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Engine oil level, checking - Volkswagen Technical Site

1. 01 5 Fuel filter draining water Diesel engine 01 5 Brake fluid changing 01 5 Brake fluid level checking 12 7 2004 Inspection service Page 4 of 5 01 5 Battery Battery Checking checking 01 5 Idle speed Idle speed Checking Diesel engine code AAZ Checking Vehicles with Diesel engine code AAZ on which no emissions test has been performed Final work procedures 01 5 Checking tire Tire filling pressure at all 4 wheels and spare wheel condition tread wear Checking pattern filling pressure and tread depth 01 5 Headlight Headlight setting Checking setting checking Service sticker Note date for next scheduled service also brake fluid change and affix sticker to driver s side door beam B pillar 01 5 Road test Road test vehicle performing Applicable only for countries where there are no country specific mandatory exhaust emission regulations Inspection service every 20 000 miles 30 000 km n Ask customer whether new wiper blades should be fitted and whether they require Windshield Clear G 052 164 cleaner and anti freeze in windshield washer system n Check First aid box storage life date has not been exceeded If this is case ask customer whether First Aid box should be replaced n Sequence of individual service positions has been tested and optimized Therefore they should be adhere
2. Check to make sure that windshield wiper system is not juddering Checking tire condition tread wear pattern filling pressure and tread depth Note n For reasons of safety only tires of same type and tread pattern should be fitted on a vehicle Note n Vehicle must be equipped with tires of same make Otherwise This can cause damage because viscous clutch would unnecessarily increase ratio of rear final drive due to rising RPM difference of both axles n However different tread depths of front axle and rear axle tires e g due to wear is harmless It is recommended however to mount tires with greater tread depth in front n If front wheels are more strongly worn out than rear wheels they have a smaller rolling circumference and turn therefore faster n Thus tensions in drivetrain rise and tires wear faster Inspection service Check tires for scuffing one sided wear porous side walls cuts and fractures It is essential that detected defects are communicated to customer Checking tire wear pattern http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 17 of 83 Tread wear pattern on front tires is an indication of whether toe and camber settings should be checked n Feathering on tread indicates incorrect toe setting n If tread is worn on one side this is usually caused by incorrect camber When wear of th
3. Tow starting towing A towing eyelet must be screwed into front right bumper beforehand in order to be able to tow vehicle towing eyelet is supplied with vehicle tool kit Using a screwdriver pry out cover toward front and remove Screw in towing eyelet to stop and tighten using lug http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 4 12 7 2004 General Information wrench After use unscrew towing eyelet and store with vehicle tool kit Re install cover Rear towing eyelet is located at right in bumper and is covered by a flap To open flap pull flap downward and let it hang freely To close flap first insert at bottom and press upward until it engages Note n Tow ropes or bars should be attached at above mentioned points only n Tow rope should be able to stretch to reduce risk of damage to both vehicles It is advisable to use synthetic fiber ropes or ropes of similar elastic material only However it is safer to use a tow bar n Avoid excessive towing effort and do not jerk During towing operations on unsurfaced roads there is always a danger that attachment points will be overstressed and damaged n Battery from another vehicle should be used for starting if possible before trying to start an engine by towing If vehicle has to be tow started or towed once Note following n Regulations concerning towing must be observed
4. Vehicles with manual transmission http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 64 of 83 n bleeder hose V A G 1238 B3 670 mm long Use only new brake fluid with part number B 000 700 A corresponds to US standard FMVSS 116 DOT 4 Caution n NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids Oils containing minerals damage seals and sleeves on brake systems Brake fluid is poisonous Due to it s caustic nature it must also never be brought into contact with paint oi Brake fluid is hygroscopic meaning that it absorbs moisture from surrounding air and must therefore always be stored in air tight containers o n Rinse off any spilled brake fluid using plenty of water n Observe disposal regulations Perform following work procedure Follow user manual for brake filling and bleeding tool VAS 5234 or brake filling and bleeding tool V A G 1869 Unscrew brake fluid reservoir cap Extract as much brake fluid as possible from brake fluid reservoir using intake hose of brake filling and bleeding tool VAS 5234 or brake filling and bleeding tool V A G 1869 with upgrade kit With brake filling and bleeding tool V A G 1869 without upgrade kit extract as much brake fluid as possible using a suction bottle with built in strainer Note n Make sure that
5. Perform following work procedure Removing Remove retaining clamp 5 Remove regulating valve with attached fuel lines http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 44 of 83 Loosen bolt arrow at filter mounting pull out filter upward Installing Install new O ring for sealing of regulating valve Note n flow direction of fuel is marked at connections by arrows please do not exchange connections Fill new filter with clean diesel fuel Thus engine can be started faster http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 45 of 83 an S T NO2 0229 Slide filter downward through filter mounting and fasten it at bolt arrow Install regulating valve with attached fuel lines Install retaining clamp 5 Slide fuel hoses across hose connections 1 and 2 and secure hoses using hose clamps Check fuel system for proper seal visual check 5 Accelerate several times afterwards fuel must flow without bubbles through transparent hose at idle Fuel filter draining water Diesel engine Note n Make sure that diesel does not come in contact with coolant hoses Clean hoses immediately if necessary n Observe disposal regulations Perform following work procedure http eb
6. Printout from battery Inspection tester service Starting output very good Battery OK Starting output good Battery OK Starting output sufficient Recharge battery 1 Starting output poor Recharge battery K Starting output very poor Recharge battery 1 Not testable Recharge battery 1 Topping off distilled water batteries with magic eye To avoid electrolyte impurities which can increase self discharge of battery only distilled water may be added to increase acid level Perform following work procedure Remove foil over sealing plug Unscrew battery sealing plugs Using battery fill bottle VAS 5045 fill with distilled water up to max marking Note n Construction of filler tube of battery filler bottle VAS 5045 prevents overfilling of battery cells and escaping of battery acid When max fill level is reached inflow of distilled water into cells is interrupted n Too low an electrolyte level below min marking causes a loss of battery capacity power due to cell plates drying out If cell plates are not surrounded with electrolyte sulfuric acid plates plate straps and cell connectors will corrode battery will not function as a consequence of this corrosion battery becomes unusable n If electrolyte level is too high above max marking electrolyte a mixture of sulfuric acid and water escapes and causes damage outside battery for example to functional parts in engine compartment http eb
7. I I Code letters Year 1995 of manufacturing http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 32 of 83 Transmission code letters are also listed on vehicle data plates Brake system visual inspection Master brake cylinder brake booster with Anti lock Brake System ABS Hydraulic unit Check brake pressure regulator brake caliper for leaks and damage Make sure that brake hoses are not twisted Make sure that brake hoses do not touch any vehicle components when steering is at full lock Check brake hoses for porosity and brittleness brake hoses and brake lines for abrasions Check brake connections and mounts for proper seating leakages and corrosion Caution Malfunctions found must be repaired repair measure Brake pads front and rear checking thickness Front disc brake pads Remove a wheel for better judgement of remaining pad thickness To do so mark position of wheel in relation to brake disc and install in same position again after test Note n Since pad wear on passenger side can be slightly larger according to experience than on driver s side it is reasonable to remove front wheel on seat passenger side http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 33 of 83 Required special tools an
