Work descriptions (part 2 of 2) Page 1 / 57

Work descriptions (part 2 of 2)

Engine oil level, checking

Note the following:

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

to flow back into oil pan.

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

Note:

„ Observe disposal regulations!

- Withdraw dipstick again and read oil level.

On the oil dipstick:

A - Oil must not be topped off.

B - Oil may be topped off. After topping off, oil may be in
range A .
C - Oil must be topped off. After topping off, it is sufficient
if oil level is somewhere in range B (shaded area).

At an oil level above marking - A - , there is a danger of

damage to catalytic converter.

- At an oil level below marking - C - , fill up with oil up to

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

Engine oil, draining or siphoning, replacing oil filter and

filling up with engine oil

Engine oil: Drain or extract and fill; replace oil filter, 01-
5, Draining or extracting engine oil .
Work descriptions (part 2 of 2) Page 2 / 57

Replacing oil filter, 01-5, Oil filter, replacing .

Filling with engine oil, 01-5, Filling with engine oil

Draining or extracting engine oil

Special tools, testers and auxiliary items required

„ Oil collecting and extracting device V.A.G 1782

„ Oil absorbing cloth VAS 6204/1

Draining or extracting engine oil

Perform the following work procedure:

Note:

„ On engines with standing oil filter module, the oil

filter should be replaced before changing engine oil
01-5, Oil filter, replacing . Removing the filter
element will open a valve and oil in the filter housing
will flow automatically into the crankshaft housing.

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

extracting device, replace oil drain plug. This will
prevent leaks.

- Extract engine oil using oil collecting and extracting

device V.A.G 1782 .

or

- Remove oil drain plug.

Note:

„ Observe disposal regulations!

Work descriptions (part 2 of 2) Page 3 / 57

„ Oil drain plug has a permanent sealing ring,

therefore oil drain plug must always be replaced.

- Drain engine oil.

- Hand-tighten new oil drain plug and tighten to specified

tightening torque.

- Fill up with engine oil, specifications 01-3, Engine

oils .

Engine oil capacity,

Repair Manual, Engine Mechanical, Repair Group 17,

Tightening torques of oil drain plug:

„ Gasoline engines 30 Nm

„ Diesel engines 30 Nm

Warning!

„ Torque specifications must not be exceeded.

„ A higher torque can lead to leaks in the area of

the drain plug or even to damage.

Oil filter, replacing

Replacing oil filter, 2.0 L TFSI engine, 01-5, Replacing

oil filter, 2.0 L TFSI engine .

Replacing oil filter, 2.5 L fuel injected engine, 01-5,

Replacing oil filter, 2.5 L fuel injected engine .

Replacing oil filter, diesel engine, 01-5, Replacing oil

filter, diesel engine .

Replacing oil filter, 2.0 L TFSI engine

Special tools, testers and auxiliary items required

Work descriptions (part 2 of 2) Page 4 / 57

„ Oil Drain Adapter T40057

„ Oil Filter Wrench 3417

„ Torque Wrench 5-50Nm VAG1331

Perform the following work procedure:

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

Before oil filter housing is removed, it must be emptied.

Work descriptions (part 2 of 2) Page 5 / 57

- Thread Oil Drain Adapter T40057 into oil filter housing

and hold hose into oil drain pan.

Note:

„ While threading in Oil Drain Adapter T40057 , a

valve in the oil filter housing is opened. If the Oil
Drain Adapter T40057 is removed, the valve closes
again automatically.

- Drain engine oil.

- Remove Oil Drain Adapter T40057 .

- Oil filter housing may now be removed using Oil Filter

Wrench 3417 .

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

Note:

„ Observe disposal regulations!

Work descriptions (part 2 of 2) Page 6 / 57

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

- Hand-tighten dust cap - 1 - to oil filter housing - 2 - .

Replacing oil filter, 2.5 L fuel injected engine

Special tools, testers and auxiliary items required

„ Oil Drain Adapter T40057

„ Oil Filter Wrench 3417

„ Torque Wrench 5-50Nm VAG1331

Perform the following work procedure:

Work descriptions (part 2 of 2) Page 7 / 57

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

Before oil filter housing is removed, it must be emptied.

- Thread Oil Drain Adapter T40057 into oil filter housing

and hold hose into oil drain pan.

Note:

„ While threading in Oil Drain Adapter T40057 , a

valve in the oil filter housing is opened. If the Oil
Drain Adapter T40057 is removed, the valve closes
again automatically.

- Drain engine oil.

- Remove Oil Drain Adapter T40057 .

- Oil filter housing may now be removed using Oil Filter

Wrench 3417 .
Work descriptions (part 2 of 2) Page 8 / 57

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

Note:

„ Observe disposal regulations!

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

- Hand-tighten dust cap - 1 - to oil filter housing - 2 - .

Replacing oil filter, diesel engine

Removing

Note:

„ Observe disposal regulations!

„ Coat new O-rings with oil before installing.

Work descriptions (part 2 of 2) Page 9 / 57

Loosen cap - arrow - e.g. using 36 mm open end wrench

or 36 mm socket T10125 .

Note:

„ Loosen cap before draining/extracting so that engine

oil can flow out of filter housing.

