System VAS 5051
 Turn on the tester.

 Switch ignition on.
Now follow information given on screen to start the desired functions.
VEHICLE IDENTIFICATION NUMBER (VIN)

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Windshield location
Fig. 12: Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) - magnified area - is located behind the windshield on the drivers
side.
Spare wheel well location
Fig. 13: Locating Vehicle Data Sticker (Spare Wheel Well)

The Vehicle Identification Number - arrow A - is located in rear of vehicle on the right by the spare wheel
recess.
Meaning of VIN:
WVG ZZZ 7L Z 3 D 000 234

Manufacturer Filler Model Filler Model year Production Serial number
code characters characters 2003 location
VEHICLE DATA STICKER

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Instrument Panel location
Fig. 14: Identifying Vehicle Data Sticker (Instrument Panel)

The vehicle data sticker - arrow - is located on the rear of the instrument panel lining. The vehicle data sticker
can also be found in the service schedule for the customer.
Left hand drive vehicles on left side, right hand drive vehicles on right side.
Spare wheel well location

The vehicle data sticker - arrow - is located in rear of vehicle on the left by the spare wheel recess.
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Contents of the vehicle data sticker
Fig. 16: Identifying Vehicle Data Label

Sticker contains the following vehicle data:
 Production control number

 VIN
 Type identification number
 Model explanation/engine output
 Engine and transmission code letters

 Paint number/interior equipment identification number
 Optional equipment identification number
INFORMATION ON TIME OR DISTANCE DEPENDENT SERVICE
Service identification
Vehicles marked with the following PR-number:
"QG2" indicates time or distance dependent service.
"QG3" without maintenance interval extension, without service interval display
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Fig. 17: Identifying Vehicle Data Sticker

 Using vehicle data sticker, check whether vehicle is equipped with PR number "QG1" , "QG2" or "QG3".
The PR number determines the service intervals --> Service tables.
The vehicle data sticker - arrow - is located on the rear of the instrument panel lining.
With right-hand drive vehicles, vehicle specification sticker is located on right side

or
 In rear of vehicle on left side of spare wheel well - B -.
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ENGINE CODE AND ENGINE NUMBER
Engine codes and engine number -->
 00 - GENERAL, TECHNICAL DATA for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION

IGNITION, ENGINE CODES: BAA, BMX
 00 - GENERAL, TECHNICAL DATA for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION
IGNITION, ENGINE CODES: BHL, BHK
 00 - GENERAL, TECHNICAL DATA for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL
INJECTION IGNITION, ENGINE CODE(S): BAR
 00 - GENERAL, TECHNICAL DATA for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL
INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 00 - GENERAL, TECHNICAL DATA for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL,
FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
RME - FUEL (BIODIESEL)
The RME capability for approved engines only applies through model year 2007
WARNING:  Vehicles with diesel particle filters may not be operated with RME
fuel (biodiesel).
 If RME fuel is used although your vehicle is not designed for it, the
fuel supply system may be damaged.
 When filling tank with Biodiesel, only use RME fuel corresponding to
EN 14214 (FAME)!
 If Biodiesel not corresponding to the norm is used, fuel filter may
become clogged.
RME fuel must correspond to EN 14214 (FAME).
Special remarks on RME fuel
 Driving performance when operating with Biodiesel may be slightly lower.

 Fuel consumption when operating with Biodiesel may be slightly higher.
 RME can be used in winter up to approx. -10°C
 At outside temperatures below -10°C, it is recommended to fill the tank with winter diesel fuel.
NOTE:  If using Biodiesel, be aware of the different intervals for changing the fuel
filter --> Service tables.
 If standing times of longer than approx. 2 weeks have been planned, it is
recommended to completely fill the tank with diesel fuel and to drive over
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a distance of approx. 50 km in order to prevent damage to the fuel

injection system.
TYPE PLATE
Fig. 19: Locating Type Plate

The Type plate - arrow - is attached on the right hand side of water box
NOTE:  Vehicles for certain countries have no type plate.
VEHICLE LIFTING MODE: SWITCHING LEVEL CONTROL SYSTEM ON AND OFF
Before vehicle is raised, level control system must be switched off.
In vehicle lift mode, level control system is switched off, in order to avoid a re-adjusting with set vehicle hoist
or trolley jack.
Level control system switched off
 Vehicle must be standing.
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Fig. 20: Switching Level Control System On And Off


 Press and hold the key LOCK located in center console - arrow - for 5 seconds.
The "vehicle lift mode" is indicated in the instrument cluster and by the blinking of the indicator lamp of the
LOCK button.
After activating, switch ignition off
Level control system switched on
Fig. 21: Switching Level Control System On And Off

Level control system can be activated by two variations again.
 With the ignition switched on, press the LOCK button in the center console - arrow - longer than 5
seconds.
or
 If the vehicle is driven faster than 5 km/h, vehicle level control is activated.
DESCRIPTION OF WORK
DESCRIPTION OF WORK
 Turbocharger: Grease servo-motor linkage --> Turbocharger: Lubricate servo-motor linkage

 Ball joints: Visual inspection --> Ball joints: Visual inspection
 Diesel particle filer soot load measurement, checking --> Diesel particle filer soot load measurement:
Checking
 Automatic transmission: ATF level, checking --> Automatic transmission: ATF level, checking
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 Battery disconnect relay: Removing --> Battery disconnect relay: Removing

 Battery: Battery terminals, checking for secure seating --> Battery: Check battery terminals for secure
seating
 Batteries: Checking --> Batteries: Check
 Checking tires: Tire condition, wear pattern, inflation pressure and tread depth --> Checking tires: Tire
condition, wear pattern, inflation pressure and tread depth
 Front and rear brake linings: Thickness, checking --> Front and rear brake pads: Checking thickness
 Brake system: Visual inspection for leaks and damage, performing --> Brake system: Visual check for
leaks and damage
 Brake fluid, changing --> Brake fluid: Changing
 Brake fluid level (depending on brake pad wear): Checking --> Brake fluid level (depending on brake
pad wear): Check
 Diesel particle filter: Replacing --> Diesel particle filter: Replacing

 Electric windows: Positioning, checking --> Electric windows: Check positioning
 Vehicles with Rear View Camera System: Check license plate --> Vehicles with Rear View Camera
System: Check license plate
 Vehicle system test: Performing --> Vehicle system test: Perform
 Constant velocity joint boots: Visual inspection --> CV joint boots: Visual inspection
 Dust and pollen filter: Housing, cleaning and filter element, replacing --> Dust and pollen filter:
Cleaning housing and replacing filter insert
 Ribbed belt: Condition, checking --> Ribbed belt: Checking condition
 Fuel filter: Draining water --> Fuel filter: Drain water
 Fuel filter: Replacing (diesel engine) --> Fuel filter: Replacing (diesel engine)
 Compass in the roof module: Adjust compass zones --> Compass in the roof module: Adjust compass
zones
 Cooling system: Coolant level and freeze protection, checking --> Cooling system: Freeze protection
and coolant level, checking
 Air cleaner: Housing, cleaning and filter element, replacing --> Air cleaner: Cleaning housing and
replacing filter insert
 Engine oil level: Checking --> Engine oil level: Check

 Engine oil: Draining or extracting; changing oil filter and filling engine oil --> Engine oil: Draining or
extracting; changing oil filter and filling engine oil
 Upper engine cover: Removing and installing --> Upper engine cover: Removing and installing
 Engine cover -bottom- (noise insulation tray), removing and installing --> Engine cover -lower- (noise
insulation tray), removing and installing
 Engine and components in engine compartment (from above and below): Visual inspection for leaks and
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damage, performing --> Engine and components in engine compartment (from above and below):
Visual check for leaks and damage
 Break-down kit (tire mobility kit), checking --> Break-down kit (tire mobility kit): Checking
 Test drive, performing --> Perform test drive
 Wheel bolts: Tightening to correct torque setting --> Wheel bolts: Tighten to correct torque setting
 Tire pressure sensors, replacing --> Tire pressure sensors: Replacing

 Tire pressure values, storing --> Storing tire pressure values
 Power assisted steering: Oil level, checking --> Power assisted steering: Fluid level, checking
 Headlight adjustment: Checking --> Headlight adjustment: Check
 Sunroof: Checking function, cleaning and lubricating guide rails --> Sunroof: Checking function,
cleaning and lubricating guide rails
 Windshield wiper blades: Check park position, adjust if necessary --> Windshield wiper blades: Check
park position, adjust if necessary
 Windshield wash/wipe system and headlight wash system: check for function and damage, top off fluid if
necessary --> Windshield wash/wipe system and headlight wash system: check for function and
damage, top off fluid if necessary
 Service interval display: Resetting --> Service interval display: Reset
 Service interval display: Recording --> Service interval display: Recording

 Tie rod ends: Play, attachment, and sealing boots, checking --> Tie rod ends: Check play, security and
joint boots
 Door arrester: Lubricating --> Door arrester: Lubricate
 Underbody protection: Visual inspection for damage, performing --> Underbody protection: Perform
visual check for damage
 Setting time, language and units: On instrument cluster display --> Setting time, language and units:
On display of instrument cluster
 Camshaft drive toothed belt: Replacing (8-cyl. gasoline engines) --> Camshaft drive toothed belt:
Replacing (8-cyl. gasoline engine)
 Spark plugs: Replacing --> Spark plugs: Replacing
 Static cornering lights and automatic headlamps: Function, checking --> Static cornering lights and
automatic headlamps: Checking function
 Diesel particle filter: check soot load value --> Diesel particle filter: Check soot load value
TURBOCHARGER: LUBRICATE SERVO-MOTOR LINKAGE
Greasing the servo-motor linkage applies to:
 Remove engine cover -bottom- (noise insulation) --> Engine cover -lower- (noise insulation tray),
removing and installing.
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1. Lubricate linkage: Turbocharger servo motor -right engine side-
Fig. 22: Identifying Engine Block

Installed location: Wheel housing, front right, above the steering boot, between the front longitudinal member
and engine block - arrow A -.
Fig. 23: Lubricating Pivot Of Servo Motor Shaft & Linkage