8. 7 2004 Oil change service Page of 2 2 Oil change service Oil change service every 10 000 miles 15 000 Km Vehicles with a yearly mileage performance greater than 10 000 miles 15 000 Km n sequence of individual service positions has been tested and optimized Therefore they should be adhered to to prevent unnecessary work interruptions n When malfunctions are found within framework of an oil change service which require repair measures inform customer n Ask customer whether new wiper blades should be fitted and whether they require Windshield Clear G 052 164 cleaner and anti freeze in windshield washer system Work to be performed page 01 5 Dust Dust and pollen filter Replace filter element and pollen filter element replacing 01 5 Toothed belt Check wear Toothed belt check wear only TDI engines TDI engines 01 5 Fuel Fuel filter Drain water filter draining water Diesel engine 01 5 Engine Engine oil Drain replace oil filter oil changing and replacing oil filter 01 5 Brake Disc brake pads front and rear Check thickness pads front and rear checking thickness 01 5 Engine Engine oil Filling oil changing and replacing oil filter Vehicles with Diesel engine which use bio diesel conforming to specification DIN E 51 606 or use diesel which does not conform to specification EN 590 http ebahn bentleypublishers
9. 7 2004 Work descriptions Page 28 of 83 Tighten first mounting bolt 2 then mounting bolt 1 to 25 Nm Front manual transmission final drive check oil level Remove bolt arrow Check oil level Oil level should reach lower edge of oil filler hole If necessary top up transmission fluid specification G 50 SAE 75W90 synthetic oil Install bolt arrow Rear final drive Syncro Check oil level Transmission fluid specification G 50 SAE 75W90 synthetic oil http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 29 of 83 Unthread bolt for checking transmission fluid arrow Oil level is correct when the rear final drive is filled up to lower edge of oil filler hole Screw in bolt arrow When filling anew note the following Unthread bolt arrow Top up transmission fluid to lower edge of oil filler hole Screw in bolt arrow Automatic transmission check final drive oil level Note n Observe disposal regulations Remove drive for speedometer wipe off with a cloth and install drive again Remove drive and check oil level Oil level must be between min and max marking Note n Oil capacity between min and max marking is 0 1L http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work des
10. Coding 00000 WSC 00000 control module identification coding and Workshop Code WSC of Scan Tool ST V A G 1551 are indicated If displayed Control module not responding HELP Press HELP button to print out an overview of all of possible malfunction causes Enter address word 02 for Transmission Electronics again after repairing malfunction and press Q button to confirm Indicated on display 096927733BA AG3 transmission 096 2754 Coding 00000 WSC 00000 Press button Indicated on display Rapid data transfer HELP Select function XX Press buttons 0 and 8 for function Read measuring value block and confirm input with Q button Indicated on display Rapid data transfer Q 08 Read measuring value block Press Q button to confirm input Indicated on display Read measuring value block Enter display group number XXX Press buttons 0 0 and 5 Press 005 to select Display group number 005 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Indicated on display Read measuring value block Q Enter display group number 005 Press Q button to confirm input ATF temperature in C appears in display field 1 exact measuring value only starting from 50 Read measuring value block 1 1234 Check ATF level at a temperature of 50 70 C using dipstick ATF level must be b
11. Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 72 of 83 load current varies depending on battery capacity and has to be adjusted on tester User manual for battery tester Perform battery load test according to user manual for battery tester and compare test printout arrow with following table Remarks concerning test printout 1 Measuring range set on tester 2 Diagram arrow indicates battery state 3 Test result 4 Battery voltage while load test is running 5 Vehicle data and date to be completed by person performing test After recharging battery perform a battery load test again 1 If after charging display shows starting output sufficient starting output poor starting output very poor or Not testable replace battery after consulting customer Explanation for battery load test Because of high load on battery during this test a high current flows battery voltage lowers If battery is in good condition voltage drops only to minimum voltage If battery is faulty or only faintly charged battery voltage will http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 73 of 83 drop rapidly to below displayed minimum voltage After test has been performed voltage will remain at this low value for a long time and will climb back up only very slowly
12. Output misfiring idling speed acceleration http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Clutch Pulling away pedal pressure odors Gear selection Ease of operation shift lever position Automatic transmission Selector lever position shift lock ignition key removal lock shift behavior instrument panel cluster display Foot operated and hand operated parking brake Function free travel and effectiveness pulling to one side juddering squeal ABS function A pulsing at 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 GALA interference Multifunction indicator MFI Functions A C system Function Vehicle Moving off line when travelling straight ahead level road Imbalance Wheels drive shafts prop shafts Wheel bearings Noises Engine Hot starting behavior Page 83 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004
13. amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 81 of 83 n For previous test screen with 15 setting line adjust as for new test screen To avoid incorrect settings ignore 15 setting line Fog lights Check whether upper light dark border touches setting line and runs across complete test screen width horizontally Other auxiliary headlights Later inserted auxiliary headlights of other systems must be checked and adjusted according to guidelines valid for them Headlights adjusting Headlight left 1 Height adjustment 2 Horizontal adjustment Perform adjustment using appropriate screwdriver do not damage adjustment wheel http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 82 of 83 Both adjustment wheels on right headlight are allocated symmetrically Note n Also check whether reflectors in both headlights adjust themselves uniformly when operating headlight range control Fog light left Turn adjusting screw toward left arrow to lower beam height Horizontal adjustment is not possible im mm ee Cate ea Adjusting screw on right headlight is allocated symmetrically Road test performing To what extent following can be checked is dependent upon vehicle equipment and local conditions urban country Following should be checked by means of a road test Engine
14. colored display of magic eye will therefore be more accurate Three different color indications are possible Green battery is sufficiently charged Black no charge or charge too low battery must be charged repair measure http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 77 of 83 Colorless or yellow gt battery must be replaced Idle speed Diesel engine code AAZ Checking Required special tools and equipment V A G 1767 n Ignition tester V A G 1767 or n Ignition tester V A G 1367 Test and adjustment requirements and specified values Emissions test Perform following work procedure Ignition tester V A G 1367 or Ignition tester V A G 1767 Check idle speed and adjust as necessary by turning idle speed adjusting screw 1 Headlight setting checking http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 78 of 83 Required special tools and equipment n headlight adjuster VAS 5046 or n headlight adjuster VAS 5047 or n headlight adjuster VAS 5208 or n headlight adjuster VAS 5209 Following test and adjustment instructions are applicable to all countries But national legislation and regulations of respective country is to be adhered to Test and adjustment requirements n Tire pressure OK
15. fuel entering catalytic converter n Tow starting vehicles with an automatic transmission is for technical reasons not possible When tow starting vehicles with manual transmission always note following Caution During tow starting vehicles up to and including 1 6L displacement risk of an accident occurring is high e g driving into towing vehicle For this reason a jump lead should be used for these vehicles Before tow starting engage 2nd or 3rd gear Switch ignition on As soon as engine starts depress clutch and shift into neutral to avoid running into towing vehicle Note n For vehicles with catalytic converter gasoline engines only engine with catalytic converter at operating http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 4 12 7 2004 General Information Page 6 of 6 temperature must not be tow started over a long distance otherwise unburned fuel reaches catalytic converter and can be burned there This may cause catalytic converter to overheat When towing a vehicle with automatic transmission following additional points must be observed n Selector lever in N position n Do not tow vehicle faster than 30 mph 50 km h n Do not tow further than 30 miles 50 km n If towing over greater distances vehicle must be suspended at front Reason When engine is not running transmission oil pump is not working and transmission is not ade
16. n Lenses must not be damaged or dirty n Reflectors and bulbs OK n Vehicle load must be established Load With one person or 165 Ibs 75 kg on driver s seat with otherwise unloaded vehicle curb weight Curb weight is weight of vehicle ready for operation with completely filled fuel tank at least 90 including weight of all equipment items carried for operation e g spare wheel tool vehicle jack fire extinguisher etc If fuel tank is not filled to at least 90 establish load as follows Check fill level of fuel tank via fuel gauge Determine additional weight according to following table and place weight in luggage compartment Table of filling quantity Fill level of Additional weight http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 79 of 83 fuel gauge in Ibs kg 1 4 100 45 1 2 66 30 3 4 33 15 Full 0 0 Example If tank is filled half way an additional weight of 66 Ibs 30 kg must be placed into luggage compartment Note n As additional weight it is recommended to use fuel canisters filled with water a 5 liter fuel canister weighs approximately 11 Ibs 5 kg Vehicle must be rolled for several meters or front and rear suspension must be bounced several times so that springs settle n Vehicle and headlight adjuster must be on a level surface User manual for headlight adjuster