- Clean sealing surfaces on screw cap and on oil filter

housing.

Installing

- Replace oil filter element - 3 - .

- Replace O-ring - 2 and 4 - .

- Install screw cap arrow and tighten to 25 Nm.

The rest of the installation follows the reverse of the

removal procedures.
Work descriptions (part 2 of 2) Page 10 / 57

Filling with engine oil

Oil specifications, see page 01-3, Engine oils

Oil filling quantity,

Repair Manual, Engine Mechanical, Repair Group 17,

, Lubrication system components, removing and

installing

General notes

Note:

„ Observe disposal regulations!

- After topping up with oil, wait at least 3 minutes, then

check oil level.

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

- Withdraw dipstick again and read oil level.

On the oil dipstick:

A - Oil must not be topped off.

B - Oil may be topped off. After topping off, oil may be in
range A .
C - Oil must be topped off. After topping off, it is sufficient
if oil level is somewhere in range B (shaded area).

At an oil level above marking - A - , there is a danger of

damage to catalytic converter.

- At an oil level below marking - C - , fill up with oil up to

marking - A - . Oil specification 01-3, Engine oils .
Work descriptions (part 2 of 2) Page 11 / 57

Break-down set, checking

Note:

„ Break-down set is located in spare wheel well.

„ Break-down set contains, among other things, a tire

inflation bottle with tire sealant.

Expiration date, checking

- Check expiration date.

Shelf-life date is located on a sticker on tire sealant -

arrow - .

- Replace tire sealant if expiration date has been reached.

(tire sealant must not be older than 4 years).

Note:

„ If tire sealant was already used once, it must be

replaced.

„ Observe disposal regulations.

Road test, performing

To what extent the following can be checked is dependent

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

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

- Engine: Output, misfiring, idling speed, acceleration

- Clutch: Pulling away, pedal pressure, odors

- Gear selection: Ease of operation, shift lever position

Work descriptions (part 2 of 2) Page 12 / 57

- Automatic transmission: Selector lever position, shift

lock / ignition key removal lock, shift behavior, instrument
cluster insert display

- Foot-operated and hand-operated parking brake:

Function, free travel and effectiveness, pulling to one side,
juddering, squeal.

- ABS function: A pulsing at the brake pedal must be felt

when performing ABS controlled braking

- Steering: Function, steering free play, steering wheel

centralized when wheels are in straight ahead position

- Sunroof: Function

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

SVC, interference

- Multifunction indicator (MFI): Functions

- A/C system: Function

- Vehicle: Moving off line when travelling straight ahead

(level road)

- Imbalance: Wheels, drive axles, prop shafts

- Wheel bearings: Noises

- Engine: Hot starting behavior

Wheel securing bolts, tightening to correct torque

setting

Special tools, testers and auxiliary items required

„ Torque Wrench 40-200Nm VAG1332

Removing wheel center cap:

Work descriptions (part 2 of 2) Page 13 / 57

Extractor - 1 - for removing cap is located in vehicle tool

kit.

- Hook extractor in one hole of wheel center cap and

remove in - direction of arrow - .

Pulling off wheel bolt cover caps:

Note:

„ Caps of wheel bolts must be removed before wheels

bolts are removed.

The extractor for removing the caps is located in the

vehicle tool kit.

- Insert the wire bracket through opening in cap.

- Pull off cap using wire bracket.

Loosen anti-theft wheel bolts:

Note:

„ A special adapter, needed for loosening anti-theft

wheel bolts, is located in vehicle tool kit.
Work descriptions (part 2 of 2) Page 14 / 57

- Slide adapter - 2 - into anti-theft wheel bolt until stop - 1

- .

- Slide lug wrench onto adapter until stop - 2 - .

- Loosen wheel bolt approx. one turn.

Tighten wheel bolts:

Note:

„ Ensure that wheel bolts are tightened alternately to

the following tightening torque:

„ Place adapter and extractor with vehicle tool kit after

completing work.

Tightening torque: 120 Nm

Radio navigation system, activating Anti-theft Coding

Radio "Sound System" - electronic anti-theft system

Radio - "Sound System" is equipped with an electronic

Comfort anti-theft system which operates in conjunction
with radio unit identification data stored in the instrument
cluster.

When an existing radio is removed (radio power supply

disconnected) and reinstalled in the same vehicle, it is not
necessary to input the anti-theft security code.

Electronic anti-theft system, function

After first activation of electronic anti-theft system, a

numeric code is stored in both the radio unit and
instrument cluster. When the radio power supply is
restored ( e.g. after removing and installing radio or
battery), a data exchange takes place between the radio
and instrument cluster.

The data exchange compares the numeric code of the

radio unit to the numeric code stored in the instrument
cluster. If numeric code is identical, the instrument cluster
recognizes that the radio "belongs to the vehicle" and is
ready for operation.

Should a radio be replaced, the anti-theft code must be

entered.

Deactivating electronic anti-theft system, see "Electronic

anti-theft system, deactivating" below.
Work descriptions (part 2 of 2) Page 15 / 57

Next, when the ignition key is inserted into the ignition

switch ( "S-contact" activated), the data exchange between
the replacement radio and instrument cluster take place
automatically.

The data exchange lasts about 5 seconds. During this

time a VAS 5051/5052/5052 must not be connected or
remain connected.