 Lubricate the pivot of the servo motor shaft and linkage - arrows A - and - B - by hand.
Only use Hot Bolt Paste G 052 112 A3 .
2. Lubricate linkage: Turbocharger servo motor -left engine side-
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Fig. 24: Locating Turbocharger Servo Motor

Installed location: Front left, between the steering and housing of front final drive, above the coolant hoses -
arrow A -.
Fig. 25: Identifying Servo Motor Shaft & Linkage

 Lubricate the pivot of the servo motor shaft and linkage - arrows A - and - B - by hand.
Only use Hot Bolt Paste G 052 112 A3 .
BALL JOINTS: VISUAL INSPECTION
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Fig. 26: Identifying Ball Joint

 Check joint boots - arrow - of upper ball joints for leaks and damage.
Fig. 27: Identifying Joint Boots

 Check joint boots - arrow - of lower ball joints for leaks and damage.
AUTOMATIC TRANSMISSION: ATF LEVEL, CHECKING
 Work procedure: --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
BATTERY DISCONNECT RELAY: REMOVING
 The battery disconnect relay protects the battery from discharging through unnecessary electrical
components while transporting from manufacturing factory to dealer.
 The battery disconnect relay must be removed during the delivery inspection.
 Collect the removed battery disconnect relays and send them back to the manufacturer.
NOTE:  Invoicing notes and parts dispatch control can be found in the "Technical
Problem Solving" information source in ELSA:
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 HST (Technical Service Handbook)

 Technical Problem Solving
 Powertrain
Function
 Engine problems with starting behavior

 Engine does not start/transport protection active (2007439/4)
Work procedure:
The battery disconnect relay is located in the footwell, in front of the driver seat.
The battery disconnect relay is fastened to the ground connection for the battery negative terminal, in front of
the driver seat.
NOTE:  The battery under the driver seat is equipped with a battery isolation
system. Observe safety measures when working on battery isolation
system, Battery disconnect relay, removing and installing --> 27 -
BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
 Switch off ignition and all electrical consumers and remove ignition key.
If the trim under the driver seat has not yet been removed:
 Remove trim under drivers seat in order to disconnect battery --> 27 - BATTERY, STARTER,
GENERATOR, CRUISE CONTROL .
Fig. 28: Separating Connector

 Separate the connection - A - from the relay cable.
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Fig. 29: Pulling Foam Covering Over Connection Of Relay Cable

 Pull a foam covering - A - over the connection of the relay cable.

 Secure the foam covering with adhesive tape.
Fig. 30: Identifying Ground Cable & Battery Relay

 Unfasten the ground cable - 2 - from the battery disconnect relay - 1 -.
Fig. 31: Identifying Ground Cable & Ground Connection

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 Unfasten the battery disconnect relay retainer from the ground connection - B -.
 Set the ground cable onto the ground connection - A - and fasten the ground connection to 20 Nm.
NOTE:  Once the ground cable for the battery is reconnected: --> 27 - BATTERY,
STARTER, GENERATOR, CRUISE CONTROL .
Fig. 32: Identifying Route For Connector Relay Cable

 Route the connector with relay cable, to the indicated point - arrows -.
 Reinstall the trim under the driver seat.
Observe the work steps after connecting the battery, --> 27 - BATTERY, STARTER, GENERATOR,
CRUISE CONTROL .
 Perform a vehicle system test --> Vehicle system test: Perform.
BATTERY: CHECK BATTERY TERMINALS FOR SECURE SEATING
There are two different battery concepts with this vehicle:
Battery concepts --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Battery under front left seat: Check battery terminals for secure seating
 Switch off ignition and all electrical consumers and remove ignition key.
After waiting 60 seconds:
 Remove front and side trim on front left seat frame.

 Remove seat spindle covers.
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 Remove seat slide rail cover caps.
Fig. 33: Identifying Seat Slide Rail Bolts

 Remove bolts - arrows -.
Fig. 34: Identifying Seat Frame

 Tilt seat frame and seat to rear - arrow -.
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Fig. 35: Identifying Bolt & Air Duct

 Remove bolt - 1 - and remove air duct - 2 -.
Fig. 36: Identifying Box Clips

 Open battery box clips - arrows - and remove cover.
Fig. 37: Identifying Battery Ground Line & Battery Positive Line
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 By moving battery ground line - 1 - and battery positive line - 2 - back and forth, check whether battery
terminals are seated securely on battery poles.
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:
The following procedure must be strictly followed!
Battery under front left seat: Disconnecting
WARNING: To increase crash safety, the battery under front left seat is equipped with
a battery isolator. In an accident, the airbag control module triggers a
charge disconnecting the voltage supply wire to the starter. Battery
isolation is performed pyrotechnically, with a very small explosive charge.
To avoid accidentally triggering the charge when working on the battery
or the battery isolator, you must absolutely first disconnect the battery
Ground (GND) on the negative terminal of the battery.
NOTE:  The battery under the front left seat is equipped with a battery isolation
system. Observe safety precautions when working on the battery isolation
system --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL
 Remove battery ground line - 1 - from battery minus pole.
Battery under front left seat: Connecting
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Fig. 39: Torque Wrench V.A.G 1331

 V.A.G 1331 Torque wrench (5 -50 Nm)
 Tighten battery plus pole terminal bolt to 9 Nm.

 Only after securing positive terminal clamp - 2 - , connect negative wire - 1 - terminal clamp to negative
terminal on battery.
 Tighten battery minus pole terminal bolt to 9 Nm.
 Reinstall cover.
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Fig. 41: Identifying Seat Frame Mounting Bolts

 Replace seat frame mounting bolts - arrows - and tighten them to a torque of 45 Nm.
NOTE:  Once the battery is reconnected: --> 27 - BATTERY, STARTER,

GENERATOR, CRUISE CONTROL
If the battery clamp on negative terminal is not seated securely:

Battery under front left seat: Tightening battery terminal on negative terminal
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 Tighten battery connection - 1 - on battery minus pole to 9 Nm.

 Reinstall cover.
Fig. 44: Identifying Seat Slide Rail Bolts

 Replace seat frame mounting bolts - arrows - and tighten them to a torque of 45 Nm.

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Second battery in luggage compartment: Check battery terminals for secure seating
Perform the following work procedure:
Fig. 45: Identifying Luggage Compartment Floor Cover & Secure With Stay Rod
 Open luggage compartment floor cover - 2 - and secure with stay rod - 1 -.
Fig. 46: Identifying Retaining Strap Anchors

 Remove retaining strap anchors - arrows - and remove battery cover along with retaining straps.
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Fig. 47: Identifying Battery Positive Wire & Battery Ground (GND) Wire
 Check battery terminal clamps are seated securely on the battery terminals by moving the battery positive
wire - 1 - and the battery Ground (GND) 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.
NOTE:  The following procedure must be strictly followed!

 If the sequence is not adhered to the pyrotechnic isolation system for the
battery may trigger which may damage electrical components in the
vehicle.
If the battery connection on positive terminal is not seated securely:
Fig. 48: Identifying Battery Connection On Positive & Negative Terminal

 First disconnect battery ground strap - arrow - on battery minus pole.
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Fig. 49: Identifying Battery Plus Pole Connection Bolt

 Then disconnect battery positive line - arrow - on battery plus pole.
Second battery in luggage compartment: Connecting

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Fig. 51: Identifying Battery Plus Pole Connection Bolt

 Tighten battery plus pole connection bolt - arrow - to 9 Nm.
Fig. 52: Identifying Battery Connection On Negative Terminal

 Only after securing positive terminal clamp, fit negative terminal clamp - arrow - to negative terminal on
battery.
 Tighten battery plus pole connection bolt - arrow - to 9 Nm.

If the battery clamp on negative terminal is not seated securely:
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Fig. 53: Identifying Battery Positive Wire & Battery Ground (GND) Wire
 Tighten battery connection - 2 - on battery minus pole to 9 Nm.

 Re-install battery cover.
 Close cover in luggage compartment floor.

BATTERIES: CHECK
 Check the battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
CHECKING TIRES: TIRE CONDITION, WEAR PATTERN, INFLATION PRESSURE AND TREAD
DEPTH
NOTE:  On vehicles with tire pressure monitor (TPM), the new tire pressures must
be adapted --> Storing tire pressure values.
WARNING:  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.
Tire condition, checking
At the delivery inspection:
 Check tire tread and side walls for damage, if necessary remove any foreign bodies, such as nails or
screws.
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WARNING: If damage is discovered, the tire must be examined to determine whether

a new one must be installed.
Inspection Service:
 Check tire tread and side walls for damage, if necessary remove any foreign bodies, such as nails or
screws.
 Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.
WARNING: The customer must be informed of malfunctions found.
Checking tire wear pattern
NOTE:  The wear pattern of the front wheels can be used to assess whether a
check of the track and camber is necessary:
Causes:
 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: Checking (including spare wheel):
 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 positioned at intervals around
the tire.
 If the tread depth is approaching the legal minimum permissible depth, the
customer must be informed.
Tire pressure: Check, if necessary correct
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Fig. 54: Tire Filling Unit VAS 5216

 Tire filling unit VAS 5216
NOTE:  Observe that the inflation pressure specifications refer to the air pressure
of cold tires. Do not reduce increased pressures on warm tires.
 Important information about recommended winter tires can be found in -->
44 - WHEELS, TIRES, WHEEL ALIGNMENT .
 Inflation pressure specifications can be found on a sticker located on the
driver door at the door jamb.
 Pressures are indicated in "BAR and PSI" !
 Pressures apply to all factory-installed mounted tire sizes!
 Check the tire size used on the vehicle with the sizes in the table and correct tire pressure regardless of
engine type.
Tire pressure values

Half load Full load
Tire sizes Front (bar/psi) Rear (bar/psi) Front (bar/psi) Rear (bar/psi)
235/70 R 16 2.4/34 2.5/36 2.4/34 2.9/42
235/65 R 17 2.5/36 2.6/38 2.6/38 3.0/44
255/60 R 17 2.5/36 2.6/38 2.5/36 3.0/44
235/60 R 18 2.7/39 2.7/39 2.9/42 3.2/46
255/55 R 18 2.6/38 2.9/42 2.8/39 3.1/45
255/50 R 19 2.8/39 3.0/44 3.0/44 3.4/49
275/45 R 19 2.7/39 3.0/44 2.8/39 3.2/46
275/40 R 20 2.8/39 3.0/44 3.0/44 3.4/49
295/35 R 21 2.7/39 2.9/42 2.8/39 3.4/49
Spare wheel
(collapsible spare
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wheel)
195/80 17 3.5/51 3.5/51 3.5/51 3.5/51
195/75 18 3.5/51 3.5/51 3.5/51 3.5/51
FRONT AND REAR BRAKE PADS: CHECKING THICKNESS
Fig. 55: Pliers VAS 3314

 Pliers 3314
Fig. 56: Torque Wrench V.A.G. 1332

 Torque wrench (40 -200 Nm) V.A.G 1332/

 Electric flashlight and mirror
NOTE:  The adapter to loosen/tighten the anti-theft wheel bolts is located with the
vehicle tool kit.
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Front disc brake pads:
 For better judgement of remaining pad thickness remove the front wheel on the drivers side.
 Remove wheel bolt caps using Pliers 3314 if necessary.
Fig. 57: Identifying Thickness Of Inner And Outer Pad

 Mark position of wheel in relation to brake disc.