17. n Vehicle and headlight adjuster must be aligned n Inclination measure must be set Inclination measure Inclination measure in is embossed at top of headlight housing Main headlights must be adjusted according to this measure percentage information on sticker is based ona projection distance of 10 meters For example inclination of 1 2 converts to approx 12 cm Inclination measure for fog lights 20 cm n Thumbwheel for headlight range control must be in base position Checking headlight setting with new test screen without 15 setting line Headlights http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 80 of 83 With low beam switched on check whether horizontal light dark border contacts hyphenated line 1 of test surface Check whether break away point 2 between left horizontal part and rising part on right of light dark border runs vertically through central point 3 Bright core of light beam must be on right of vertical line Note n 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 Next check low beam again n After correct adjustment of low beams center point of light beam of high beams must lie on central mark 3 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair
18. no brake fluid runs through strainer after completing extraction sequence brake fluid level in reservoir must stop at lower edge of strainer Caution Do not reuse used extracted brake fluid http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 65 of 83 Install brake depressor V A G 1869 2 between driver s seat and brake pedal and tension Screw adapter VAS 5234 1 or adapter V A G 1869 1 onto brake fluid reservoir Connect filler hose of brake filling and bleeding tool VAS 5234 or brake filling and bleeding tool V A G 1869 to adapter Vehicles with manual transmission Remove cover cap from bleeder screw of clutch slave cylinder Connect bleeder hose of collector bottle on bleeder screw of clutch slave cylinder open bleeder screw and allow approx 0 1 liters to flow out Close bleeder screw and install cover cap onto it Operate clutch pedal repeatedly Continuation for all vehicles Remove cover caps from bleeder screws of wheel brake cylinders and brake calipers Connect bleeder hose of collector bottle to rear bleeder screw open bleeder screw and allow corresponding bake fluid quantity to flow out see table on page 01 5 Table Sequence quantity of brake fluid Close bleeder screw For left hand drive vehicles bleed rear right first and for right hand drive vehicles bleed rear left
19. serious malfunctions or damage to engine can occur a Cooling system anti freeze protection and coolant level checking T10007 Required special tools and equipment n Refractometer T10007 Note n Read bright dark boundary to obtain an accurate reading for following tests Place a drop of water on glass to improve readability of bright dark boundary bright dark boundary can be clearly recognized on WATERLINE Check concentration of coolant additive using refractometer T10007 follow user manual http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions scale 1 of refractometer is designed for coolant additives G 12 according to TL VW 774 D and G 11 according to TL VW 774C scale 2 is designed for coolant additive G 13 Note n Coolant additive G 13 is currently used only in vehicles of type L 80 n Freeze protection additives protect against frost to about 25 C about 35 C in arctic climates n If for climatic reasons greater freeze protection protection is required amount of G 12 can be increased but only up to 60 freeze protection protection to about 40 C otherwise freeze protection protection and cooling effectiveness will be reduced E r 10 Giz anna PROPYLENE ETHYLENE WATERLINE F If freeze protection protection is insufficient drain off required quantity sh
20. servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 35 of 83 n Malfunctions found must be repaired repair measure This inhibits corrosion and rusting through Tie rod ends checking Perform following work procedure With vehicle raised wheels hanging free check play by moving tie rods and wheels arrow Play zero play Check mountings Check joint boots for damage and proper seating Ball joints checking Perform following work procedure NO2 0256 Check joint boots arrow of ball joints for leaks and damage Cooling system anti freeze protection and coolant level checking Make sure that coolant additive G 12 color red can be already filled in When adding coolant use only coolant G http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 36 of 83 12 according to TL VW 774 D Some vehicles are filled with coolant additive G 11 color green When adding coolant use only coolant G 11 according to TL VW 774 D If these vehicles were filled with G 12 for repairs only G 12 may be refilled Caution n Coolant additives G 11 and G 12 must never be mixed If fluid in expansion tank is brown G12 or G 11 has been mixed with another coolant additive In this case coolant must be replaced immediately repair measure If coolant is not changed
21. terminal connections for damage If battery terminals are damaged contact with wiring connections cannot be guaranteed This can cause a cable fire and interfere with function of electrical system Check battery for secure seating tighten securing bolt 1 on retaining bracket to 22 Nm if necessary http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 70 of 83 If battery is not securely seated following dangers exist n Shortened service life due to damage from vibration danger of explosion n If battery is not secured properly normal shock and vibration can damage battery plates which results in premature battery failure n battery casing can be damaged by fastening clip this might possibly allow acid to escape from battery which would have severe consequences n Poor crash safety Checking batteries batteries with magic eye and with top sealed battery cell plugs Checking battery batteries with magic eye and without battery cell plugs 01 5 Checking battery batteries with magic eye and without battery cell plugs magic eye arrow gives information regarding acid level and charge level of battery Before performing a visual check lightly and carefully tap onto magic eye using a screwdriver handle Air bubbles which can affect display are dispersed by doing this Reading colored display o
22. 0 22 2 6 Wagon 2 0 2 0 22 2 8 74 kW and 85 kW Sedan 2 2 2 2 2 4 2T Wagon 2 2 22 2 4 3 0 110kW Sedan 2 6 2 6 2 8 3 1 Wagon 2 6 2 6 2 8 3 4 128 kW Sedan 2 6 2 6 2 8 3 1 Wagon 2 6 2 6 2 8 3 4 135 kW Synchro Sedan Wagon 2 6 2 8 2 8 3 4 110 kW Sedan 2 6 2 6 2 8 3 1 Wagon 2 6 2 6 2 8 3 4 128 kW Sedan 2 6 2 6 2 8 3 1 Wagon 2 6 2 6 2 8 3 4 Vehicles with Diesel engine 55 kW Sedan 2 0 2 0 2 2 2 6 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Wagon 2 0 2 2 22 2 4 2 4 2 0 Dd 2 2 2 4 2 4 4 2 22 2 4 2 4 2 6 2 6 2 8 2T 3 0 2 9 lt a Meet highest intended inflation pressure for vehicle Engine oil level checking After switching engine OFF wait at least 3 minutes to allow oil to flow back into pan Remove dipstick wipe with a clean cloth and reinsert as far as stop Note n Observe disposal regulations Remove dipstick again and read oil level Area a Oil must be topped off Afterward it is sufficient if oil level is somewhere in area b Area b Oil need not be topped off Area c Oil must not be topped off Note n At an oil level above area c there is a danger of damage to catalytic converter Engine oil changing and replacing oil filter Required special tools and equipment Page 19 of 83 http ebahn bentleypublishers com vw servle
23. 1331 n Torque wrench V A G 1331 5 50 Nm http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions VAS 5097 A VAS 5097 IDD00OO00OOTOOO0OOTOUONIUUOVON n Battery tester with printer VAS 5097 or n Battery tester with printer VAS 5097 or n battery tester VAS 5096 or n battery tester VAS 5033 n Battery fill bottle VAS 5045 Page 68 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 69 of 83 n Commercially available hydrometer Inspection service Batteries with magic eye Perform a visual check 01 5 Performing visual check all batteries and check battery condition via magic eye 01 5 Checking batteries batteries with magic eye and with top sealed battery cell plugs Inspection service Batteries without magic eye Perform a visual check 01 5 Performing visual check all batteries and check electrolyte level 01 5 Checking acid level batteries without magic eye If topping off with distilled water was required also perform a battery load test 01 5 Battery load check Performing visual check all batteries Perform following work procedure Check battery housing for damage Battery acid can leak out if housing is damaged Check battery terminals battery