After successful data exchange, the replacement radio unit

is ready for operation without renewed input of anti-theft
code (should power supply subsequently be disconnected
and reconnected).

The electronic anti-theft system is activated and will lock

the radio as soon as:

„ radio unit is installed in a different vehicle

„ instrument cluster is replaced

A radio which has been locked by the electronic anti-theft

system will show "SAFE" and "1000" on display when
switched on.

To cancel lock, deactivate electronic anti-theft warning

system, see "Electronic anti-theft system, deactivating"
below.

Electronic anti-theft system, deactivating

Reactivating a locked radio is only possible by entering

correct code number for electronic anti-theft system.

Note:

„ Code number for electronic anti-theft system is listed

along with radio serial number on radio card,
operating instructions .

„ For security reasons, radio card should not be stored

in the vehicle. Obtain the code number from the
customer, if necessary.

„ If a radio is replaced, code number from

replacement radio must be used.

„ Inform the customer that the code number has

changed.
Work descriptions (part 2 of 2) Page 16 / 57

- Obtain radio code number.

- Switch on radio unit.

Radio displays "SAFE" and then "1000" . No button inputs

are required.

- Using station buttons -1- to -4-, enter code number

affixed to radio card. Press preset button 1 to enter first
digit of code number, preset button 2 for second digit and
so on.

- Then press the Arrow button, which is located above

the FAD button and hold it firmly until the anti-theft
coding is activated. This is indicated by a short signal
sound.

If the code number has been entered correctly into radio

unit, a radio frequency appears on the display.

Note:

„ If the anti-theft code has been entered incorrectly, it

can be corrected immediately in another attempt. If
anti-theft code is entered incorrectly twice, then the
radio unit is locked for an hour. Radio unit can then
be switched on and insert ignition key in ignition
lock. After one hour, then the procedure for
deactivating the electronic anti-theft system can be
repeated. Remember: Always two attempts to input
code, after that the radio unit is locked for one hour.

Radio "Premium Sound System" - Electronic anti-theft system

Radio - "Premium Sound System" is equipped with an

electronic Comfort anti-theft system which operates in
conjunction with radio unit identification data stored in the
instrument cluster.

When an existing radio is removed (radio power supply

disconnected) and reinstalled in the same vehicle, it is not
necessary to input the anti-theft security code.

Electronic anti-theft system, function

After first activation of electronic anti-theft system, a

numeric code is stored in both the radio unit and
instrument cluster. When the radio power supply is
restored ( e.g. after removing and installing radio or
battery), a data exchange takes place between the radio
and instrument cluster.

The data exchange compares the numeric code of the

radio unit to the numeric code stored in the instrument
Work descriptions (part 2 of 2) Page 17 / 57

cluster. If numeric code is identical, the instrument cluster

recognizes that the radio "belongs to the vehicle" and is
ready for operation.

Should a radio be replaced, the anti-theft code must be

entered.

Deactivating electronic anti-theft system, see "Electronic

anti-theft system, deactivating" below.

Next, when the ignition key is inserted into the ignition

switch ( "S-contact" activated), the data exchange between
the replacement radio and instrument cluster take place
automatically.

The data exchange lasts about 5 seconds. During this

time a VAS 5051/5052/5052 must not be connected or
remain connected.

After successful data exchange, the replacement radio unit

is ready for operation without renewed input of anti-theft
code (should power supply subsequently be disconnected
and reconnected).

The electronic anti-theft system is activated and will lock

the radio as soon as:

„ radio unit is installed in a different vehicle

„ instrument cluster is replaced

A radio which has been locked by the electronic anti-theft

system will show "SAFE" and "1000" on display when
switched on.

To cancel lock, deactivate electronic anti-theft warning

system, see "Electronic anti-theft system, deactivating"
below.

Electronic anti-theft system, deactivating

Reactivating a locked radio is only possible by entering

correct code number for electronic anti-theft system.

Note:

„ Code number for electronic anti-theft system is listed

along with radio serial number on radio card,
operating instructions .

„ For security reasons, radio card should not be stored

in the vehicle. Obtain the code number from the
customer, if necessary.
Work descriptions (part 2 of 2) Page 18 / 57

„ If a radio is replaced, code number from

replacement radio must be used.

„ Inform the customer that the code number has

changed.

- Obtain code number for the unit.

- Switch on radio unit.

Radio displays "SAFE" and then "1000" . No button inputs

are required.

- Using station buttons -1- to -4-, enter code number

affixed to radio card. Press preset button 1 to enter first
digit of code number, preset button 2 for second digit and
so on.

- Then press the Stations button located beneath "OK"

on the display (normally it is the last station button) and
hold it firmly until anti-theft coding is activated. This is
indicated by a short signal sound.

If the code number has been entered correctly into radio

unit, a radio frequency appears on the display.

Note:

„ If the anti-theft code has been entered incorrectly, it

can be corrected immediately in another attempt. If
anti-theft code is entered incorrectly twice, then the
radio unit is locked for an hour. Radio unit can then
be switched on and insert ignition key in ignition
lock. After one hour, then the procedure for
deactivating the electronic anti-theft system can be
repeated. Remember: Always two attempts to input
code, after that the radio unit is locked for one hour.