 Unbolt wheel securing bolts and remove wheel.
 Measure inner and outer pad thickness.
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 discs for wear --> 46 - BRAKES - MECHANICAL COMPONENTS

 Install wheel to marked position.
 Tighten wheel securing bolts, using diagonal sequence to following tightening torque:
Tightening torque: 180 Nm
 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.

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Fig. 58: Identifying Thickness Of Inner Pad

 Determine thickness of outer pad by checking visually.

 Illuminate inner pad using an electric flashlight and mirror.
 Determine thickness of inner pad by checking visually.
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 discs for wear --> 46 - BRAKES - MECHANICAL COMPONENTS
BRAKE SYSTEM: VISUAL CHECK FOR LEAKS AND DAMAGE
Check the following components for leaks and damage:
 Brake master cylinder

 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.
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WARNING: Malfunctions found must be rectified (repair measure).
BRAKE FLUID: CHANGING
Notes on application and safety, --> Notes on application and safety precaution.
Specification of brake fluid, --> Specification of brake fluid.
Work procedure, changing brake fluid, --> 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.
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.
 Do not reuse, (used) extracted brake fluid.

 Observe waste disposal regulations!
Specification of brake fluid
Permitted brake fluid specifications
 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).
Work procedure, changing brake fluid
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Fig. 59: VAS 5234 Brake Filler And Bleeder Unit

 Brake charger/bleeder unit VAS 5234
Fig. 60: Identifying Securing Bolts For Cover

 Release securing bolts - 1 - and - 2 - and remove cover upward.
Fig. 61: Removing/Installing Brake Fluid Reservoir Cap

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 Remove brake fluid reservoir cap - 1 -.

 Extract as much brake fluid as possible using suction hose from brake charger/bleeder unit VAS 5234 or
from V.A.G 1869 or using a suction bottle with built-in strainer.
NOTE:  After extracting, observe that no further brake fluid runs into the reservoir
(the brake fluid level in the reservoir must align with the lower edge of the
strainer).
WARNING: Do not reuse, (used) extracted brake fluid.
 Brake pedal depressor Install V.A.G 1869/2 between drivers seat and brake pedal and apply tension.
 Screw adapter onto brake fluid reservoir.
Vehicles with manual transmission
Procedure for changing brake fluid in clutch system
Continue for all vehicles
 Connect filler hose of VAS 5234 or V.A.G 1869 to adapter.

 Pull cover caps off bleeder screws of brake calipers.
 Connect bleeder hose of collector bottle to rear bleeder screw * See footnote , open bleeder screw, and
allow the corresponding quantity to flow out (see table below). Close bleeder screw.
NOTE:  Use a suitable bleed hose. It must seat tightly on bleed screw so that no
air can enter brake system.
*Bleed rear right first
Repeat work sequence on other side of vehicle at rear.
NOTE:  Front brake calipers with two valves, first connect the inner bleeder valve
then connect the outer valve.
 Connect the collecting bottle bleeder hose to the front bleeder screw * See footnote . Open bleeder screw
and let the corresponding amount of brake fluid (see SEQUENCE/BRAKE FLUID QUANTITY) flow
out. Close bleeder screw.
*Bleed front right first
Repeat work sequence on other side of vehicle at front.
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SEQUENCE/BRAKE FLUID QUANTITY

Sequence: Clutch slave cylinder, wheel brake Quantity of brake fluid that must flow out:
cylinder, brake caliper
Clutch slave cylinder bleeder valve 0.15 liter
Right rear 0.25 liter
Left rear 0.25 liter
Right front 0.25 liter
Left front 0.25 liter
Total quantity: approx. 1.15 liter
 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. 62: Removing/Installing Brake Fluid Reservoir Cap

 Check brake fluid level and correct if necessary.

 Reinstall brake fluid reservoir cover - 1 -.
 Re-install cover.
 Remove brake pedal depressor.
 Check pedal pressure and brake pedal free play. Free play: Max. 1/3 of pedal travel
BRAKE FLUID LEVEL (DEPENDING ON BRAKE PAD WEAR): CHECK
Notes on application and safety, --> Notes on application and safety precaution.
Specification of brake fluid, --> Specification of brake fluid.
Work procedure, brake fluid level (depending on brake pad wear): Checking --> Work procedure, brake fluid
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level (depending on brake pad wear): Check.
Work procedure, brake fluid level (depending on brake pad wear): Check
Fig. 63: Identifying Securing Bolts For Cover

 Release securing bolts - 1 - and - 2 - and remove cover upward.
Note the following:
Fig. 64: Identifying Brake Fluid Min/Max Level

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:
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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.
Fig. 65: Identifying Brake Fluid Min/Max Level

 Recommended brake fluid level when brake pad wear limit has almost been reached:
"At MIN marking and slightly above" - 2 - : "TOPPING OFF NOT NECESSARY".
 Recommended brake fluid level, if brake pads are new or are far from the brake pad wear limit:
"Between MIN- and MAX-Marking".
WARNING: If fluid level is below MIN. marking - 2 - , brake system must be checked
before brake fluid is added "repair measure".
DIESEL PARTICLE FILTER: REPLACING
Installation location of diesel particle filter, see vehicle underbody.
 Diesel particle filter, removing and installing -->

 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE
MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
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NOTE:  Each time the diesel particle filter is changed, the soot load measurement
adaptation must be set to 0.
DIESEL PARTICLE FILER SOOT LOAD MEASUREMENT: CHECKING
NOTE:  Soot load measurement gives information about the filling level of the
particle filter.
 Only applies to vehicles with diesel particle filter and additive system.
 Connect diagnostic tester --> Diagnostic unit, connecting.

 Touch button/field on screen: "GUIDED FUNCTIONS" on screen.
If the indications shown in the work procedure are not indicated on the display: User manual for VAS5051
tester
 Press " >" button to confirm.

 Select in succession:
 Brand
 Model
 Model year
 Engine Code
 Confirm vehicle identification.

 Press "jump" button.
 Press "Function/component selection".
 Select "powertrain".
 Press "Engine code".

 Press "01 - Systems capable of On Board Diagnostic (OBD)".
 Select "Diesel direct injection and glow plug system"
 Press "Functions "
 Select "Function or component".

 Select "soot load measurement".
NOTE:  If the limit value is reached, replace diesel particle filter --> Diesel particle
filter: Replacing.
 Replacing the diesel particle filter is a repair measure.
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 End the operating mode Guided functions.

 Turn off ignition and disconnect diagnostic connection.
ELECTRIC WINDOWS: CHECK POSITIONING
WARNING: After disconnecting and connecting the battery (in luggage compartment
and/or under front left seat) the excess force limitation of electric
windows does not function. This can cause serious injuries if e.g. fingers
are caught in the window!
NOTE:  After disconnecting and connecting the vehicle battery (in luggage
compartment and/or under front left seat) the automatic opening and
closing features for the electric windows do 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.
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.
 Close all doors and windows completely.

 Open front left side window fully by pressing and holding the button in the drivers door.
 Close the front left side window fully by lifting and holding the button in the drivers door, then release
button.
 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.
VEHICLES WITH REAR VIEW CAMERA SYSTEM: CHECK LICENSE PLATE
NOTE:  In vehicles with Rear View Camera System, it is not permitted to install an
additional license plate holder or an additional license plate base. For
additional information, see --> 94 - LIGHTS, SWITCHES - EXTERIOR .
VEHICLE SYSTEM TEST: PERFORM

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 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 and to prevent
a second vehicle identification on the tester.
 To do so, press operating mode button and then Guided Functions.
 Refer to the corresponding work descriptions for the continued sequence.
 In order to return to Guided Fault Finding, press the operating mode
button and then Guided Fault Finding.
WARNING: 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.
The window that now appears confirms that all sporadic faults were cleared.
Then the diagnostic protocol is sent "online" or stored on the tester.
NOTE:  If tester is not connected to the network, diagnostic protocol is stored and
the transmission follows as soon as tester is connected to the network.
 Protocols that have been stored and are older than four days are erased
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automatically.
Vehicle system test is completed.
CV JOINT BOOTS: VISUAL INSPECTION
Fig. 66: Identifying CV Joint Boots

 Check outer and inner CV joint boots - arrows - for leaks and damage.
NOTE:  Also check the CV joint boots at the rear axle.
DUST AND POLLEN FILTER: CLEANING HOUSING AND REPLACING FILTER INSERT
Removing:
 Remove cover under glove compartment in passenger footwell --> 68 - INTERIOR EQUIPMENT .
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Fig. 67: Identifying Screws & Filter Element

 Remove screws - 1 - and take out filter element - 2 - downward.
NOTE:  Observe installed position of filter element.

Installing:
 Insert new filter.