24. Both drivers must be familiar with specifics of towing procedures Inexperienced drivers should not attempt to tow start or tow When using a tow rope driver of towing vehicle must engage Clutch very gently when driving off and changing gear Driver of vehicle being towed must make sure that tow rope is always tight Emergency lights must be switched on both vehicles unless local regulations differ http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 4 Page 4 of 6 12 7 2004 General Information Page 5 of 6 n Ignition must be switched on so that steering wheel is free and turn signals horn and if necessary windshield wiper and washer can be used n Because brake booster only works when engine is running more pressure is required accordingly on brake pedal when engine is not running n In vehicles with Power Assisted Steering PAS more force must be used to steer when engine is not running n When there is no lubricant in a manual transmission or automatic transmission vehicle may only be towed with driving wheels lifted Important notes concerning tow starting a vehicle It is generally recommended not to tow start vehicle Instead jump leads should be used Other reasons against tow starting a vehicle n During tow starting risk of an accident occurring is high e g driving into vehicle towing n Vehicles with gasoline engines can be damaged by unburned
25. G On Board Diagnostic OBD HELP 2 Blink code output is displayed alternately Press button 1 to select Rapid data transfer operating mode Indicated on display Rapid data transfer HELP Enter address word XX Press buttons 0 and 0 for address word Automatic test sequence Indicated on display Rapid data transfer Q 00 Automatic test sequence http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 3 of 83 12 7 2004 Work descriptions display indicates number of stored errors or indicates no malfunction recognized DTCs stored in system are indicated in sequence and printed out Then VAG1551 Scan Tool ST V A G 1551 sends next address word Automatic test sequence has ended when following indication appears on display VAG On Board Diagnostic OBD HELP 1 Rapid data transfer or VAG On Board Diagnostic OBD HELP 2 Blink code output is displayed alternately Switch ignition off If malfunctions are stored then a repair measure is required Pass malfunction protocol on for repair Checking DTC memory of all systems using Vehicle Diagnosis Testing and Information System VAS 5051 Required special tools and equipment VAS 5051 Gf n Vehicle Diagnostic Test and Information System VAS 5051 Va MONM SI r L WW S DOS vac anni SSS http ebahn bentleypublishers com vw servlet Display a
26. VW standard 502 00 This oil suitable for gasoline engines corresponds to VW standards 501 00 505 00 as well as 500 00 and additionally exhibits further advantages It is particularly suitable for application with more strenuous operating conditions e g difficult road conditions predominant use of trailer high portion of uphill driving and driving in hot climate zones Note n Single range oils are generally not all year round usable because of their limited viscosity range These oils should be used therefore only in extreme climate zones n When using Multi grade oil SAE 5 W 30 continuously high engine speeds and constant strong load must be avoided This restriction does not apply to multi grade light duty oils Engine and components in engine compartment from above and below check for leaks and damage Perform visual check as follows Check engine and components in engine compartment for leaks and damage http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 25 of 83 Check hoses pipes and connections of n Fuel system n Cooling and heating system n Brake system For leaks abrasions porosity and brittleness Note n Make sure that all malfunctions detected are repaired within repair measures n If fluid losses are greater than can be reasonably expected determine cause and repair repair measure V bel
27. W Volkswagen Passat 1995 1996 1997 Gasoline Turbo Diesel TDI 4 cylinder and VR6 including wagon Maintenance Maintenance Engine overview Oil change service Oil change service every 10 000 miles 15 000 Km Inspection service Inspection service every 12 months Inspection service every 20 000 miles 30 000 km General Information Type plate Vehicle Identification Number VIN Engine code and engine number Vehicle lifting Tow starting towing Work descriptions Driver s and front passenger airbags visual check of airbag units On Board Diagnostic OBD checking DTC memory of all systems Door check straps and securing bolts lubricate Sunroof checking function cleaning and lubricating guide rails Windshield wiper washer system and headlight cleaning system checking function Windshield wiper blades check park position and pitch angle Checking tire condition tread wear pattern filling pressure and tread depth Engine oil level checking Engine oil changing and replacing oil filter Engine and components in engine compartment from above and below check for leaks and damage V belt checking condition and tension Ribbed belt Check condition and tension engines without automatic tensioning roller Front manual transmission final drive check oil level Rear final drive Syncro Check oil level Automatic transmission check final drive oil level Brake system visual inspection Brake pads fron
28. ahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 74 of 83 Screw in battery sealing plugs Checking acid level batteries without magic eye Markings on battery housing arrow Note n Maintaining correct electrolyte level in battery is an important factor affecting length of battery s service life Electrolyte level too low Note n Too low an electrolyte level below min marking causes a loss of battery capacity power due to cell plates drying out If cell plates are not surrounded with electrolyte sulfuric acid plates plate straps and cell connectors will corrode battery will not function as a consequence of this corrosion battery becomes unusable http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 75 of 83 To avoid electrolyte impurities which can increase self discharge of battery only distilled water may be added to increase acid level Unscrew battery sealing plugs Using battery fill bottle VAS 5045 fill with distilled water up to max marking Note n Construction of filler tube of battery filler bottle VAS 5045 prevents overtilling of battery cells and escaping of battery acid When max fill level is reached inflow of distilled water into cells is interrupted Screw in battery sealing pl
29. ahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 46 of 83 Remove retaining clamp A and regulating valve B with fuel hoses attached Connect hose at connection sleeve of dewatering bolt arrow remove bolt and drain approx 0 1L of fluid Tighten dewatering bolt arrow and disconnect hose Install new O ring for sealing of regulating valve Install regulating valve and attach retaining clamp Check fuel system for proper seal visual check Accelerate several times Afterwards fuel must flow without bubbles through transparent hose at idle Automatic transmission Checking ATF level Vehicles 01 95 gt with 01M transmissions Required special tools and equipment http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 47 of 83 lt V AG 1551 n VAG1551 Scan Tool ST V A G 1551 lt V A G 1551 3 A lt n ATF filler tool V A G 1924 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 48 of 83 V A G 1331 n Torque wrench V A G 1331 5 50 Nm Test requirements n Transmission not in emergency running mode ATF temperature not above approx 30 C n Vehicle on level ground n Selector lever in P Perform fo
30. andard FMVSS 116 DOT 4 Caution n NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids Oils containing minerals damage seals and sleeves on brake systems n Brake fluid is poisonous Due to it s caustic nature it must also never be brought into contact with paint n Brake fluid is hygroscopic meaning that it absorbs moisture from surrounding air and must therefore always be stored in air tight containers n Rinse off any spilled brake fluid using plenty of water n Observe disposal regulations Note following http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 67 of 83 Note n To make sure that brake fluid will not overflow reservoir max marking must not be exceeded Inspection service fluid level must always be judged in conjunction with brake pad wear When vehicle is in use fluid level tends to drop slightly due to brake pad wear and automatic adjustment When fluid level is at min marking or just above it is not necessary to top up if brake pad wear limit is almost reached If pads are new or well above wear limit then fluid level must be between min and max markings If fluid level is below min marking brake system must be checked before brake fluid is added repair measure Battery checking Required special tools and equipment V A G
31. be found fastest on sticker arrow on toothed belt guard 4 cyl engine or on left valve cover 6 cyl engine Vehicle lifting Caution n Vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent vehicle from tipping n Never start engine and engage a gear with vehicle lifted so long as even one wheel has contact with floor There is a risk of an accident if this is not observed n If work is to be performed under vehicle it must be supported by suitable stands Floor jack In order to prevent damage to vehicle underbody a suitable rubber or wood liner must be used Vehicle must never be lifted on engine oil pan transmission rear axle front axle or bottom sill Serious damage can occur Workshop hoist Before driving onto hoist make sure weight of vehicle does not exceed permissible hoist capacity Lift points for workshop hoists and floor jacks Front http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 4 12 7 2004 General Information Page 3 of 6 At reinforcing plate welded to floor panel Position support so rear edge aligns with center of sill depression Rear At reinforcing plate welded to floor panel Position support so rear edge aligns with center of sill depression Caution Do not lift vehicle on vertical sill reinforcement or damage to vehicle could result