Radio "Radio - Navigation System" Electronic anti-theft system

Radio - Navigation System is equipped with an electronic

Comfort anti-theft system which operates in conjunction
with radio unit identification data stored in the instrument
cluster.

When an existing radio - navigation unit is removed (power

supply disconnected) and reinstalled in the same vehicle, it
is not necessary to input the anti-theft security code.

Electronic anti-theft system, function

Work descriptions (part 2 of 2) Page 19 / 57

After first activation of electronic anti-theft system, a

numeric code is stored in both the radio - navigation unit
and instrument cluster. When the unit power supply is
restored ( e.g. after removing and installing unit or battery),
a data exchange takes place between the radio -
navigation unit and instrument cluster.

The data exchange compares the numeric code of the unit

to the numeric code stored in the instrument cluster. If
numeric code is identical, the instrument cluster recognizes
that the radio - navigation unit "belongs to the vehicle" and
is ready for operation.

Should a radio - navigation unit be replaced, the anti-theft

code must be entered.

Deactivating electronic anti-theft system, see "Electronic

anti-theft system, deactivating" below.

Next, when the ignition key is inserted into the ignition

switch ( "S-contact" activated), the data exchange between
the replacement radio - navigation unit and instrument
cluster take place automatically.

The data exchange lasts about 5 seconds. During this

time a VAS 5051/5052/5052 must not be connected or
remain connected.

After successful data exchange, the replacement unit is

ready for operation without renewed input of anti-theft code
(should power supply subsequently be disconnected and
reconnected).

The electronic anti-theft system is activated and will lock

the radio - navigation unit as soon as:

„ radio - navigation unit is installed in a different

vehicle

„ instrument cluster is replaced

A radio - navigation unit which has been locked by the

electronic anti-theft system will show "SAFE" and "1000"
on display when switched on.

To cancel the lock, deactivate the electronic anti-theft

warning system, see "Electronic anti-theft system,
deactivating" below.

Electronic anti-theft system, deactivating

Reactivating a locked radio navigation system is only

possible by entering correct code number for electronic
Work descriptions (part 2 of 2) Page 20 / 57

anti-theft system.

Note:

„ Code number for electronic anti-theft system is listed

along with radio serial number on radio card,
operating instructions .

„ For security reasons, radio card should not be stored

in the vehicle. Obtain the code number from the
customer, if necessary.

„ If a radio navigation system is replaced, code

number from replacement unit must be used.

„ Inform the customer that the code number has

changed.

- Obtain radio code.

- Switch on radio navigation system.

The word "SAFE" and the number row "0000" appear in

the display.

- Enter the code number listed on the radio card, do this by

selecting and confirming characters on the selection
screen for letters and numbers in succession.

Note:

„ With the entry of the first character, the number row

"0000" is overwritten.

- Confirm code by pressing the right rotary press button.

- When the anti-theft code has been entered, confirm with

Taste located next to the word "OK" on the display.

The unit is enabled and ready for operation.

Note:

„ If the anti-theft code has been entered incorrectly, it

can be corrected immediately in two subsequent
attempts. If anti-theft code is entered incorrectly
three times, then the radio navigation system is
locked for an hour. Radio navigation system can
then be switched on and insert ignition key in ignition
lock. After one hour, then the procedure for
deactivating the electronic anti-theft system can be
Work descriptions (part 2 of 2) Page 21 / 57

repeated. Remember: Always three attempts to input

code, after that the radio navigation system is locked
for one hour.

Tire pressure monitoring display, performing basic

setting

Note:

„ Basic setting of Tire Pressure Monitoring Display

Indicator Lamp K220 should always be performed
only "after" having corrected tire pressure values to
correct values.

„ If no tire pressure loss or tire damage is determined

after a tire pressure warning, the malfunctioning
warning can be erased by a basic setting.

The Tire Pressure Monitoring System (TPMS) is a software

component in ABS Control Module J104 .

The ABS control module compares the speed and thus the
rolling circumference of the individual wheels using the
ABS sensors. If there is a change in rolling circumference
of a wheel, this is indicated via Tire Pressure Monitoring
System (TPMS). The wheel circumference of a tire
changes when:

„ Tire pressure is too low.

„ Tire has structural damage.

„ Load is imbalanced in vehicle to one side.

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

pulling a trailer or when driving up- and downhill).

„ Snow chains are used.

„ Spare wheel is mounted.

„ One wheel on an axle was replaced.

Work descriptions (part 2 of 2) Page 22 / 57

Tire Pressure Monitoring Display Indicator Lamp K220 is

indicated by a yellow warning lamp in the instrument
cluster - arrow - .

„ "FLASHING LIGHT" means that no "INITIAL BASIC

SETTING" has been performed yet.

„ "CONSTANT LIGHT" in conjunction with a warning

tone means "WARNING" , a tire pressure loss was
detected, check tire pressure, perform basic setting.

Performing "INITIAL" basic setting

- Switch ignition on.

- Press button for ESP - 1 - and button SET - 2 - in

center console simultaneously for more than 2 seconds.

If button ESP is not present, press button for ASR .

Start of basic setting is indicated by a tone.

When switching ignition on next time, warning tone will no

longer be heard.

