CONTENT
✓ 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF
Technical data
Engine, removing and installing
Engine, disassembling and assembling
Sealing flanges and dualmass flywheel, removing and installing
Crankshaft, removing and installing
Piston and connecting rod, disassembling and assembling
Cylinder head, servicing
Valve gear, servicing
Lubrication system components, servicing
Cooling system components, servicing
Components of fuel supply system, servicing
Evaporative Emissions
Electronic Power Control (EPC)
Exhaust system components, servicing
Secondary air system
✓ 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF
On Board Diagnostic (OBD)
DTC memory
DTC table: SAE PO codes
DTC table: SAE P1 codes
DTC table: SAE P2 codes
DTC table: SAE P3 codes
Output Diagnosis Test Mode (DTM)
Readiness code
Readiness code
Measured value (data) blocks
Fuel injection system, servicing
Components, checking
Functions, checking
Motronic Engine Control Module (ECM) -J220-
Additional signals, checking
Ignition system, servicing
✓ 5 & 6 Spd. Manual Transmission 02M
Transmission identification
Transmission layout
Calculating overall ratio “i”
General repair instructions
Clutch mechanism, repairing
Clutch release mechanism, servicing
Clutch, servicing
Gear selector mechanism, servicing
Transmission, removing and installing
Transmission gear oil, checking
Transmission, disassembling and assembling
Transmission housing, servicing
Clutch housing, servicing
Transmission selector mechanism, disassembling and assembling
Selector forks, disassembling and assembling
Input shaft, disassembling and assembling
Input shaft, adjusting
Output shaft, 1st-4th gear, disassembling and assembling
Output shaft for 1st-4th gears, adjusting
Output shaft for 5th, 6th and reverse gear, disassembling and assembling
Output shaft for 5th, 6th and reverse gear, adjusting
Oil seals for flanged shafts, replacing
Differential, disassembling and assembling
Adjustment overview
Differential, adjusting
✓ Brake System On Board Diagnostic (OBD)
ABS ITT Mark 20 IE On Board Diagnostic (OBD)
Electrical/electronic components and locations
ABS ITT MK 20 IE On Board Diagnostic (OBD) program
ABS, ABS/EDL and ABS/EDL/ASR ITT Mark 20 IE, electrical check
ABS Mark 60 On Board Diagnostic (OBD), vehicles from my 10.00
Electrical/electronic components and installing locations
Diagnostic Trouble Codes (DTCs) displayed by warning lights -K47-, -K118-,-K155-
On Board Diagnostic (OBD), performing
Electrical check of Mark 60
Definitions
✓ Brake System
Technical data
Technical data, brakes
Anti-lock brake system (ABS) and antilock brake system with electronic differential lock (ABS/EDL) ITT Mark 20 IE
Hydraulic unit, brake booster/master cylinder, overview
ABS system components for front axle, removing and installing
Anti-lock brake system (ABS) Mark 60
VAS 5051 Vehicle Diagnostic, Testing and Information System, connecting and electing functions
Electrical/electronic components and installing locations (ABS) Mark 6
Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview
DTCs displayed by (ABS) Mark 60 warning lights -K32-, -K47-, -K118-, and -K155-
ABS system components for front and rear axles, removing and installing
ESP system components, removing and installing
Front brakes
Rear wheel brakes (disc brakes – front wheel drive), assembly overview
Rear wheel brakes/disc brakes (allwheel drive), servicing
Parking brake cables for disc brakes – front wheel drive, removing and installing
Parking brake cables for disc brakes – all wheel drive, removing and installing
Parking brake lever, assembly overview
Brake pedal assembly overview
Front brake calipers, servicing
FN 3 front brake calipers, servicing
Rear brake caliper, servicing
Brake pressure regulator, assembly overview
Brake system, bleeding
Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 10.00
Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP Mark 60 from m.y. 10.00, assembly overview
Brake master cylinder, removing and installing
Brake booster, removing and installing
Definitions
✓ Suspension, Wheels, Steering
Technical data
Check list for evaluating the suspension of accident vehicles
Evaluation of accident vehicles
Electrical/electronic components and installation locations
Front suspension, servicing
Front suspension R32, servicing
Front drive axle, servicing
Evaluation of accident vehicles
Rear axle, servicing
Wheel bearing, servicing
Rear axle, servicing (all wheel drive vehicles)
Trailing arm and transverse links (allwheel drive vehicles), assembly overview
Subframe with final drive, assembly overview
Rear drive axle, servicing
Evaluation of accident vehicles
Tightening torques for wheel bolts
Protecting wheel centering seat against corrosion
Wheels, tires
Wheel alignment
Wheels, tires
Evaluation of accident vehicles
Connecting VAS 5051 and selecting functions
Airbag
Steering column
Power steering, servicing
Power steering pump, reservoir and hydraulic lines
Definitions
✓ Body Collision Repair
Technical data
Body foam insulation
Reinforced body sheet metal
Laser welding
Galvanized body panels
Body panel gaps/mating lines
Body dimensions
Straightening fixture
50 40 55 50 Engine mount bracket, replacing
50 52 55 50 Intermediate piece, replacing
50 53 55 50 fender connecting plate, replacing
50 72 55 50 long member for upper wheel house, replacing
50 74 55 00 Front wheel house, partial replacing
50 75 55 50 Front inner fender, replacing
50 79 55 00 Front long member, replacing
50 79 55 02 Front long member, partial replacing
50 80 55 00 Long member front section, replacing
51 03 55 00 Roof, replacing (Golf)
51 03 55 00 Roof, replacing (Jetta)
51 03 55 20 Roof, replacing (Jetta wagon)
51 07 55 50 Front roof cross member, replacing
51 08 55 50 Roof reinforcement, replacing
51 09 55 50 Rear roof cross member, replacing (Golf)
51 09 55 50 Rear cross member, replacing (Jetta)
51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)
51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)
51 37 55 00 Apillar, inner, replacing
51 38 55 50 Apillar, inner, replacing
51 41 55 62 B-pillar, replacing (4 door), 51 41 55 52 B-pillar, replacing (Jetta)
51 42 55 50 Inner B-pillar, replacing (2-door)
51 42 55 60 Inner B-pillar, replacing (4-door), 51 42 55 50 inner B-pillar, replacing (Jetta)
51 45 55 00 Outer side member, replacing (2-door)
51 45 55 10 Outer side member, replacing (4-door), 51 45 55 00 outer side member, replacing (Jetta)
51 49 55 50 Side member reinforcement, replacing
51 73 55 50 Floor plate, partial replacement
53 05 55 50 Rear cross panel, replacing
53 05 55 20 Rear cross panel, exterior, replacing (Jetta wagon)
53 05 55 23 Rear cross panel, complete, replacing (Jetta wagon)
53 48 55 50 Rear long member, replacing (Jetta)
53 47 55 52 Long member, partial replacement (Jetta)
53 55 55 10 Quarter panel, partial replacement (Golf 4-door)
53 55 55 00 Quarter panel, partial replacement (Jetta)
53 55 55 20 Side panel, partial replacement (Jetta wagon)
53 69 55 50 Quarter panel, partial replacement (Golf)
53 69 55 50 Wheel house connecting panel, partial replacement (Jetta)
53 36 55 50 Connecting panel, replacing (Jetta)
53 69 55 70 Rear wheelhousing, outer, replacing – partial section- (Jetta wagon)
53 80 55 50 Spare wheel well, replacing (Golf)
53 80 55 52 Spare wheel well, partial replacement (Golf)
53 80 55 50 Spare wheel well, replacing (Jetta)
✓ Body Exterior
Body, front
Hood
Rear lid (Golf)
Rear lid (Jetta)
Rear lid, (Jetta Wagon)
Tank flap unit
Front door
Central locking system
Rear doors
Sunroof
Sunroof with glass panel (Webasto)
Sunroof with glass panel (Meritor)
Front bumper
Rear bumper
Flush-bonded windows
Door windows
Wheelhousing liner, removing and installing