 Re-install cover.
RIBBED BELT: CHECKING CONDITION
 Remove engine cover if necessary
Fig. 68: Identifying Ribbed Belt

 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)
 Traces of oil and grease
 Install engine cover

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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.
FUEL FILTER: DRAIN WATER
Fuel filter, draining water (10-cyl. diesel engines)
Fig. 69: Identifying Suction Pump VAS 5226

 Suction pump VAS 5226
Fig. 70: Identifying Suction Pump Hose

 Insert hose of suction pump VAS 5226 , with a suitable adapter, into the hole for water extraction - arrow
-.
 Extract about 100 ml of diesel fuel using the suction pump VAS 5226.
 Replace the seal of the water extraction plug.
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 Tighten water extraction plug to 3 Nm.
FUEL FILTER: REPLACING (DIESEL ENGINE)
Replace fuel filter: 10-cyl. diesel engines --> Replace fuel filter: 10-cyl. diesel engines.
Replace fuel filter: 10-cyl. diesel engines
NOTE:  There are two different fuel filter systems.

 In system 1, the fuel filter is located on the engine, under the engine cover.
 In system 2, the fuel filter is located to the left in the engine compartment,
on the strut tower.
Fig. 71: Identifying Suction Pump VAS 5226

 Suction pump VAS 5226
Remove engine cover --> Upper engine cover: Removing and installing.
Removing:
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Fig. 72: Identifying Suction Pump Hose

 Remove plug - arrow - from fuel filter housing water drain connector.
 Extract diesel fuel via water drain connection located on the side of the fuel filter housing - arrow - using
V.A.G 1390 and V.A.G 1390/1.
 Seal off oil plug again and tighten to 3 Nm.
Fig. 73: Identifying Mounting Bolts

Remove pipe connectors for fuel lines
 Remove screws - arrows - along with connection lines to fuel filter housing
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Fig. 74: Identifying Fuel Filter Cover Screws

Remove fuel filter cover:
 Remove screws - arrow - for fuel filter housing and remove cover
Fig. 75: Identifying Fuel Filters & Cover

 Remove fuel filters - 3 - from cover - 1 -
NOTE:  Observe waste disposal regulations!
Installing:
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Fig. 76: Identifying Fuel Filters & Cover

 Install new fuel filters - 3 - and replace seal - 2 -

 Install fuel filter cover - 1 -.
Fig. 77: Identifying Fuel Filter Cover Screws

 Tighten screws - arrows - for fuel filter cover (8 Nm)
Fig. 78: Identifying Mounting Bolts

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 Install pipe connectors for fuel lines.
NOTE:  Replace seal between fuel filter cover and fuel hose connections.
 Tighten bolts - arrows - to 8 Nm.
Fuel system, bleeding
In order to ensure engine starts immediately after changing fuel filter, fuel system must be bled with diagnostic
tester.

 Select "Guided Functions".
 Perform vehicle identification.
 Select "Bleed Fuel System".

 Follow the instructions on the diagnostic tester.
 After bleeding, exit "Guided Functions" with Exit button.
COMPASS IN THE ROOF MODULE: ADJUST COMPASS ZONES
The compass indicates the direction vehicle is facing.
For a correct reading, the correct compass zone must be adjusted.
Adjust compass settings
 Determine your geographical location on the zone map
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Fig. 79: Zone Map

Fig. 80: Identifying Compass Roof Module

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 With ignition switched on press button - 3 -

 Select with the function keys - 2 - in the display - 1 - the symbol "N" and confirm OK
 Select the function keys - 2 - the selected zone between "1 and 15" and confirm OK in order to adjust the
compass zone.
The selected zone is stored, the compass reading appears in the display.
COOLING SYSTEM: FREEZE PROTECTION AND COOLANT LEVEL, CHECKING
Fig. 81: Refractometer T10007

 Refractometer T10007
Fig. 82: Cooling System Filler Unit VAS 6096

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 Cooling system charge unit VAS 6096
Fig. 83: Adapter VAG 1274/8

 Adapter V.A.G 1274/8
NOTE:  All engines are filled with coolant additive G 12 Plus conforming 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 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 -25°C [-25°C]) and should not exceed 60% (freeze protection
to -40°C [-40°C]). Otherwise the freeze protection will be reduced and the
cooling efficiency will be worsened.
 Freeze protection must be guaranteed to approx. -25°C (approx. -35°C in
countries with an arctic climate).
Checking freeze protection and adding coolant additive if necessary
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Check freeze protection:
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. 85: Identifying Refractometer Scales

The scale - 1 - of the refractometer refers to the coolant additives -G 12- , -G 12 Plus- and -G 11-.
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Scale - 2 - refers only to coolant additive G 13. (previously L80)
 If freeze protection ratio is too low, drain listed amount and replace it with coolant additive G 12 Plus
conforming to TL "VW 774 F".
Freeze protection table
Freeze protection to °C Difference amount in liters

Actual value Specified value 5-cyl. engine 5-cyl. engine * 6-cyl. engine 6-cyl. engine *
See footnote See footnote
0 -25 3.5 5.5 4.0 6.0

-35 4.0 7.0 4.5 7.5
-5 -25 3.0 4.5 3.5 5.0
-35 3.5 6.0 4.0 6.5
-10 -25 2.0 3.5 2.5 4.0
-35 3.0 5.0 3.5 5.5
-15 -25 1.5 2.5 2.0 3.0
-35 2.5 4.0 3.0 4.5
-20 -25 1.0 2.0 1.0 2.0
-35 2.0 3.5 2.0 3.5
-25 -35 1.5 2.0 1.5 2.0
-30 -35 1.0 1.5 1.0 1.5
-35 -40 0.5 1.0 0.5 1.0
* Models with 2 heat exchangers
Freeze protection to °C Difference amount in liters

Actual value Specified value 8-cyl. engine 8-cyl. engine * 10 and 12-cyl. 10 and 12-cyl.
See footnote engine engine * See
footnote
0 -25 5.0 8.0 5.0 8,0

-35 6.0 10.0 6.0 10.0
-5 -25 4.5 7.0 4.5 7.0
-35 5.5 9.0 5.5 9.0
-10 -25 3.5 6.0 3.5 6.0
-35 4.5 8,0 4.5 8.0
-15 -25 2.5 4.0 2.5 4.0
-35 3.5 6.0 3.5 6.0
-20 -25 1.5 3.0 1.5 3.0
-35 2.5 4.5 2.5 4.5
-25 -35 1.5 2.5 1.5 2.5
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-30 -35 1.0 2.0 1.0 2.0

-35 -40 0.5 1.5 0.5 1.5
* Models with 2 heat exchangers
Mixture ratio:
Freeze protection to Coolant additive G 12 Plus Water

-25°C approx. 40% approx. 60 %
-35°C approx. 50 % approx. 50 %
-40°F approx. 60 % approx. 40%
 Check coolant additive concentration after test drive again.
Checking coolant level and adding coolant if necessary
Fig. 86: Identifying Cap For Coolant Expansion Tank

Check coolant level in expansion tank with engine cold.
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Fig. 87: Identifying Min/Max Marks Within Filler Range

 Unscrew cap - 1 - from expansion tank.
 Delivery inspection: Coolant level at max. marking.

 Inspection service: Coolant level between min. and max. marking.
 If coolant is too low, add required amount according to mixture ratio.
NOTE:  Small quantities of coolant can be refilled When larger quantities of

coolant are needed when filling, Cooling system filling equipment VAS
6096 should be used.
Follow operating instructions for cooling system charge unit VAS 6096.
NOTE:  Determine cause of fluid loss which cannot be attributed to normal use
and rectify (repair measure).
 Checking coolant level and adding coolant if necessary
NOTE:  Coolant additive -G 12- Plus prevents freezing and corrosion damage,
scaling and also raises boiling point of coolant. 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: CLEANING HOUSING AND REPLACING FILTER INSERT
Microsoft
NOTE:  Vehicles with 6 cylinder engines are equipped with an air filter.
 Vehicles with 8, 10 cylinder engines have two air filters in the engine
compartment.
Air filter element, removing and installing on 10-cyl. diesel engines --> Air filter element, 10-cyl. diesel
engines, removing and installing:.
Air filter element, removing and installing 6-, 8-cyl. gasoline engines --> Air filter element, 6-, 8-cyl. gasoline
engines, removing and installing:.
Air filter element, 10-cyl. diesel engines, removing and installing:
Removing
NOTE:  The following describes removing and installing the left air filter insert.
Removing and installing the right air filter insert is performed in the same
way.
Fig. 88: Identifying Air Filter Housing Fasteners

 Open snap fasteners - 1 -.

 Remove intake hose securing pins - 2 -.
Remove intake hose securing pins:

Microsoft
Fig. 89: Turning Pin Far Enough That Marking Point Aligns With Mark On Air Cleaner Housing
 Turn pin far enough that marking point - 1 - aligns with mark on air cleaner housing - 3 -.
 Pull out securing pin upward.
 Pull off intake hose.
Fig. 90: Identifying Line Connection & Air Filter Housing

 Disconnect line connection at air filter housing - arrow - as follows:
Microsoft
Fig. 91: Identifying Sealing Ring, Line Flange, Securing Sleeve, And Air Filter Connection
 Press off locking ring - 1 - using a screwdriver - C - from line flange - 3 -.

 Press securing sleeve - 2 - in direction of arrow and at the same time disconnect line - A - from line - B -.
 Remove upper part of air filter housing upward.
NOTE:  Observe installation position of air filter
Fig. 92: Identifying Air Filter Element

 Remove air filter insert - A -.

 Clean air cleaner housing if necessary using compressed air and install new air filter element.
Installing
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 Insert air filter insert - A -.
NOTE:  Make sure sealing surfaces on air filter housing are correctly positioned.
 Make sure that no cables or lines are pinched.
Fig. 94: Identifying Air Filter Housing Fasteners

 Secure air filter housing again using fasteners - 1 -.
Microsoft
Fig. 95: Identifying Reconnect Line

 Reconnect line - arrow -.
 Then press locking ring - 1 - on line flange - 3 - so that it engages audibly.