Performing basic setting

- Switch ignition on.

Work descriptions (part 2 of 2) Page 23 / 57

- Press button for ESP - 1 - and button SET - 2 - in

center console simultaneously for more than 2 seconds.

If button ESP is not present, press button for ASR .

Tire Pressure Monitoring Display Indicator Lamp K220

lights up in instrument cluster - arrow - as long as button
is pressed.

Start of basic setting is indicated by a tone.

When switching ignition on next time, warning tone will no

longer be heard.

Intake manifold bolts, tightening flange bolts to

tightening torque (2.5L 5-cyl. fuel injected engine)

Special tools, testers and auxiliary items required

„ Torque Wrench 5-50Nm VAG1331

„ Bit XZN 18 T10107 A

Required work conditions:

„ Engine cover was already removed for replacing

spark plugs, 01-5, Spark plugs, replacing .
Work descriptions (part 2 of 2) Page 24 / 57

Note:

„ At intake manifold bolt connection, flange bolts

should be retightened to tightening torque, e.g. when
replacing spark plugs.

„ This covers vehicles of model year 2005, with

Vehicles Identification Numbers (VIN) 1K5M600098
to 1K5M603002.

Work procedure:

- Check tightening torque of 9 bolts - arrows - using

Torque Wrench 5-50Nm VAG1331 and socket and
extended bit T10107 A .

„ Tightening torque is 9 Nm.

Dust and pollen filter, cleaning housing and replacing

filter element

Note:

„ Clean surrounding area of dust and pollen filter in air

conditioner/heater shaft before installing new filter.

- Perform the following work procedure:

Work descriptions (part 2 of 2) Page 25 / 57

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

- .

Screw clips - A - come in different versions, e.g. - C - and

- D - .

- If necessary, remove bolts - A - .

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

cover - B - in case catches - D - no longer hold.

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

cover.

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

conditioner or heater.
Work descriptions (part 2 of 2) Page 26 / 57

Note:

„ Observe disposal regulations!

- Clean shaft - B - of air conditioner or heater e.g. using a

vacuum cleaner.

- Install in reverse order of removal.

Headlight setting, checking

Adjusting Halogen headlights, 01-5, Adjusting main

headlights with halogen lamps .

Adjusting gas-discharge headlights, 01-5, Adjusting

main headlights with gas discharge lamps .

Adjusting fog lights and other auxiliary headlights, 01-5,

Adjusting fog lights and other auxiliary headlights .

Test requirements

Special tools, testers and auxiliary items required

„ Headlight adjuster VAS 5046 or

„ Headlight adjuster VAS 5047

Test and adjustment requirements:

„ Tire pressure OK

„ Lenses must not be damaged or dirty.

„ Reflectors and bulbs OK.

„ Vehicle load must be established.

Work descriptions (part 2 of 2) Page 27 / 57

„ Vehicle and headlight adjuster must be on a level

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

„ Vehicle and headlight adjuster must be aligned.

„ Inclination measure must be set.

Inclination specification in "%" is embossed in trim above

headlight. Headlights must be adjusted according to this
specification. Percentage specification is based on a
projection distance of 10 meters. For example: inclination
of 1.0 % converts to approx. 10 cm.

For vehicles with Halogen headlights with manual

headlight range control:

„ Thumb wheel for headlight range control must stand

in position - 0 - .

Load: With one person or 75 kg on the drivers seat with

otherwise unloaded vehicle (curb weight).

The curb weight is the weight of the vehicle ready for

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

If the fuel tank is not filled to at least 90 %, establish the

load as follows:

- Check fill level of fuel tank via fuel gauge. Determine the
additional weight according to the following table and place
the weight in the luggage compartment.

Table of filling quantity:

Fill level of Additional weight

fuel gauge in kg
1/4 30
1/2 20
3/4 10
Full 0

Example:
Work descriptions (part 2 of 2) Page 28 / 57

If the tank is filled half way, an additional weight of 20 kg

must be placed into the luggage compartment.

Note:

„ As additional weight it is recommended to use fuel

canisters filled with water (a 5-liter fuel canister
weighs approximately 5 kg).

Vehicles with manual headlight range control:

„ Thumb wheel for headlight range control must stand

in position - 0 - .

Checking headlight setting (with test screen without 15

setting line)

Main headlights:

Check the following:

- With the low beam switched on, check whether the

horizontal light-dark border contacts the hyphenated line -
1 - of the test surface and

- 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 low
beam again.

„ After correct adjustment of low beams the center

Work descriptions (part 2 of 2) Page 29 / 57

point of the light beam of high beams must lie on the

central mark - 3 - .

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

adjust as for new test screen. To avoid incorrect
settings disregard 15 -setting line.

Fog lights:

- Check whether the upper light-dark border touches the

setting line and runs across the entire test screen width
horizontally.

Other auxiliary headlights:

Later inserted auxiliary headlights of other systems must

be checked and adjusted according to the guidelines
applicable to them.

Adjusting main headlights with halogen lamps

Main headlight (left):

Adjustment screws for right headlight are arranged

symmetrically
Work descriptions (part 2 of 2) Page 30 / 57

„ Adjustment screw - 1 - for vertical adjustment

„ Adjustment screw - 2 - for vertical-/lateral

adjustment

- For vertical adjustment, turn adjustment screws - 1 - and

- 2 - with the same number of rotations.