32. cle Diagnostic Test and Information System VAS 5051 sends next address word Automatic test sequence has ended when following indication appears on display Press Print button 1 on display and then press Screen in print menu Vehicle Diagnostic Test and Information System VAS 5051 prints out all malfunctions or 0 malfunctions detected If malfunctions are stored then a repair measure is required Pass malfunction protocol on for repair Press Go to button 2 on display Indicated on display Press End button arrow on display Press Exit button in exit menu http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 7 of 83 12 7 2004 Work descriptions Page 8 of 83 Switch off ignition and disconnect diagnostic connector Door check straps and securing bolts lubricate Lubricate side area of door arrester arrow A using lubricant G 000 150 a5 Lubricate securing bolts arrow B using lock cylinder grease spray G 400 01 Sunroof checking function cleaning and lubricating guide rails Perform following work procedure Check function of sunroof http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 9 of 83 Clean guide rail arrows and lubricate using lubricant G 000 450 02 Windshield wiper washe
33. com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 2 12 7 2004 Oil change service Page 2 of 2 Service sticker Note date for next scheduled service also brake fluid change on sticker and affix sticker to door beam B pillar http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 2 12 7 2004 Inspection service Page 1 of 5 3 Inspection service Inspection service every 12 months n Ask customer whether new wiper blades should be installed and whether they require Windshield Clear G 052 164 cleaner and anti freeze in windshield washer system n sequence of individual service positions has been tested and optimized Therefore they should be adhered to to prevent unnecessary work interruptions n work description sequence corresponds with Inspection service work procedure which is most commonly performed service n When malfunctions are found within framework of an inspection service which require repair measures inform customer Work to be performed page Electronics Front lights check function Parking light low beam high beam fog lights turn signals emergency flashers Rear lights check function Brake light also 3rd brake light tail light back up lights fog light license plate lights luggage compartment light turn signals emergency flashers Interior and glove compartment lighting cigare
34. components in engine compartment from above Visual check for leaks and damage Windshield wipe wash system Top up with fluid G 052 164 Cooling system Checking freeze protection and coolant level 35 C actual value measured value F Dust and pollen filter Replace filter element Toothed belt Check wear only TDI engines Air cleaner Clean housing and replace filter element every 2 years or every 60 000 km whichever occurs first Fuel filter Drain water Diesel engine Change brake fluid additional work as a separate charge every 2 years Brake fluid level depending on brake pad wear Checking http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 3 Specification 13 F 25 C in countries with arctic climate 31 Page 3 of 5 checking thickness 01 5 Tie rod ends checking 01 5 Ball joints checking 01 5 Engine oil changing and replacing oil filter 01 5 Engine and components in engine compartment from above and below check for leaks and damage 01 5 Check freeze protection protection content of windshield wiper washer system top off if necessary 01 5 Coolin system anti freeze protection and coolant level checking 01 5 Dust and pollen filter element replacing 01 5 Toothed belt check wear TDI engines
35. criptions Page 30 of 83 If oil level is too low top off axle oil Automatic transmission 096 until December 1994 Manufacturing date see side 01 5 Transmission identification SAE 75 W 90 synthetic n Container size 0 5 L part number G 052 145 A1 n Container size 1 0 L part number G 052 145 A2 Note n Lubricants SAE 75 W 90 and VW ATF must not be mixed with each other Automatic transmission 01M from January 1995 to 8 24 1996 Manufacturing date see side 01 5 Transmission identification VW ATF n Container size 0 5 L part number G 052 162 A1 n Container size 1 0 L part number G 052 162 A2 Note n lubricants SAE 75 W 90 and VW ATF must not be mixed with each other http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 31 of 83 Automatic transmission 01M from 8 25 1996 Manufacturing date see side 01 5 Transmission identification SAE 75 W 90 synthetic n Container size 0 5 L part number G 052 145 A1 n Container size 1 0 L part number G 052 145 A2 Note n lubricants SAE 75 W 90 and VW ATF must not be mixed with each other If oil level is too high extract oil using Oil siphoning unit V A G 1358 A Install drive for soeedometer Continuation for all vehicles Transmission identification Identification arrow 1 Automatic transmission 01M arrow 2 Example 5
36. ction Goto amp type repair amp id V W B4 ME01 01 5 Page 4 of 83 12 7 2004 Work descriptions n Diagnostic cable 5m without voltage supply VAS 5051 3 Connect VAS 5051 tester Engage parking brake Manual transmission Shift gear stick in neutral With ignition switched off connect Vehicle Diagnostic Test and Information System VAS 5051 using diagnostic cable 5m without voltage supply VAS 5051 3 Check DTC memory Switch ignition on http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 5 of 83 12 7 2004 Work descriptions Page 6 of 83 Indicated on display Select operating mode Press button for vehicle On Board Diagnostic OBD on display arrow Note n If indications shown in work procedure are not indicated on display User manual for VAS5051 tester Indicated on display Select vehicle system Press 00 Check DTC memory complete system on display arrow VAS5051 tester VAS 5051 sends all known address words in sequence When a control module responds with its identification display indicates number of stored errors or indicates no malfunction recognized http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Any system malfunctions that are stored will be displayed one after other Next Vehi
37. d Windshield wash wipe system fluid reservoir must be filled up to edge Use only Genuine Volkswagen Windshield Clear all year round when topping up windshield wash wipe system Note n Genuine Volkswagen Windshield Clear G 052 164 protects spray nozzles fluid reservoir and hoses from freezing n Fill with genuine Volkswagen Windshield Clear G 052 164 in warmer season also powerful cleanser removes wax and oil deposits from windows Water 3 parts 2 parts 1 part Page 10 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 11 of 83 n Freeze protection must be guaranteed to approx 5 F 15 C approx 31 F 35 C in countries with an arctic climate in windshield washer system Windshield washer system check jet setting and adjust if necessary Required special tools and equipment n V A G3125A Note n Never use a needle or a similar object since it may damage water hoses in spray nozzle n Windshield wash wipe system fluid reservoir must be filled up to edge Check jet setting adjust using V A G3125A adjustment tools for windshield wiper nozzle if necessary Jet adjustment setting dimensions for windshield a 400 mm c 520 mm http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions b 300 mm d 600 m
38. d equipment V A G 1332 n Torque wrench V A G 1332 40 200 Nm n Fashlight Perform following work procedure Measure outer and inner pad thickness a Pad thickness without backing plate Wear limit 2 mm With a pad thickness of 2 mm without backing plate brake pads have reached their wear limit and must be replaced repair measure NO1 10137 Mount wheel and tighten wheel securing bolts to 110 Nm Rear disc brake pads Determine thickness of outer pad by visual check using a flashlight through a hole in wheel Determine thickness of inner pad by visual check using a flashlight through a hole in wheel http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 34 of 83 a Pad thickness including backing plate Wear limit 2 mm NO1 10136 With a pad thickness of 2 mm without backing plate brake pads have reached their wear limit and must be replaced repair measure Rear drum brake pads Check thickness of brake pads through inspection holes in brake carrier metal sheets arrow Wear limit 2 5 mm only pad thickness Note n Pay attention to pads smeared with brake fluid or fat Underbody sealant checking When performing visual inspection for damage to underbody sealant also check underbody wheel housings and sill panels Note http ebahn bentleypublishers com vw
39. d screw in hand tight Tighten locking bolt arrow 1 with new seal to 15 Nm f JAR n EA http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 52 of 83 End Output 01 5 End Output If ATF in overflow tube runs out of hole Top off ATF Pry off cap arrow with a screwdriver for protection of sealing plug While doing so locking mechanism of cap will be destroyed therefore always replace cap Note n With some transmissions a cap with a clip bolting device is installed This cap can be reused Remove sealing plug from filler tube Add ATF using ATF filler tool V A G 1924 until ATF exits from check hole arrow Fill up only following VW ATF Container size 0 5 L part number G 052 162 A1 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 53 of 83 Container size 1 0 L part number G 052 162 A2 Note n Adding to little or too much ATF impairs functioning of transmission Cut seal arrow of locking bolt with a side cutter and remove seal Install locking bolt with new seal and screw in hand tight Tighten locking bolt arrow 1 with new seal to 15 Nm Plug sealing plugs onto filler tube until locking straps engage or Plug sealing plugs onto filler tube and secure with a n