Outside rear view mirror
✓ Body Interior
Seatbelts
Seatbelts, inspecting
Inspecting child seat anchors after accident (ISOFIX)
Airbag
Crash sensors
Instrument panel
Door trim
Pillar and side trim
Luggage compartment trim
Rear lid trim
Headliner
Front seats
Rear seats
Front seat cushion and cover
Seat heating elements
Rear seat upholstery and cover
✓ Body On Board Diagnostic (OBD)
On Board Diagnostic (OBD)
Airbag system, On Board Diagnostic (OBD)
Convenience system (vehicles with power windows), On Board Diagnostic (OBD)
Central locking system (vehicles without power windows), On Board Diagnostic (OBD)
Driver’s side seat adjustment, On Board Diagnostic (OBD)
✓ Heating and Air Conditioning
On Board Diagnostic (OBD) through m.y. 2001
On Board Diagnostic (OBD) from m.y. 2002
Climatronic On Board Diagnostic (OBD) through m.y. 2001
Heating and ventilation system, servicing Manual A/C Climatronic
A/C refrigerant system
A/C refrigerant system, servicing
A/C refrigerant system, troubleshooting
A/C refrigerant system, capacities
Compressor bracket, removing and installing
✓ Refrigerant R134a – Servicing
General information for A/C system
General information on refrigerant circuit
Laws and regulations
Refrigerant circuit
Complaints
Service station, connecting
Pressures, checking on vehicles
Components, replacing
Testing equipment and tools
✓ Electrical Equipment On Board Diagnostic (OBD)
On Board Diagnostic (OBD) through m.y. 2001
On Board Diagnostic (OBD) from m.y. 2002
Instrument cluster through m.y. 1999, On Board Diagnostic (OBD)
Instrument cluster m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)
Data Bus On Board Diagnostic Interface -J533- (“Gateway”) m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)
Anti-theft immobilizer, On Board Diagnostic (OBD)
✓ Electrical Equipment
Battery
Battery, checking
Battery, charging
Battery, disconnecting and reconnecting
Battery, removing and installing
Battery, tightening torques
Starter
Starter, tightening torques
Generator (GEN)
Generator (GEN) through 04.99
Generator (GEN) from 05.99
Generator (GEN) -4- cylinder gasoline engines
Generator (GEN) -6- cylinder gasoline engines
Generator (GEN) -4- cylinder TDI engines
Generator (GEN) -4- cylinder TDI-PD engines
Generator (GEN), tightening torques
Cruise Control System (CCS) through m.y. 2001
Cruise Control System (CCS) from m.y. 2002
Instrument cluster
Windshield wiper system
Windshield wiper system, tightening torques
Washer system
Rear window wiper & washer system
Rear window wiper system, tightening torques
Washer hoses, repairing
Headlights Golf
Headlights – Jetta
Side mounted turn signals
Rear lights
Rear lights, tightening torques
License plate lights
High-mount brake light
Steering column switches
Ignition/starter switch and lock cylinder
Interior lights and switches
Anti-theft Immobilizer
Fuse holder and relay carriers
Fuse holder and relay carriers, tightening torques
Wiring harnesses and connectors, repairing
Antenna cables, replacing
✓ Communication
Radio system – “Premium IV” and “Premium V” (including “Monsoon”) through 11.01, On Board Diagnostic (OBD)
Radio system – “Premium VI” (including “Monsoon) from 12.01, On Board Diagnostic (OBD)
Multi-function steering wheel through 11.01, On Board Diagnostic (OBD)
Multi-function steering wheel from 12.01, On Board Diagnostic (OBD) Communication
Radio systems
Radio, “Premium IV”
Radio, “Premium V” & “Premium V – Monsoon”
Radio, “Premium VI” & “Premium VI – Monsoon”
Amplifier system – “Monsoon”
Speaker system
Antenna systems
CD Changer / CD Player
Multi-function steering wheel
Telematics
Mobile telephone and two-way radio operation, notes
✓ Maintenance
Engine overview
Service work
Oil change service
Delivery inspection
Maintenance service
General
Description of work (part 1 of 2)
Description of work (part 2 of 2)
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