- Only use adjustment screw - 2 - for lateral adjustment.

Adjusting main headlights with gas discharge lamps

Perform basic setting:

- Connect diagnostic tester 01-3, Diagnostic tester,

connecting .

- Switch on ignition.

- Select "Guided Fault Finding" .

Work descriptions (part 2 of 2) Page 31 / 57

Enter vehicle data, all control modules are checked.

- Select the following options in the sequence indicated:

„ Go to

„ Function/Component selection

„ Body

„ Electrical system

„ 01 - On Board Diagnostic (OBD) capable systems

„ 55 - Dynamic vertical headlight aim control

„ J431 - Headlamp Range Control Module, functions

„ J431- Headlamp Range Control Module, basic

setting

„ Press button

- Follow the procedure on tester and confirm the entry until

the following text is displayed:

J431- Headlamp Range Control Module, basic setting

„ Press button

- Follow the procedure on tester and confirm the entry until

the following text is displayed:

J431- Headlamp Range Control Module, basic setting

- Follow the procedure on tester.

- Check headlight adjustment and correct if necessary

- Complete function program for J431-Headlamp Range

Control Module, basic setting.

Note:

„ Also check whether both headlights work evenly

when operating the manual headlight range control.
Work descriptions (part 2 of 2) Page 32 / 57

Adjusting left main headlight:

Adjustment screws for right headlight are arranged

symmetrically

„ Adjustment screw - A - for vertical adjustment

„ Adjustment screw - B - for vertical-/lateral

adjustment

- For vertical adjustment, turn adjustment screws - A - and

- B - with the same number of rotations.

Adjusting fog lights and other auxiliary headlights

Fog lights in main headlights:

Note:

„ Adjustment of fog lights occurs automatically with

adjustment of main headlights.

Other auxiliary headlights

Later inserted auxiliary headlights of other systems must

be checked and adjusted according to the guidelines
applicable to them.

Sunroof, checking function, cleaning and lubricating

guide rails
Work descriptions (part 2 of 2) Page 33 / 57

Perform the following work procedure:

- Check function of sunroof.

- Clean guide rails - arrows - and lubricate with special

grease.

Windshield wash/wipe system and headlight wash

system, check function

Check freeze protection of windshield cleaner concentrate

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

Windshield wipe-/wash system: Check spray nozzle

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

Headlight wash system: Check spray nozzle adjustment,

adjust if necessary 01-5, Headlight wash system, check
spray nozzle adjustment, adjust if necessary .

Checking frost protection content of fluid, if necessary top off

with fluid

Special tools, testers and auxiliary items required

„ Refractometer T10007
Work descriptions (part 2 of 2) Page 34 / 57

Read the bright/dark boundary to obtain an accurate

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

- Check the concentration of the anti-freeze additive using

refractometer T10007 (operating instructions).

Scale - 1 - of refractometer applies to windshield cleaner

concentrate G 052 164 .

The scale - 2 - is designed for commercially available

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

Mixture ratio:

Freeze protection to W/screen clear Water

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

-22/-23 C 1 part 2 parts

-37/-38 C 1 part 1 part

Filling-up with fluid:

The windshield wash/wipe system fluid reservoir must be

filled up fully.

Use only windshield cleaner concentrate G 052 164 all-

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

Note:

„ Windshield cleaner concentrate G 052 164 protects

the spray nozzles, fluid reservoir and hoses from
Work descriptions (part 2 of 2) Page 35 / 57

freezing.

„ All vehicles with fan type spray jets must be filled

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

„ Fill with windshield cleaner concentrate G 052 164

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

„ Frost protection (anti-freeze) must be guaranteed to

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

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

adjust if necessary

Special tools, testers and auxiliary items required

„ Adjustment tool T10127 equipped with needle 3125/

5A

Note:

„ The spray jets must not be cleaned opposite to

direction of spray, e.g. blown-through from front.
Work descriptions (part 2 of 2) Page 36 / 57

Spray nozzle adjustment of front window:

The washer nozzles are preset. Small height adjustments

can be made.

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

direction upward or downward as follows:

- Adjust the spray stream by turning at the adjuster -

arrow - with a screwdriver.

„ "Clockwise" deeper adjustment.

„ "Counterclockwise" higher adjustment.

Headlight wash system, check spray nozzle adjustment, adjust

if necessary

Special tools, testers and auxiliary items required

Work descriptions (part 2 of 2) Page 37 / 57

„ adjustment fixture 3019A or

„ Adjustment device T10167

Spray jet adjustment for left headlight (right headlight is

identical but reversed)

Check spray jet setting.

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.

Spray pattern should encounter headlight lamps at center,

see - B - and - C - .

Adjusting nozzles

- Switch on driving lights.

- Operate windshield washer system for front window.

Headlights are washed when windshield washer lever is

held in "wipe position" at least 1.5 seconds.
Work descriptions (part 2 of 2) Page 38 / 57

Spray nozzles - arrow - are driven outward.