 Install intake hose.
Install intake hose securing pins as follows:
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Fig. 97: Inserting Securing Pins So Mark On Pin And Mark On Air Cleaner Housing Align
 Insert securing pins so that the mark on the pin - 1 - and the mark on the air cleaner housing - 2 - align.
 Install engine cover.
Air filter element, 6-, 8-cyl. gasoline engines, removing and installing:
Removing
Remove engine cover if necessary --> Upper engine cover: Removing and installing.
 Loosen coolant hose from clamps.
Fig. 98: Identifying Clamps, Throttle Valve Control Module Connector & Bolts
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 Open clamps - 1 -.
 Disconnect connector - 3 - of throttle valve control module.
 Remove bolts - 2 - of throttle valve control module.
Fig. 99: Identifying Line Connector At Air Filter Housing

 Disconnect line connections at air filter housing - arrow - as follows:
 On the rear line, press off locking ring - 1 - using a screwdriver - C - from line flange - 3 -.
 Press securing sleeve - 2 - in direction of arrow and at the same time disconnect line - A - from line - B -.
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Fig. 101: Compressing Securing Ring At Front Line And Disconnecting Line From Air Filter Housing
 Compress the securing ring - B - at the front line and disconnect line - A - from air filter housing.
 Remove air filter housing part upward.
NOTE:  Observe installation position of air filter

 Remove air filter element - A -

 Clean air cleaner housing if necessary using compressed air and install new air filter element.
Installing
 Insert air filter insert.
NOTE:  Make sure sealing surfaces on air filter housing are correctly positioned.
 Make sure that no cables or lines are pinched.
Microsoft
Fig. 103: Identifying Clamps, Throttle Valve Control Module Connector & Bolts
 Secure air filter housing again using fasteners - 1 -.

 Bolt on throttle valve control module - 2 - again and tighten to 3 Nm.
 Connect connector - 3 -.
 Reconnect line - arrow -.

 Then press locking ring - 1 - on line flange - 3 - so that it engages audibly.
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Fig. 105: Re-Connecting Line

 Re-connect line - A - until it engages.

 Clip coolant hose back into clamps.
 Install engine cover.
ENGINE OIL LEVEL: CHECK
Note the following:
 After stopping engine, wait at least 3 minutes to allow oil to flow back into oil pan.
 Remove dipstick and wipe with clean rag. Replace dipstick and push down to stop.
 Pull out dipstick again and read oil level.
Fig. 106: Identifying Various Oil Dipsticks

If the dipstick appears as illustrated:

Microsoft
-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 --> Service
tables.
ENGINE OIL: DRAINING OR EXTRACTING; CHANGING OIL FILTER AND FILLING ENGINE
OIL
Engine oil capacities: -->
 17 - ENGINE - LUBRICATION for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION

IGNITION, ENGINE CODES: BAA, BMX
 17 - ENGINE - LUBRICATION for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION
IGNITION, ENGINE CODES: BHL, BHK
 17 - ENGINE - LUBRICATION for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION
IGNITION, ENGINE CODE(S): BAR
 17 - ENGINE - LUBRICATION for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION
IGNITION, ENGINE CODE(S): AXQ, BHX
 17 - ENGINE - LUBRICATION for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL
INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
or in Fluid Capacity Charts.
Engine oil, draining or extracting, * See footnote --> Engine oil, draining or extracting.
Oil filter, replacing --> Oil filter, replacing.
Engine oil, filling --> Filling engine oil.
*It is not permitted to siphon engine oil from V8-cylinder engine.
Engine oil, draining or extracting
WARNING:  On engines with standing oil filter module, oil filter should be
changed before the oil change --> Oil filter, replacing. Removing the
filter element will open a valve and oil in the filter housing will flow
automatically into the crankshaft housing.
 It is not permitted to siphon engine oil from V8-cylinder engine.
Microsoft
 The oil drain plug is equipped with a permanent seal, therefore the
oil drain plug must always be replaced.
Fig. 107: Identifying Old Oil Collecting And Extracting Device V.A.G 1782
 Extract engine oil using old oil collecting and extracting unit V.A.G 1782.
or
 Remove oil drain plug

 Drain engine oil.
 Screw in the new oil drain plug hand-tight and then fasten to the specified torque.
 Fill up with engine oil, specification --> Service tables.
Tightening torque:
 Oil drain plug M14: 30 Nm

 Oil drain plug M24: 50 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
Oil filter, replacing (6-cyl. gasoline engine) --> Oil filter, 6-cylinder gasoline engine, replacing.
Oil filter, replacing (8-cyl. gasoline engine) --> Oil filter, replacing (8-cyl. gasoline engine with engine code
Microsoft
AXQ and BHX).
Oil filter, replacing (10-cyl. diesel engine) --> Oil filter, replacing (10-cyl. diesel engine).
Oil filter, replacing (8-cyl. gasoline engine with engine code AXQ and BHX)
Removing
Fig. 108: Identifying Oil Drain Plug & Filter


 Oil new O-rings before installation.
 Unscrew oil drain plug - 1 - of screw cap and drain oil.

 Loosen filter lower part - 2 - on hexagon - 1 - or on circumference and remove.
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Fig. 109: Oil Filter Housing Components

 Clean sealing surfaces at cap and at oil filter housing.

 Install oil filter - 5 -
Installing
 Install cap - 3 - with new O-ring - 4 - and tighten to 25 Nm.

 Install new sealing ring - 2 - for oil drain plug - 1 - and tighten to 10 Nm.
Oil filter, replacing (8-cyl. gasoline engine with engine code BAR)
 Socket insert SW 32.
Removing

 Cover area surrounding oil filter cover, e.g. with Oil absorbent cloth VAS 6204/1.
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Fig. 110: Identifying Sealing Cap

 Loosen the sealing cap - arrow - using a socket wrench 32 mm.

 Remove the sealing cap together with the oil filter element.
Fig. 111: Identifying Filter Component, Cover, And O-Rings

 Separate the oil filter element - 3 - from the sealing cap - 1 -.

Installing
 Replace the oil filter element - 3 -.

 Install sealing cap - 1 - with new O-rings - 2 - and - 4 - and tighten to 35 Nm.
Microsoft
Installation is reverse of removal.
Oil filter, replacing (10-cyl. diesel engine)
Removing

 Cover engine with a cloth.
Fig. 112: Oil Filter Wrench T10192

 Unscrew oil filter housing cap from filter housing using tool T10192.
Fig. 113: Remove/Installing Oil Filter Components

 Install oil filter - 3 -

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Installing
 Install cap - 1 - with new O-rings - 2 - and - 4 - and tighten to 25 Nm.
Oil filter, 6-cylinder gasoline engine, replacing

 Avoid engine oil drips on components in engine compartment.
Fig. 114: Identifying Oil Drain Plug & Lower Part Filter
 Unscrew oil drain plug - 1 - of screw cap and drain oil.

 Loosen filter lower part - 2 - on hexagon - 1 - or on circumference and remove.
Installing
Fig. 115: Remove/Install Oil Filter Components

Microsoft
 Replace the filter element - 4 - and the seal - 3 -.

 Install cap - 2 - with new O-ring and tighten to 25 Nm.
 Install oil drain plug - 1 - with new seal and tighten to 10 Nm.
Filling engine oil
Oil specifications, see --> Service tables.
General notes
 After topping off with oil wait at least 3 minutes then check oil level.
 Pull out oil dipstick and wipe with clean rag. Replace dipstick and push down to stop.
Fig. 116: Identifying Various Oil Dipsticks

 Pull out dipstick again and read oil level.
If the dipstick appears as illustrated:
-A- Oil must not be topped off.

-B- Oil can be topped off. This will cause the oil level to
be in area - A -.
-C- Oil must be topped off. It is sufficient when oil level
is in area - B - (grooved field).
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 -.
Microsoft
UPPER ENGINE COVER: REMOVING AND INSTALLING
Side engine compartment cover
Remove right engine cover as follows:
Fig. 117: Identifying Engine Cover

 Pry off cover - 2 -.

 Remove engine cover from catches - arrows - and remove it upward.
Middle engine compartment cover for 6-cyl. gasoline engine
Fig. 118: Identifying Engine Compartment Covers

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 Unclip engine compartment covers - 1 - and - 2 - and remove upward and off.
WARNING:  To install engine cover or to engage at mounting points, be sure not

to strike the engine cover with a fist or tool, danger of damage.
Middle engine compartment cover for 10-cyl. diesel engine
Removing:
Fig. 119: Identifying Dipstick, Cover, & Catches

 Remove oil dipstick - 2 -.

 Unclip cover - 1 - from catches - arrows - and remove upward.
Installing:
 Set engine cover - 1 - onto fastening points - arrows - and press it on, until it engages.
 Do not forget oil dipstick - 2 -.
WARNING:  Make sure to not strike the engine cover with a fist or a tool when
installing the engine cover and engaging the fastening points, there
is the risk of damage.
ENGINE COVER -LOWER- (NOISE INSULATION TRAY), REMOVING AND INSTALLING
NOTE:  On some vehicle equipment versions, the engine compartment is

equipped with an additional underbody impact guard from below.
 Underbody protection, removing and installing --> 50 - BODY, FRONT .
Front sound insulation cover:
Microsoft
NOTE:  In the illustration, the fittings on the left hand side of the sound insulation
is located in front. The fittings on the right-hand side are similar.
 For removing the sound insulation cover, screws must be removed.
Fig. 120: Identifying Screws

 Remove screws - 1 - and - 2 -
Noise insulation, front and rear:
Fig. 121: Noise Insulation, Front And Rear

 Remove bolts - A -.
 First, remove sound insulation - 3 -
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 Remove screws - B -.
 Remove the rear sound insulation - 2 - out of the spring latches - 1 -.
 Tighten bolts to torque of 8 Nm.
ENGINE AND COMPONENTS IN ENGINE COMPARTMENT (FROM ABOVE AND BELOW):

VISUAL CHECK FOR LEAKS AND DAMAGE
Perform visual check as follows:
 Check engine and components in engine compartment for leaks and damage.
 Check hoses, pipes and connections of
 Fuel system
 Cooling and heating system
 Oil circuit
 Air conditioning
 Intake system
 And brake system
For leaks, abrasions, porosity and brittleness.
WARNING: 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)
BREAK-DOWN KIT (TIRE MOBILITY KIT): CHECKING
Fig. 122: Locating Break-Down Set

Microsoft
Break-down set is located in spare wheel well - arrow -.
Break-down set contains a tire inflation cylinder with sealant next to the compressor.
NOTE:  The tire sealant in the bottle has a limited shelf-life.