40. d to to prevent unnecessary work interruptions n Work description sequence corresponds with Inspection service work procedure which is most commonly performed service n When malfunctions are found within framework of an inspection service which require repair measures inform customer http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 3 12 7 2004 Inspection service Page 5 of 5 Applicable only for countries where there are no country specific mandatory exhaust emission regulations http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 3 12 7 2004 General Information Page 1 of 6 4 General Information lt r Cae ANA Type plate A Type plate Located on front lock carrier plate lt a A cE Vehicle Identification Number VIN B Vehicle Identification Number VIN It is stamped on rear engine compartment bulkhead and is visible through a window in plenum chamber cover Meaning of Vehicle Identification Number VIN WYW ZZZ 3A Z R Eor B 000 001 Manufacturer s Filler Model Filler Model year Production Serial characters characters 1994 location number mark Engine code and engine number http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 4 12 7 2004 General Information Page 2 of 6 Engine code and engine number can
41. es and spark plug connectors for secure seating Dust and pollen filter element replacing Filter is located below plenum chamber on right Perform following work procedure Removing Turn buttons 1 for mounting of cover around 45 and remove cover from partition to engine compartment http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 41 of 83 Unlock spring latches 2 of filter element remove filters upward Note n Observe disposal regulations Installing Install new filter element Install rubber seal and cover Toothed belt for camshaft drive Diesel engine code AAZ Ccheck condition and tension Performing work procedure 4 cyl Diesel Engine Mechanical Repair Group 13 Crankcase disassembling and assembling toothed belt removing and installing tensioning Toothed belt and toothed belt tensioning roller Diesel engine codes AFN and 12 replacing Performing work procedure 4 cyl Diesel Engine Mechanical Repair Group 13 Crankcase disassembling and assembling toothed belt removing and installing tensioning Toothed belt for camshaft drive gasoline engine check condition and tension http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 42 of 83 Condition of toothed belt must be checked
42. etween min and max marking of dipstick If ATF level is too low add ATF using a funnel If ATF level is too high extract ATF using probe V A G 1358 A2 and V A G1358 Shift once into all selector lever positions while standing and with engine running Check ATF level again at 50 70 C At Scan Tool ST V A G 1551 Press button Indicated on display Rapid data transfer HELP Select function XX Press buttons 0 and 6 for function End data transfer and confirm input with Q button Switch off ignition and disconnect diagnostic connector Page 60 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 61 of 83 Power steering fluid level checking Fluid when cold Perform following work procedure With engine not running bring front wheels into straight ahead position Unscrew reservoir cap arrow with dipstick Clean off dipstick with a clean rag Tighten cap by hand and remove again Note n Fluid level is only valid if cap has been screwed on Check oil level Fluid level must be between MIN and MAX markings Note n If fluid level is above specified range oil must be suctioned off n If oil level is below specified area then hydraulic system must be checked for leaks repair measure It is not enough to simply top off with fluid n If hydraulic sy
43. ew Cap arrow 2 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 54 of 83 Lock cap Note n Cap without clip bolting device must always be replaced cap secures sealing plug n With some transmissions a cap with a clip bolting device is installed This cap can be reused End Output Indicated on display Read measuring value block 5 gt 40 C0011011 0900 RPM Press button Indicated on display Rapid data transfer HELP Select function XX Buttons 0 and 6 press Press 06 to select End Output function Indicated on display Rapid data transfer Q 06 End Output Press Q button to confirm input Indicated on display Rapid data transfer Help Enter address word XX http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions AULVINAUUL LIGHSITISSIUIT CIGMIYIY AIT Vehicles gt 12 94 with 096 transmissions Use following VW ATF yellowish color n Container size 0 5 L part number G 052 162 A1 n Container size 1 0 L part number G 052 162 A2 Note n Current supplies of ATF Dextron Il can be used up in transmissions until December 1994 Required special tools and equipment lt V A G 1551 n VAG1551 Scan Tool ST V A G 1551 lt V A G 1551 3 A n adapter cable V A G 1551 3 A V A G 1358A a
44. f magic eye will therefore be more accurate Note n magic eye can be located at various positions on battery http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 71 of 83 n Three different color indications are possible Green gt battery is sufficiently charged Black no charge or charge too low repair measure amp 1430915 105 AC 12y 2004 Ar ON ETN 56002 046 4fO4 LISA Colorless or yellow gt critical acid level reached distilled water must be topped up 01 5 Topping off distilled water batteries with magic eye Then perform a battery load test 01 5 Battery load check Note n If battery is older than 5 years and magic eye is a light color or a yellow like color then replace battery after consulting customer Battery load check Note n Following description refers to Batterie tester with printer VAS 5097 If battery load test is performed with another battery tester gt user manual for respective battery tester n When using battery tester VAS 5097 A or Battery tester with printer VAS 5097 it is not necessary to remove battery You also do not have to disconnect battery Switch ignition off Connect tester cable clamps to battery terminal User manual for battery tester clips must make good contact with battery terminals http ebahn bentleypublishers com vw servlet
45. first Repeat work procedure on other side of vehicle at rear Connect bleeder hose of collector bottle to front bleeder screw open bleeder screw and allow corresponding quantity to flow out see table below Close bleeder screw Repeat work procedure on other side of vehicle at front Table Sequence quantity of brake fluid Order Brake fluid quantity which must flow out of brake brake calipers Left Hand Drive LHD calipers vehicles Right rear 0 4 to 0 5 liters Left rear 0 4 to 0 5 liters Right front 0 4 to 0 5 liters http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 66 of 83 Left front 0 4 to 0 5 liters Total quantity 1 2 Liter 1 with siphoned brake fluid from brake fluid reservoir and replacement capacity of hydraulic clutch mechanism Install cover caps to brake caliper bleed screws Move filler lever on VAS5234 or brake filling and bleeding tool V A G 1869 to position B See user manual Remove filler hose from adapter Unscrew adapter from brake fluid reservoir Check brake fluid level and correct if necessary Screw sealing cap onto brake fluid reservoir Remove brake pedal depressor Check pedal pressure and brake pedal free play Free play Max of pedal travel Brake fluid level checking Use only new brake fluid with part number B 000 700 A corresponds to US st
46. for n Cracks or tears A cross sectional breaks n Lateral scouring B n Fraying and or outbreaks C n Tears in tooth base D n Layer separation toothed belt carcass cord strands n Traces of oil and grease Note n It is essential to replace toothed belt if malfunctions are found This will avoid possible break downs or operating problems replacement of a toothed belt is a repair measure Check tension of toothed belt and tension toothed belt if necessary Work descriptions can be found in corresponding Repair Manual Engine Mechanical Repair Group 15 Cylinder Head Valvetrain Toothed belt check wear TDI engines Required special tools and equipment n Caliper commercially available http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 43 of 83 Perform following work procedure Open clips of upper toothed belt protection Pull upper toothed belt protection forward or remove it if necessary Measure width of toothed belt using a caliper OK L TEN W Wear limit 22 mm Note n With a toothed belt width of 22 mm toothed belt has reached its wear limit and must be replaced repair measure Inform customer Fuel filter replacing diesel engine Note n Make sure that diesel does not come in contact with coolant hoses Clean hoses immediately if necessary n Observe disposal regulations
47. is nature is noticed determine cause by performing alignment checks repair measure Tire tread depth including spare wheel checking Check tread depth Minimum depth 1 6 mm Note n This value may vary for individual countries due to different legislative regulations n minimum tread depth is reached when tires have worn down level with 1 6 mm high tread wear indicators positioned at intervals around tire n If tread depth is approaching legal minimum permissible depth customer must be informed Tire inflation pressure including spare wheel checking correcting inflation pressures Required special tools and equipment n Tire pressure gauge Note n Spare wheels with a rectangular opening in wheel disk do not need to be removed Filler valve must be reached through opening n Pressures listed in table are valid for cold tires Do not reduce increased pressures on warm tires http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 18 of 83 AN p SS ed ad NTA n Important information concerning winter tires recommended by Volkswagen is found in Fault finding Wheels tires Chapter 4 No 2 Tire inflation pressure table for normal tires For all factory installed tire sizes Filling pressure values in bar Half load Full load front rear front rear Vehicles with gasoline engine 55 kW and 66 kW Sedan 2 0 2