- Perform the following work procedure:

- Direct the spray direction of respective nozzle using

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

Windshield wiper blades, checking rest position

Front windshield wiper blades: Checking rest position

Note:

„ Every second time the wiper motor is switched off it

returns the wiper arms to a slightly higher rest
position, thus tipping the wiper blade lips the other
way.

„ To achieve this, the wiper motor moves the wiper

arms to rest position and then slightly again. This
raised rest position must not be used to adjust/check
the wiper crank.

„ To check, use rest position where wiper motor runs

directly into normal end position (not lowered). If
Work descriptions (part 2 of 2) Page 39 / 57

necessary, operate touch-sweep function once

again.

- Switch windshield wiper on and off and let run to end

position.

- Switch ignition off.

- Check the distance between wiper blade tips and plenum

chamber cover at bottom edge of windshield:

„ Dimension - a - = 0...10 mm

„ Dimension - b - = 10...20 mm

- If necessary, adjust wiper arm:

Adjusting windshield wiper blades

Repair Manual, Electrical Equipment, Repair Group 92,

Windshield wiper blades - end position

Tie rod ends, checking play, security and joint boots

Perform the following work procedure:

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

moving track rods and wheels. Play: none

- Check mountings.
Work descriptions (part 2 of 2) Page 40 / 57

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

proper seating.

Door arrester, lubricating

Perform the following work procedure:

- Grease door arrester at points shown - arrows - .

Use solid lubricant G 000 150 .

Transport mode, switch off

Special tools, testers and auxiliary items required

Work descriptions (part 2 of 2) Page 41 / 57

„ Diagnostic Operation System VAS5051A

„ Vehicle Diagnosis Service Syst. VAS5052 or

succeeding models

„ Diagnostic Cable-5 Meters VAS5051/6A

Work descriptions (part 2 of 2) Page 42 / 57

- Connect Diagnostic Operation System VAS5051A or

Vehicle Diagnosis Service Syst. VAS5052 via Diagnostic
Cable-5 Meters VAS5051/6A .

- Switch on ignition

Indicated on display:

Select operating mode

- Press "Vehicle Self-Diagnosis" on display.

Note:

„ If indications shown in work procedure are not

shown on display: Operating instructions for
Diagnostic Operation System VAS5051A or Vehicle
Diagnosis Service Syst. VAS5052 .
Work descriptions (part 2 of 2) Page 43 / 57

Indicated on display:

- Press "Collecting services" on display

Indicated on display:

- Press "Switch off transport mode" on display

End Output

Indicated on display:

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

Work descriptions (part 2 of 2) Page 44 / 57

Indicated on display:

- Press "End" button - arrow - on the display.

- Press "End" button in the exit menu.

- Switch ignition off.

Note:

„ Diagnostic Operation System VAS5051A or Vehicle

Diagnosis Service Syst. VAS5052 may possibly
remain connected for various tests.

Transport locks, removing locking elements from front

axle springs

There are locking elements installed in front axle springs

on vehicles with sport suspension. These vehicles can be
identified by a tag attached at the mirror - arrow - .

Note:

„ The locking elements prevent damage to vehicle

caused by compression of springs when driving onto
an auto transporter or railway car.
Work descriptions (part 2 of 2) Page 45 / 57

Warning!

Make sure that locking elements are removed before

delivery! A "WARNING!" tag, attached to interior
rearview mirror, is an explicit reminder.

Perform the following work procedure:

Note:

„ Removal of the wheels is not necessary.

„ Be careful not to damage surface of springs!

- Relieve tension on coil springs by lifting vehicle using

platform.

- Press locking element - arrow - off coil spring.

Underbody sealant, performing visual check for

damages

During visual check, observe floor pan, wheel housings

and sills!

Note:

„ Malfunctions found must be rectified (repair

measure). This inhibits corrosion and rusting
through.

Clock, setting

The adjustment buttons are located on left side under

tachometer.
Work descriptions (part 2 of 2) Page 46 / 57

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

only briefly to set one hour ahead.

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

only briefly to set one minute ahead.

Toothed belt for camshaft drive - TDI pump injector

engines, checking

Condition of toothed belt, checking

- Remove toothed belt cover,

Repair Manual, 1.9 Liter 4-Cyl. 2V TDI PD Engine

Mechanical, Fuel Injection Glow Plug, Engine Code(s):
BRM, Repair Group 15, Cylinder head, removing and
installing

- Check condition of toothed belt for:

„ - A - Cracks, cross-sectional breaks, tears (cover-

side)
Work descriptions (part 2 of 2) Page 47 / 57

„ - B - Lateral movement

„ - C - Fraying of cord strands

„ - D - Tears (in tooth base)

„ Layer separation cover layer, cord strands)

„ Surface cracks (plastic sheathing)

„ Traces of oil and grease

Note:

„ It is essential to replace toothed belt if malfunctions

are found. This will avoid possible break-downs or
operating problems. The replacement of a toothed
belt is a repair measure.