 Therefore, on the bottle, the expiration date - arrow - is displayed.
Fig. 123: Tire Inflation Cylinder With Sealant and Expiration Date
In this example, the expiration date 05/2003 has passed, and the bottle must then be replaced.
 Verify the expiration date.

 Replace tire sealant, if expiration date has been reached.
WARNING:  Tire sealant must not be older than 4 years.

 If the bottle was opened, e.g. if a tire went flat, is must 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.
Dispose of tire sealant according legal requirements.
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:
Microsoft
 Engine: Output, misfiring, idling speed, acceleration

 Clutch: Pulling away, pedal pressure, odors
 Gear selection: Ease of operation, shift lever position
 Automatic transmission: Selector lever position, shift lock/ignition key interlock, shift behavior, display
in instrument cluster
 Foot brake: Function, free travel and effectiveness, pulling to one side, juddering, squeal
 Parking brake: At most after 5-7 notches for effective parking on the street. 2-3 notches of free travel on
operating lever before start of braking.
 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, SCV, interference
 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 BOLTS: TIGHTEN TO CORRECT TORQUE SETTING
Fig. 124: Torque Wrench V.A.G. 1332

 Torque wrench V.A.G 1332/
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Fig. 125: Master Wheel Bolt Key Set T10101

 Master wheel bolt key set T10101
The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.
NOTE:  Be sure to tighten wheel bolts in diagonal sequence to the following

specified torque:
Tightening torque: 180 Nm
TIRE PRESSURE SENSORS: REPLACING
NOTE:  Tire pressure sensor is located on inside of disc wheel or rim.

 For removal and installation of tire pressure sensor, wheel and tire must
be separated.
 Work procedure, removing and installing tire pressure sensor --> 44 - WHEELS, TIRES, WHEEL
ALIGNMENT
STORING TIRE PRESSURE VALUES
 Correct tire pressure set --> Checking tires: Tire condition, wear pattern, inflation pressure and
tread depth
 Tires must be cold
Microsoft
Fig. 126: Identifying Menu Selection Button & Thumb Wheel

 Press button - 1 - to show menu selection in instrument cluster display.

 Select menu item "tire pressure" using thumb wheel - 2 -.
Fig. 127: Identifying Menu Display

When the menu item "tire pressure" is selected in display - 1 - confirm the menu item by pressing the thumb
wheel.
 In the sub-menu "Tire pressure monitor" , turn the thumb wheel until the position "Store" is marked on
the display - 1 - and save the current inflation pressure by pressing the thumb wheel.
 Then drive vehicle continuously for approx. 8-10 minutes.
POWER ASSISTED STEERING: FLUID LEVEL, CHECKING
Fluid, when cold
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Fig. 128: Identifying Reservoir Cap

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

 Remove reservoir cap - arrow - with dipstick.
 Clean dipstick with clean cloth.
 Screw cap on hand-tight and remove again.
WARNING: Screw cap fully in to get an accurate fluid level reading.
Fig. 129: Power Assisted Steering Fluid Level Dipstick

 Check fluid level: Fluid level must be in area of MIN mark (up to 2 mm above or below mark).
NOTE:  If fluid level is above specified range, oil must be extracted off.
 If the fluid level is below the specified level, check the hydraulic system for
leaks (repair measure). It is not enough to simply top off with fluid.
 If no leaks are detected, top off with fluid "G 002 000".
 Part numbers are for reference only. Always check with your Parts
Microsoft
Department for the latest parts information.
 Screw in cap hand tight.
Warm oil (at approx. 50°C):
 With engine not running, move front wheels in straight-ahead position.
Fig. 130: Identifying Reservoir Cap

 Unscrew reservoir cap - arrow - with fitted dipstick.

 Clean dipstick with clean cloth.
 Screw cap on hand-tight and remove again.
WARNING: Screw cap fully in to get an accurate fluid level reading.
Fig. 131: Power Assisted Steering Fluid Level Dipstick

 Check fluid level: Check fluid level. It must be between MIN and MAX markings.
Microsoft
NOTE:  If the fluid level is above the MAX mark, siphon fluid off.
 If the fluid level is below the MIN mark, check the hydraulic system for
leaks (repair procedure). It is not enough to simply top off with fluid. If no
leaks are detected, top off with hydraulic fluid "G 002 000".
 Part numbers are for reference only. Always check with your Parts
Department for the latest parts information.
 Screw in cap hand tight.
HEADLIGHT ADJUSTMENT: CHECK
Test requirements --> Test requirements:.
Check headlight adjustment --> HEADLIGHT ADJUSTMENT, CHECKING (WITH TEST SCREEN
WITHOUT 15° adjustment line).
Main headlights with halogen lamps: adjusting --> Headlamps with halogen lamps: adjusting.
Main headlights with gas discharge lamps without cornering light system: adjusting --> Main headlamps with
HID lamps without cornering light system: adjusting.
Main headlights with gas discharge lamps with cornering light system: adjusting --> Headlamps with HID
lamps and cornering light system: adjusting.
Fog lights and other auxiliary headlights: adjusting --> Adjusting fog lights and other auxiliary headlights.
Test requirements:
Test and adjustment requirements:
 Tire pressure OK.

 Lenses must not be damaged or dirty.
 Reflectors and bulbs OK.
Move vehicle back and forth for 1 meter (3 to 4 feet) or bounce front and rear of vehicle several times up and
down to settle suspension.
 Vehicle and headlight adjuster must be on a level surface. User manual for headlight adjuster.
 Vehicle and headlamp adjuster must be aligned.
 Inclination must be set.
In the trim above the headlight, inclination measurements are stamped in "%". 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.
Microsoft
NOTE:  If the vehicle is equipped with separate low beams and high beams, high
beam must be adjusted extra. Note that the adjuster must be set to 0%
when adjusting the high beams.
Vehicles with gas discharge lamps with dynamic headlight range adjuster:
NOTE:  On vehicles with high-intensity discharge (HID) headlamps, the basic

setting must be performed with diagnostic tester before every headlamp
adjustment.
Headlight adjustment, checking (with test screen without 15° adjustment line)
Fig. 132: Head Light Adjusting Unit VAS 5046

 Headlight adjuster VAS 5046

 or
 Headlight adjuster VAS 5047
Main headlights:
Check the following:
Microsoft
Fig. 133: Identifying Headlight Setting Line, Break-Away Point & Center Point
 With the dipped 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 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 headlight (as viewed when looking forward) a few times. Then check
dipped beam again.
 After correct adjustment of dipped beams the center point of the main
beam must lie on the center mark - 3 -.
 To avoid incorrect settings, ignore 15° setting line.
Fig. 134: Identifying 15 Degree Angle

Fog lights:
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Fig. 135: Fog Light Test Screen

 Check whether the upper light-dark border touches the setting line horizontally over the complete test
screen width.
Other additional headlamps:
Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.
Main headlamps with HID lamps without cornering light system: adjusting
Headlamp range control, performing basic setting

 Select vehicle system "Automatic headlamp range control".

 Mark "Perform basic setting" and confirm with -->.
 Now the number of malfunctions is read out and if there are "0" malfunctions, "Complete" can be
selected.
 Observe displayed notes and confirm by selecting "Complete".
 Switch low beams on and confirm with "Complete".

 Now adjust headlamps as follows:
Left headlamp
Left headlamp side adjustment
Microsoft
Fig. 136: Identifying Dip Beam Lateral Adjustment & High Beam Lateral Adjustment Screws
 Turn respective dip beam lateral adjustment screw - 1 - and high beam lateral adjustment screw - 2 - until
the correct settings are achieved.
Left headlamp height adjustment
Fig. 137: Identifying Height Adjustment Screw

 Turn the adjustment screw for height adjustment - 1 - until the correct setting is achieved.
Adjustment screws for right headlight are arranged symmetrically
 After adjustment, confirm on tester with "Complete".

 "Guided Functions" can be exited with "Go to" "End".
Headlamps with HID lamps and cornering light system: adjusting
Headlamp range control, performing basic setting
Microsoft

 Select vehicle system "Automatic headlamp range control cornering light".

 Mark "Perform basic setting" and confirm with -->.
 Now the number of malfunctions is read out and if there are "0" malfunctions, "Complete" can be
selected.
 Observe displayed notes and confirm by selecting "Complete".
 Switch low beams on and confirm with "Complete".

 Now adjust headlamps as follows:
Identification of main headlights with cornering light system:
NOTE:  An additional reflector with halogen lighting for the static cornering light is
located between the low-beam headlight and turn signal.
The headlights for cornering light system contain 4 lamps.
Left headlights, adjusting, through model year 2006
Fig. 138: Identifying Adjustment Screws & Hex Head Wrench

 Turn the adjustment screw for side adjustment - B - until the correct setting is achieved.
Left headlamp height adjustment:
 Adjust adjusting screw with hex head wrench - 1 -.
Microsoft
 Turn the adjustment screw for height adjustment - A - until the correct setting is achieved.

Left headlights, adjusting, from model year 2007
Fig. 139: Identifying Adjustment Screw

 Position adjusting screws with a hex head wrench.

 Turn the adjustment screw for side adjustment - 2 - until the correct setting is achieved.