48. ithout automatic tensioning roller Checking condition of ribbed belt Checking n Sub surface cracks cracks core ruptures cross sectional breaks n Layer separation top layer cord strands n Base break up n Fraying of cord strands n Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 27 of 83 n Traces of oil and grease Note n It is essential to replace ribbed belt if malfunctions are found This will avoid possible break downs or operating problems replacement of a ribbed belt is a repair measure Tensioning ribbed belt Note n With engines with tensioning roller stretching of ribbed belt is not required since by a spring loading tensioning device correct tension of belt is always ensured Loosen mounting bolts 1 and 2 for generator at least one turn Press down generator at least three times up to stop using Clamping lever 3297 in order to ensure optimal freedom of movement With generator still disconnected let engine run at idle for at least 10 seconds Note n Next note tightening order when tightening bolts for generator Do not lean on generator and do not touch ribbed belt http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12
49. le Diagnostic Test and Information System VAS http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 2 of 83 5051 01 5 Checking DTC memory of all systems using Vehicle Diagnosis Testing and Information System VAS 5051 Interrogating DTC memory of all systems with scan tool VAG 1551 Required special tools and equipment lt V A G 1551 n VAG1551 Scan Tool ST V A G 1551 lt V A G 1551 3 A n adapter cable V A G 1551 3 A Connecting scan tool VAG 1551 Perform following work procedure Engage parking brake Automatic transmission Shift selector lever into position p or N i Manual transmission Shift gear stick in neutral With ignition switched off connect Scan Tool ST V A G 1551 as follows http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Unclip cover below instrument cluster Tor PS 1 td Wud t of jf me gt j iy a 4 V A G 1551 3A X ha J With ignition switched off connect Scan Tool ST V A G 1551 using Adapter cable V A G 1551 3 A Interrogating DTC memory Start engine and let run at idle Switch printer on via Print button indicator lamp in button lights up Indicated on display VAG On Board Diagnostic OBD HELP 1 Rapid data transfer or VA
50. leaks and damage Brake system Visual check for leaks and damage Brake pads front and rear Checking thickness http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 3 and headlight cleaning system checking function 01 5 Windshield wiper blades check park position and pitch angle 01 5 Checking tire condition tread wear pattern filling pressure and tread depth 01 5 Checking tire condition tread wear pattern filling pressure and tread depth 01 5 Checking tire condition tread wear pattern filling pressure and tread depth 01 5 Checking tire condition tread wear pattern filling pressure and tread depth 01 5 Checking tire condition tread wear pattern filling pressure and tread depth 01 5 Engine oil changing and replacing oil filter 01 5 Engine and components in engine compartment from above and below check for leaks and damage 01 5 Brake system visual inspection 01 5 Brake pads front and rear Page 2 of 5 12 7 2004 Inspection service Exhaust system Perform visual check for leaks security and damage Track rod ends Check play security and joint boots Ball joints Perform visual check of swivel joint boots for leaks and damage Engine compartment Engine oil Filling Engine and
51. llowing work procedure Secure container of ATF filler tool V A G 1924 to vehicle Connect Scan Tool ST V A G 1551 using adapter cable V A G 1551 3 A 01 5 Connecting scan tool VAG 1551 V A G 1924 V A G 1551 At Scan Tool ST V A G 1551 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 49 of 83 Indicated on display VAG On Board Diagnostic OBD HELP 1 Rapid data transfer or VAG On Board Diagnostic OBD HELP 2 Blink code output Two operating modes are displayed alternately Press button 1 to select Rapid data transfer operating mode Indicated on display Rapid data transfer HELP Enter address word XX buttons 0 and 2 press 02 is address word for Transmission Electronics Indicated on display Rapid data transfer Q 02 Transmission Electronics Press Q button to confirm input Indicated on display 01M927733BB AG4 Transmission 01M 2029 Coding 00000 WSC 00000 control module identification coding and Workshop Code WSC of Scan Tool ST V A G 1551 are indicated If displayed Control module not responding HELP Press HELP button to print out an overview of all of possible malfunction causes Enter address word 02 for Transmission Electronics again after repairing malfunction and press Q button to confirm Indicated on display 01M927733BB AG4 Tra
52. m Liters kW RPM Nm RPM Compression ratio Fuel injection ignition system RON at least On Board Diagnostic OBD Catalytic converter Oxygen sensor control Exhaust Gas Recirculation EGR Exhaust turbocharging system 1 In exceptional cases fuel with a RON of at least 91 may be used although engine performance will be diminished Engines gt http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 1 Diesel engine Page 1 of 2 1 Gas engine AAA 10 93 6 2 2 8L 128 5800 235 4200 81 0 90 3 10 0 Motronic M 2 9 95 unleaded Yes Yes Gas engine ABA 03 95 4 2 2 0L 85 5400 165 3200 82 5 92 8 9 4 1 Motronic MFI 91 unleaded Yes Yes Yes No Diesel engine 12 7 2004 Engine overview Code letters Manufactured from Number of cylinders valves per cylinder Displacement Liters Output kW RPM Torque Nm RPM Bore mm Stroke mm Compression ratio Fuel injection ignition system CN at least On Board Diagnostic OBD Catalytic converter Oxygen sensor control Exhaust Gas Recirculation EGR Exhaust turbocharging system http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 1 AAZ 10 93 4 2 1 9L 55 4400 140 2200 2800 79 5 95 5 22 5 1 Turbo Diesel 49 Page 2 of 2 1Z 10 93 4 2 1 9L 66 4000 202 1900 79 5 95 5 19 5 1 TDI 49 Yes 12
53. m Tolerance 20 mm Jet setting dimension for rear window Spray jet center wiper area Note n If spray jet is uneven or cannot be adjusted to specified dimensions spray nozzle must be replaced repair measure Headlight cleaning system check jet setting and adjust if necessary Required special tools and equipment n 3019A adjustment device Check jet setting adjust using 3019A adjustment device if necessary Following jet setting dimensions apply for left headlight right headlight symmetrical http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 12 of 83 12 7 2004 Work descriptions Page 13 of 83 Windshield wiper blades check park position and pitch angle Windshield wiper blades check park position and adjust if necessary Required special tools and equipment V A G 1331 n Torque wrench V A G 1331 5 50 Nm Perform following work procedure Check whether wiper blades are in park position Windshield A 50mm B 35mm If necessary adjust rest position by shifting wiper arms Tightening torque wiper arms 20 Nm Rear window Wagon a 20mm http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 14 of 83 If necessary adjust park position by shifting wiper arm vo2 0433 Tightening torque wiper arm 16 Nm Wi
54. may damage turbocharger or cause it to fail completely Only when warning light goes out full oil pressure is reached and driver may accelerate After topping off 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 Note n Observe disposal regulations Withdraw dipstick and read oil level Area a Oil must be topped off Afterward it is sufficient if oil level is somewhere in area b Area b Oil need not be topped off Area c Oil must not be topped off Note n At an oil level above area c there is a danger of damage to catalytic converter Oil properties Multi grade oils conforming to VW standard 501 01 and 505 00 are oils with following properties n All season usability in moderate climate zones n Excellent cleanability http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 24 of 83 n Secure lubrication properties at all engine temperature and load conditions n High resistance to aging Multi grade light duty oils according to VW standard 500 00 exhibit beyond that following advantages n All season usability at almost all occurring outside temperatures n Smaller friction losses of engine n Optimum cold starting ability also at very low temperatures Multi grade light duty oils according to
55. mp TS ii http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 55 of 83 12 7 2004 Work descriptions V A G 1358A amp n V A G1358A and sensor V A G 1358 A2 V A G 1331 n Torque wrench V A G 1331 5 50 Nm Perform following work procedure Extract ATF using probe V A G 1358 A2 and V A G1358 Note n Observe disposal regulations n Engine must not be started without ATF and vehicle must not be towed Remove oil pan with ATF strainer Remove spacers from old oil pan seal Clean oil pan Pay attention to cleanliness during following installation Snap new seal into new ATF strainer Snap removed spacers into new oil pan seal Page 56 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Install new ATF strainer with new seal Tightening torque for securing bolts 8 Nm Install oil pan with new seal Make sure that spacers are fastened Tightening torque for securing bolts 12 Nm a Next add 3 0L ATF replacement capacity using a funnel Note n To wipe dipstick off a lint free cloth must be used n Adding to little or too much ATF impairs functioning of transmission Shift once into all selector lever positions while standing and with engine running Check ATF level using dipstick Test requirements