Toothed belt and toothed belt tensioning roller - TDI

pump injector engines, replacing

- Toothed belt, removing and installing

Repair Manual, 1.9 Liter 4-Cyl. 2V TDI PD Engine

Mechanical, Fuel Injection Glow Plug, Engine Code(s):
BRM, Repair Group 15,

Toothed belt for camshaft drive - 2.0 L TFSI, replacing

- Toothed belt, removing and installing

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

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

Toothed belt for camshaft drive - 4 cyl. - Gasoline

engines, checking
Work descriptions (part 2 of 2) Page 48 / 57

Condition of toothed belt, checking

- Remove toothed belt cover,

Repair Manual, Engine Mechanical, Repair Group 15,

Cylinder head, removing and installing

- Check condition of toothed belt for:

„ - A - Cracks, cross-sectional breaks, tears (cover-

side)

„ - B - Lateral movement

„ - C - Fraying of cord strands

„ - D - Tears (in tooth base)

„ Layer separation (cover layer, cord strands)

„ Surface cracks (plastic sheathing)

„ Traces of oil and grease

Note:

„ It is essential to replace toothed belt if malfunctions

are found. This will avoid possible break-downs or
operating problems. The replacement of a toothed
belt is a repair measure.
Work descriptions (part 2 of 2) Page 49 / 57

Spark plugs, replacing

Replacing spark plugs, 2.0 L Turbo direct fuel injection

engine 01-5, Replacing spark plugs, 2.5 L fuel injected
engine .

Replacing spark plugs, 2.5 L fuel injected engine 01-5,

Replacing spark plugs, 2.5 L fuel injected engine .

Special tools, testers and auxiliary items required

„ Spark Plug Removal Tool 3122B

„ Torque Wrench 5-50Nm VAG1331

Work descriptions (part 2 of 2) Page 50 / 57

„ Ignition Coil Puller T40039

„ Puller For Ignition Coil T10094

„ Spark Plug Connector Tool T10029

„ Puller T10112
Work descriptions (part 2 of 2) Page 51 / 57

„ Assembly Tool T10118

Replacing spark plugs, 2.0 L Turbo direct fuel injection engine

Removing:

Perform the following work procedure:

Note:

„ To remove spark plugs, position Ignition Coil Puller

T40039 at uppermost rib - arrow - of ignition coil
with power output stage.

„ If lower ribs are used, ribs could be damaged.

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

removing and installing .
Work descriptions (part 2 of 2) Page 52 / 57

Spark plugs are located beneath ignition coils with power

output stage - 2 - .

Note:

„ Note installation position of ignition coils with power

output stage!

- Remove both bolts - 1 - .

- Remove all ignition coils approx. 30 mm out of cylinder

head in direction of - arrow - using Ignition Coil Puller
T40039 .

- Push connector in direction of ignition coils with power

Work descriptions (part 2 of 2) Page 53 / 57

output stage, press catch down by hand and disconnect

connector - arrows - .

- Remove spark plugs using Spark Plug Removal Tool

3122B .

Note:

„ Spark plug identification and tightening torque,

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

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

„ Observe disposal regulations!

Installing

- Thread in new spark plugs using Spark Plug Removal

Tool 3122B .

- Guide ignition coils with power output stage into cylinder

head.
Work descriptions (part 2 of 2) Page 54 / 57

- Align ignition coils with power output stage into

designated recesses of cylinder head cover.

- Connect all connectors to ignition coils - arrows - .

- Press ignition coils with power output stage onto spark

plugs by hand until stop. They must engage noticeably.

- Secure wire routing using bolts - 1 - .

- Install engine cover.

Replacing spark plugs, 2.5 L fuel injected engine

Caution!

„ When replacing spark plugs for the first time,

make sure flange bolts of intake manifold
connection are retightened to tightening torque,
01-5, Intake manifold bolts, tightening flange bolts
to tightening torque (2.5L 5-cyl. fuel injected
engine) .

Removing:

Note:
Work descriptions (part 2 of 2) Page 55 / 57

„ To remove spark plugs, position Ignition Coil Puller

T40039 at uppermost rib - arrow - of ignition coil
with power output stage.

„ If lower ribs are used, ribs could be damaged.

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

removing and installing .

Spark plugs are located beneath ignition coils with power

output stage.

- Disconnect connector - 1 - using Assembly Tool

T10118 in direction of arrow.

Note:

„ Disconnecting connector is necessary in order to lay

aside ignition coils with power output stage,
including connected cables and wiring!
Work descriptions (part 2 of 2) Page 56 / 57

- Remove all ignition coils with power output stage - 1 -

upward using Ignition Coil Puller T40039 .

Note:

„ When removing ignition coils with power output

stage, wires and ignition coil connectors may remain
connected.

„ Note installation position of ignition coils with power

output stage!

- Carefully lay aside ignition coils with power output stage

and connected wires.

Caution!

Make sure wires are not kinked or damaged.

- Remove spark plugs using Spark Plug Removal Tool

3122B .

Installing

- Thread in new spark plugs using Spark Plug Removal

Tool 3122B and tighten to 20 Nm.
Work descriptions (part 2 of 2) Page 57 / 57

- Guide ignition coils with power output stage into cylinder

head and align ignition coils to designated recesses in
cylinder head cover.

- Press ignition coils with power output stage onto spark

plugs until stop, they must engage noticeably.

- Connect connector onto exhaust gas recirculation valve

until it engages noticeably.

Note:

„ Make sure that wiring of ignition coils with power

output stage is routed properly.

- Install engine cover 01-4, Upper engine cover,

removing and installing .