Headlamps with halogen lamps: adjusting
Left headlamp side adjustment:
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Fig. 140: Identifying Dip Beam Lateral Adjustment & High Beam Lateral Adjustment Screws
 Turn respective dip beam lateral adjustment screw - 1 - and high beam lateral adjustment screw - 2 - until
the correct settings are achieved.
Fig. 141: Identifying Height Adjustment Screw

NOTE:  Also check whether both headlights work evenly when operating the
headlight range adjuster.
Adjusting fog lights and other auxiliary headlights
Fog lights in main headlights:
NOTE:
Microsoft
 The adjustment of fog lights is performed automatically when adjusting

headlights.
Left fog lamp in bumper:
Adjusting screw on right fog light is arranged symmetrically.
Fig. 142: Identifying Cover Caps

 Release cover caps - 1 - from locking devices in direction of arrow.
Fig. 143: Identifying Hex Socket Head & Screws

 Perform adjustment:
 Turn height adjustment screw - 1 - with hex socket head wrench until the correct setting is achieved.
Lateral adjustment is not possible.
Other auxiliary headlights
Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.
Microsoft
SUNROOF: CHECKING FUNCTION, CLEANING AND LUBRICATING GUIDE RAILS
Fig. 144: Identifying Sunroof Guide Rails

 Check function of sunroof.

 Clean guide rails and lubricate with Grease G 000450 02 .
WINDSHIELD WIPER BLADES: CHECK PARK POSITION, ADJUST IF NECESSARY
Windshield, Drivers side:
 Check the park position.
Fig. 145: Identifying Wiper Blade (Drivers Side)

The space - A - between the wiper rubber and bottom edge of windshield must be 9 mm.
The distance - B - between wiper blade and lower edge of windshield must be 12 mm.
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 Adjust park position by moving wiper arm if necessary.
Torque wiper arm: 32 Nm
Windshield, Passenger side:
Fig. 146: Identifying Wiper Blade (Passenger Side)

The space - A - between the wiper rubber and bottom edge of windshield must be 12 mm.
The distance - B - between wiper blade and lower edge of windshield must be 44 mm.
 Adjust park position by moving wiper arm if necessary.
Torque wiper arm: 32 Nm
Back window:
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Fig. 147: Checking Distance Between Wiper Blade And Lower Edge Of Windshield
The distance - a - between wiper blade and lower edge of windshield must be 55 mm (measured from lower
edge of glass).
 If necessary, adjust the park position by relocating the wiper arm. Torque wiper arm: 12 Nm
WINDSHIELD WASH/WIPE SYSTEM AND HEADLIGHT WASH SYSTEM: CHECK FOR

FUNCTION AND DAMAGE, TOP OFF FLUID IF NECESSARY
Checking freeze protection concentration of fluid, adding fluid, --> Checking freeze protection concentration
of fluid, adding fluid.
Windshield wash/wipe system and headlight wash system: Check jet setting, adjust jets if necessary, -->
Windshield wash/wipe system and headlight wash system: Checking nozzle setting, adjusting nozzles if
necessary
Checking freeze protection concentration of fluid, adding fluid
Checking freeze protection concentration:

 Read the bright/dark boundary to obtain an accurate reading for the following tests.
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 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 the refractometer T10007 (follow the operating
instructions).
Fig. 149: Identifying Refractometer T10007 Scales

The scale - 1 - of the refractometer is designed specifically for genuine Volkswagen windshield cleanser "G 052
164".
The scale - 2 - is designed for commercially available windshield washer fluid as well as a mixture of
commercially available windshield washer fluid and "G 052 164".
Mixture ratio:
Freeze protection to W/screen clear G 052 164 Water

-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 "Genuine Volkswagen Windshield Clear" all-year-round when topping-up the windshield wash/wipe
system.
NOTE:  Genuine Volkswagen windshield cleanser "G 052 164" protects the spray
jets, fluid reservoir and hoses from freezing.
 Vehicles with fan type spray jets must be filled with "Genuine Volkswagen
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windshield clear 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. "Genuine Volkswagen windshield clear" assures
that the fan type spray jets remain functional even at low temperatures.
 Use genuine Volkswagen windshield cleanser "G 052 164" in the warmer
periods of the year 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 wash/wipe system and headlight wash system: Checking nozzle setting, adjusting nozzles if necessary
NOTE:  In case of an uneven spray field due to dirt in spray nozzles, remove
nozzle --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM and flush out
with water opposite to spraying direction.
 Subsequently blowing through in the opposite direction of the spray flow
with compressed air is permitted.
 Do not use any objects to clean the spray jets!
Preset washer jets
Fig. 150: Identifying Preset Washer 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:
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Fig. 151: Identifying Spray Jet

 Adjust spray jet on adjuster - 1 - by hand upward or downward.
Headlamp washer nozzle, adjusting
Fig. 152: Adjustment Tool VAS 3019A

 Adjustment device 3019A

 or
 Adjustment device T10167
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Fig. 153: Spray Jet Adjustment For Left Headlight (Right Headlight Is Identical But Reversed)
Spray jet adjustment for left headlight (right headlight is identical but reversed):
 Check nozzle adjustment.
a 100 mm
b - 75 mm
c - 230 mm
d - 50 mm
 If necessary, adjust spray jets as follows:
Fig. 154: Identifying Headlight Spray Nozzles

 Switch on headlights and operate windshield wiper/washer system long enough until spray nozzles for
headlight cleaning system are driven out.
 Hold spray nozzle - arrow - firmly and pull out up to stop and align to the respective spray points using
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adjustment tool T10167.
Adjustment of spray nozzles, rear windshield wipe/wash system:
NOTE:  Spray nozzle of rear windshield wipe/wash system is a component of

auxiliary brake light and cannot be adjusted.
 If spray nozzle sprays unevenly or does not spray the wiper area, replace
the auxiliary brake light with spray nozzle.
Removing and installing auxiliary brake light, --> 94 - LIGHTS, SWITCHES - EXTERIOR
SERVICE INTERVAL DISPLAY: RESET
Service Reminder Indicator must for
 Vehicle delivery inspection

 Every service
(adapted)!

 Touch button/field on screen: GUIDED FUNCTIONS on screen.
If the displays indicated in the work procedure are not indicated on display: Operating instructions for Vehicle
Diagnosis, Testing and Information System 5051 or Vehicle Diagnosis Service Syst VAS 5052
 Press > button to confirm.

 Brand
 Model
 Model year
 Engine Code

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Fig. 155: Identifying "Instrument Cluster" Selection On Scan Tool

 "Instrument cluster" - ARROW -.

 "Resetting Service Reminder Indicator (SRI)".
Fig. 156: Identifying "Go To" Button On Scan Tool Display

 Perform adaptation according to instructions of "GUIDED FUNCTIONS".
End Adaptation
Indicated on display:
 Press the Go to button - arrow - on display.
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Fig. 157: Identifying "Exit" Button On Scan Tool Display

 Press exit button - arrow - on display.

 Press exit button in exit menu.
After switching on the ignition, service event is no longer indicated in the odometer display in the instrument
panel insert.
SERVICE INTERVAL DISPLAY: RECORDING

 Touch button/field on screen: "GUIDED FUNCTIONS" on screen.
NOTE:  If the displays indicated in the work procedure are not indicated on
display: Operating instructions for Vehicle diagnosis, testing and
information system VAS 5051 or Vehicle diagnosis and service system
VAS 5052.
 Brand
 Model
 Model year
 Engine Code
If the vehicle identification procedure was performed correctly, press > button for confirmation.
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Fig. 158: Identifying "Instrument Cluster" Selection On Scan Tool

 "Instrument cluster" - ARROW -.

 "Adapt service interval extension".
 Perform adaptation according to instructions of "GUIDED FUNCTIONS".
End Adaptation
Fig. 159: Identifying "Go To" Button On Scan Tool Display

 Press the Go to button - arrow - on display.
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Fig. 160: Identifying "Exit" Button On Scan Tool Display

 Press exit button - arrow - on display.

 Press exit button in exit menu.
TIE ROD ENDS: CHECK PLAY, SECURITY AND JOINT BOOTS
 With vehicle raised (wheels hanging free), check play by moving track rods and wheels. Play: zero play
Fig. 161: Identifying Track Rod Joint Boots

 Check mountings.
 Check track rod joint boots - arrow - for damage and proper seating.
DOOR ARRESTER: LUBRICATE
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Fig. 162: Identifying Door Arrester Points

 Lubricate door arrester at points shown - arrows -.
Use solid lubricant G 000 150 .
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.
SETTING TIME, LANGUAGE AND UNITS: ON DISPLAY OF INSTRUMENT CLUSTER
 Time: The time can be set here and can be switched between the 12 and 24 hour display.
 Language: The language of the instrument cluster display can be set here.
 Units: The units for temperature, consumption and pressure can be set here.
Instrument cluster, Highline (one-color display):
The menu can be operated using either the control elements in the windshield wiper stalk, or the control
elements in the multi-function steering wheel.
1. Operating with windshield wiper stalk:
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Fig. 163: Identifying Selector & Button

 Press selector - B - longer than 2 seconds, until the main menu is displayed.
 Press the top or bottom selector, until the menu selection "COMFORT SETUP" is displayed inverted.
The main menu "COMFORT SETUP" has the following functions, e.g. "Light" , "Speed warning" , "Time" ,
"Comfort" , "Language" , "Units" , "Reset".
 Press the button - A - enough times until the appropriate menu is selected.
Using the button and selector, all of the other instrument cluster menus can be operated.
2. Operating with multi-function steering wheel:
Fig. 164: Identifying Menu Display Controls

 Touch (press) button - 1 - or button - 3 - to change menus and use thumb wheel - 2 - to make a selection
(turn).
 Press button - 1 - or button - 3 - , until the menu selection "COMFORT SETUP" is displayed inverted.
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Turn the thumb wheel - 2 - until the desired menu selection is displayed.
 Press the thumb wheel. The selected menu is displayed.
For example, set clock via multi-function steering wheel:

 Press button - 1 - to activate menu selection in instrument panel insert display.
Fig. 166: Identifying Menu Display

 Select the menu option "Clock" with the thumb wheel - 2 -
When the menu item "Clock" is selected in display - 1 - confirm the menu setting by pressing the thumb wheel.
 Set the time using the thumb wheel as well as the 12/24 hour clock mode settings.
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NOTE:  If the clock is found in the tachometer, the clock can be set using the
adjustment knob below the tachometer.
Instrument cluster, premium (color display)
NOTE:  In the color display, outside temperature, time and mileage are continually
displayed.
Operating with multi-function steering wheel:

 Touch (press) button - 1 - or button - 3 - to change menus and use thumb wheel - 2 - to make a selection
(turn).
 Press button - 1 - or button - 3 - , until the menu selection "COMFORT SETUP" is displayed inverted.
Turn the thumb wheel - 2 - until the desired menu selection is displayed.
 Press the thumb wheel. The selected menu is displayed.
CAMSHAFT DRIVE TOOTHED BELT: REPLACING (8-CYL. GASOLINE ENGINE)
 Perform work sequence: -->

 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 3.2L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 3.6L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 4.2 LITER V8 4V ENGINE
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 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 4.2 LITER V8 5V ENGINE

MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 15 - ENGINE - CYLINDER HEAD, VALVETRAIN for 5.0 LITER V10 2V TDI PD ENGINE
MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
SPARK PLUGS: REPLACING
Spark plugs, 6-cyl. engine, replacing --> Vehicles with 6-cyl. gasoline engine
Spark plugs, 8-cyl. engine, replacing --> Vehicles with 8-cyl. gasoline engine
NOTE:  Plug designation and torque specification -->

 28 - IGNITION/GLOW PLUG SYSTEM for 3.2L V6 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA,
BMX
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL,
BHK
 28 - IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ,
BHX
 28 - IGNITION/GLOW PLUG SYSTEM for 5.0 LITER V10 2V TDI PD
ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE
CODE(S): BKW, BWF
Fig. 168: Identifying Spark Plug Wrench 3122 B

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 Spark plug wrench 3122B

 Torque wrench V.A.G 1331
Fig. 170: Identifying Assembly Tool T10118

 Removal/installation tool T10118
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Fig. 171: Identifying Puller For Ignition Coil T10095 A

 Puller T10095 A
Fig. 172: Identifying Ignition Coil Puller T40039

 Puller T40039
Fig. 173: Spring-Type Clip Pliers VAS 5024A

 Spring type clip pliers VAS 5024

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Vehicles with 6-cyl. gasoline engine
Removing:

 Remove engine covers - 1 - and - 2 - upward
Unlock connector release:
Fig. 175: Inserting Assembly Tool T10118 At Plug Resting Set

 Insert Assembly tool T10118 at the plug resting set - arrow - and carefully pull up, until the plug rest
releases.
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Fig. 176: Identifying Ignition Coils

 Remove plugs - 1 through 6 - for ignition coils with power-output stages upward
NOTE:  Before removing plugs, note installation position of ignition coils with
power-output stages, if necessary, mark installation position of plugs
Fig. 177: Identifying Ignition Coil With Power Output Stage

The straight side of the connector must fit to the straight side of the ignition coil with power output stage -
arrow -.
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Fig. 178: Pushing The Remover T10095/A From Straight Connector Side
 Push the puller T10095/A from the straight connector side, in the direction of the arrow, on the ignition
coil with power output stage
Fig. 179: Removing/Installing Spark Plugs With Spark Plug Wrench VAS 3122B
 Pull the ignition coil with power output stage up perpendicularly and out.
 Remove spark plugs using spark plug wrench 3122B.
Installing:
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Fig. 180: Removing/Installing Spark Plugs With Spark Plug Wrench VAS 3122B
 Screw in new spark plugs using spark plug removal tool 3122 B.
NOTE:  Observe torque specification!
Fig. 181: Identifying Ignition Coil With Power Output Stage

 Carefully insert ignition coils with power output stages on spark plugs by hand so that the straight
connector sides fit to each other - arrows -.
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Fig. 182: Identifying Ignition Coils

 Install new spark plugs - 1 through 6 -

 Install engine covers - 1 - and - 2 -
Vehicles with 8-cyl. gasoline engine
Removing:
 Remove oil dipstick.
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Fig. 184: Identifying Bracket For Left Engine Cover & Bolts
 Remove bracket for left engine cover - 1 -.

 Remove bolts as well as retaining bolts for engine cover - arrows -.
Fig. 185: Disconnecting/Connecting Ignition Coil Connectors

Press connector catches - arrows - in direction of arrow and disconnect connectors - A - from ignition coils
with power output stages.
NOTE:  Before removing plugs, note installation position of ignition coils with
power-output stages, if necessary, mark installation position of plugs
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Fig. 186: Pushing Puller T40039 Onto Ignition Coil With Power Output Stage, And Pulling It Off
 Remove ignition coils with power-output stages using Puller T40039 in direction of -arrow-
Fig. 187: Removing/Installing Spark Plugs Using Spark Plug Wrench 3122B
 Remove spark plugs using spark plug wrench 3122B.
Installing:
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Fig. 188: Removing/Installing Spark Plugs Using Spark Plug Wrench 3122B
 Screw in new spark plugs using spark plug removal tool 3122 B.
NOTE:  Observe torque specification! Current values -->

MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA,
BMX
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL,
BHK
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ,
BHX
 28 - IGNITION/GLOW PLUG SYSTEM for 5.0 LITER V10 2V TDI PD
ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE
CODE(S): BKW, BWF
 Install ignition coils with power output stages while lightly turning. They should noticeably engage.
Fig. 189: Disconnecting/Connecting Ignition Coil Connectors

 Re-connect connectors - A - so that they engage.

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 Re-install left bracket for engine cover - 1 - and tighten it to 10 Nm.
STATIC CORNERING LIGHTS AND AUTOMATIC HEADLAMPS: CHECKING FUNCTION
Static cornering lights
 Switch ignition and low beams on

 Turn steering wheel out of center position one turn to the right and check in right headlamp whether
cornering light bulb comes on.
 Repeat this step for left side.
Automatic headlamps
 Condition: There must be daylight when testing.
 Turn light switch to automatic headlamps position.
When there is daylight, headlamps must not come on.
 Using your hand or another suitable object, cover Rain and Light Recognition Sensor from outside behind
front window in rearview mirror area.
This causes a decrease in light and both headlamps are switched on.
DIESEL PARTICLE FILTER: CHECK SOOT LOAD VALUE
NOTE:  When checking the diesel particle filter, the soot load limit is requested.
 Only applies to vehicles with diesel particle filter and without additive
system.
 Connect the diagnostic unit, --> Diagnostic unit, connecting.

 Touch button/field on screen: GUIDED FUNCTIONS on screen.
If the displays indicated in the work procedure are not indicated on display: Operating instructions for Vehicle
diagnosis, testing and information system 5051 or Vehicle diagnosis and service system VAS 5052.
 Press > button to confirm.

 Brand
 Model
 Model year
 Engine Code
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Select vehicle system or function is shown.
 Select "Engine" vehicle system.

 Select "Read measured value block".
 Press " >" button twice to confirm.
Follow instructions on the screen.
 Mark "measured value block 68, field 2" , read out soot load.
 Determine current value using "Read button".
Follow instructions on the screen.
NOTE:  If the threshold is reached, replace diesel particle filter --> Diesel particle
filter: Replacing.
 Replacing the diesel particle filter is a repair measure.
 End test.
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What are the different types of engines discussed in the document?

What are the different types of engines discussed in the document?

What maintenance procedures are described for checking ignition coils and spark plugs?

What maintenance procedures are described for checking ignition coils and spark plugs?

2004 Volkswagen Touareg

Maintenance Maintenance Procedures

Engines --> Gasoline engine Gasoline engine Gasoline engine

Leak detection system (e.g. USA no no yes

Engines --> Gasoline engine Gasoline engine Gasoline engine

Leak detection system (e.g. USA yes no yes

Engines: --> Gasoline engine Gasoline engine Gasoline engine

Leak detection system (e.g. USA no no no

Engines --> Gasoline engine Gasoline engine Gasoline engine

Leak detection system (e.g. USA no yes no

Engines --> Diesel engine Diesel engine Diesel engine

Number of cylinders/valves per cylinder 10/2 5/2 6/4

Engines --> Diesel engine Diesel engine Diesel engine

Engines: --> Diesel engine Diesel engine Diesel engine

Fuel injection/Ignition PD injection 1.5 PD injection 1.5 PD injection 1.5

*No RME fuel (biodiesel) permitted

This chapter contains information on the following subjects:

 Service tables --> Service tables

VW engine oil standards

WARNING: Only oils approved by VW must be used; Fluid Capacity Charts.

Filter change interval

Toothed belt change interval

OIL CHANGE SERVICE

NOTE:  Inform the customer of the repair measures required if a problem is

INSPECTION SERVICE 2004

SERVICE INTERVAL 2005

SERVICE INSPECTION INTERVAL 2005

NOTE:  Inform the customer of the repair measures required if a problem is

 Ask the customer if he or she would like:

 New wiper blades,

TIME AND/OR DISTANCE DEPENDENT ADDITIONAL WORK

Refer to --> Maintenance Schedule for appropriate model and year.

 Vehicle data sticker --> Vehicle data sticker

 Type plate --> Type plate

RAISING VEHICLE WITH HOIST AND FLOOR JACK

WARNING:  Before driving on to a hoist ensure there is sufficient clearance

 If work is to be performed under vehicle it must be supported by

Hoist and floor jack lifting points:

Fig. 1: Hoist And Floor Jack Lifting Points (Front)

WARNING: On no account must front of vehicle be raised on side member vertical

Fig. 2: Hoist And Floor Jack Lifting Points (Rear)

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

Fig. 3: Identifying "First Service" Sticker

Affix sticker "Your next service events" --> Service Sticker

"First service" sticker

Apply sticker "Next service" :

Fig. 4: Identifying Service Sticker "Next Service"

 Apply sticker to drivers side door jamb (B Pillar).

Applying "data sticker" in service schedule

Fig. 5: Locating Data Sticker

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

DIAGNOSTIC UNIT, CONNECTING

Special tools, testers and auxiliary items required

 Vehicle Diagnosis, Testing and Information System VAS 5051 B

Fig. 7: Diagnostic Cable - VAS 5051/6A

 Diagnostic cable VAS 5051/6A