56. n Vehicle on level ground n Hand brake is engaged n Selector lever in P n Engine running at idle http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 57 of 83 12 7 2004 Work descriptions ATF must be filled up in cold condition at least up to 20 C marking otherwise add ATF Bring ATF to a temperature of 50 70 C temperature will be measured using Scan Tool ST V A G 1551 as follows Let engine run at idle Connect Scan Tool ST V A G 1551 using adapter cable V A G 1551 3 A 01 5 Connecting scan tool VAG 1551 At Scan Tool ST V A G 1551 Indicated on display VAG On Board Diagnostic OBD HELP 1 Rapid data transfer or VAG On Board Diagnostic OBD HELP 2 Blink code output Two operating modes are displayed alternately Press button 1 to select Rapid data transfer operating mode Indicated on display Rapid data transfer HELP Enter address word XX Press buttons 0 and 2 for address word Transmission electronics and confirm input with Q button Indicated on display http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 58 of 83 12 7 2004 Work descriptions Page 59 of 83 Rapid data transfer Q 02 Transmission Electronics Press Q button to confirm input Indicated on display 096927733BA AG3 transmission 096 2754
57. ndshield wiper blades Check pitch angle adjust if necessary Note n Check pitch angle only if wiper blades are juddering or making noises Required special tools and equipment n Windshield wiper adjustment device VAS 3358B n Open end wrench 24 mm Perform following work procedure Bring windshield wiper arms in park position Remove windshield wiper blade Install windshield wiper arm 2 into Windshield wiper adjustment device VAS 3358B and secure using mounting http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 15 of 83 screw 3 NO2 0331 Pitch angle specified values for 2 5 4 D 0 Windshield wiper blade with plastic spoiler vehicles from 05 94 on If necessary adjust pitch angle to specified value as follows Place open end wrench 24 mm 1 onto adjustment device and set windshield wiper arm 2 to specified value arrows Remove windshield wiper arm 2 from adjustment device and secure again using mounting screw 3 Check adjusted value according to table If necessary repeat setting and checking procedure until specified value is reached Remove adjustment device and install windshield wiper blade http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 16 of 83 NO2 0331
58. nsmission 01M 2029 Coding 00000 WSC 00000 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Press button Raise vehicle Place appropriate receptacle underneath transmission Indicated on display Rapid data transfer HELP Select function XX Buttons 0 and 8 press Press 08 to select Read measuring value block function Indicated on display Rapid data transfer Q 08 Read measuring value block Press Q button to confirm input Indicated on display Read measuring value block Enter display group number XXX Press buttons 0 0 and 5 Press 005 to select Display group number 005 Indicated on display Read measuring value block Q Enter display group number 005 Press Q button to confirm input Indicated on display Read measuring value block 5 gt 30 C 0011011 0 900 RPM First display field displays ATF temperature Bring ATF to test temperature Test temperature 35 C to 45 C Page 50 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 51 of 83 ATF present in overflow tube arrow 2 runs off If ATF drips from hole ATF must not be topped off Cut seal arrow of locking bolt with a side cutter and remove seal Install locking bolt with new seal an
59. own in freeze protection protection table 01 5 Freeze protection protection table and add coolant additive G 11 or G 12 Note n Observe disposal regulations Freeze protection protection table Check coolant additive concentration after test drive again Freeze protection protection to C F Quantity difference in Liters Actual value Specified value 4 cyl 6 cyl engine engine http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 Page 37 of 83 12 7 2004 Work descriptions 0 32 25 13 3 5 35 31 4 0 5 23 25 13 3 0 35 31 3 5 10 14 25 13 2 0 35 31 3 0 15 5 25 13 1 5 35 31 2 0 20 4 25 13 1 0 35 31 1 5 25 13 35 31 1 0 30 22 35 31 0 5 35 31 40 40 Checking coolant level and adding coolant if necessary Check coolant level in expansion tank with engine cold n Delivery inspection Coolant level at max marking n Inspection service Coolant level between min and max marking If coolant is too low add required amount according to mixture ratio Note n If fluid losses are greater than can be reasonably expected determine cause and repair repair measure Mixture ratio Freeze protection protection to Coolant additive Water 5 0 6 0 4 5 ae 3 5 4 5 23 3 5 1 5 2 3 1 5 1 0 Page 38 of 83 http ebahn bentleypublishers com vw
60. proved engine oils Page 21 of 83 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 22 of 83 2 Vg amp 3 SAE 2040 2949 SAE ON ICIIWAD SAE SW 19W49 SAE 10W 30 SAE 10W40 SAE SW SAE 10W 5010W 50 SAE SWS Gasoline engine specifications A Multi grade light duty oils specification VW 500 00 or VW 502 00 B Multi grade oils specification VW 501 01 Multi grade oils specification API SF or SG These oils may only be used in exceptional cases if no approved engine oil is available Y SWAN SAE OWI AV 49 my SAE SW 40 15W459 SAE 201 40 29W 49 59 3 G 2 w 3 SAE Ow SAE SW Specification for Diesel engines A Multi grade light duty oils specification VW 500 00 B Multi grade oils specification VW 505 00 suitable for all Diesel engines without restrictions Multi grade oils specification API CD Multi grade oils specification VW 501 01 Continuation for all engines Turbo engines After engine oil and oil filter are replaced following must be considered after first engine start http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 23 of 83 As long as oil pressure warning light in instrument panel is lit engine may run only at idle Do not accelerate Throttle bursts
61. quately lubricated for high speeds or long distances Using a breakdown vehicle vehicle may only be towed suspended at front Reason If given a rear suspended tow drive shafts turn backward planetary gears in automatic transmission then turn at such high speeds that transmission will be severely damaged in a short time http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 4 12 7 2004 Work descriptions Page 1 of 83 5 Work descriptions Driver s and front passenger airbags visual check of airbag units You can see whether an airbag s is installed by inscription AIRBAG on steering wheel padded panel driver s side and on far side of dash panel passenger side Perform visual check of pad panel 1 and surface of instrument panel right side 2 for exterior damage Caution n Steering wheel padded panel surface must not have stickers attached or be covered or be otherwise modified This ensures that future function of airbag is guaranteed Make sure customer is aware of these instructions Steering wheel padded panel must only be cleaned with a dry cloth or a cloth moistened with water On Board Diagnostic OBD checking DTC memory of all systems Interrogating DTC memory can be performed using one of two methods n using Scan Tool ST V A G 1551 01 5 Interrogating DTC memory of all systems with scan tool VAG 1551 or the n Vehic
62. r system and headlight cleaning system checking function Note n If during function test it is determined that wiper blades are juddering or making noises check pitch angle of wiper blades 01 5 Windshield wiper blades check park position and pitch angle Required special tools and equipment T10007 n Refractometer T10007 Check freeze protection protection content of windshield wiper washer system top off if necessary Checking freeze protection protection concentration Read bright dark boundary to obtain an accurate reading for http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions following tests Place a drop of water on glass to improve readability of bright dark boundary bright dark boundary can be clearly recognized on WATERLINE Check concentration of anti freeze additive using refractometer T10007 follow user manual Scale 1 of refractometer is designed specifically for genuine Volkswagen Windshield Clear G052164 o SSOP Ess AIEA WATERUNE Scale 2 is designed for commercially available windshield cleanser as well as a mixture of commercially available windshield cleanser and G052164 Mixture ratio Freeze protection to Windshield Clear G 052 164 1 0 5 F 17 18 1 part 7 5 9 5 F 22 23 1 part 34 5 36 5 F 37 38 1 part Topping off with flui
63. servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 39 of 83 25 C 13 F approx 40 approx 60 35 C 31 F approx 50 approx 50 40 C 40 F approx 60 approx 40 Note n Coolant additives G 11 or G 12 prevent frost and corrosion damage scaling and also raises boiling point of coolant Therefore cooling system must be filled year round with frost and corrosion protection additives n A higher boiling point improves engine reliability under heavy load particularly in countries with tropical climates Spark plugs replacing Spark plug identification and replacement intervals Emissions Test Required special tools and equipment n Spark plug removal tool VAS 3122B n Assembly tool T10029 http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 40 of 83 V A G 1331 Sz n Torque wrench V A G 1331 5 50 Nm n Emissions Test binder Perform following work procedure Disconnect spark plug connectors using assembly tool T10029 Remove spark plugs using spark plug removal tool VAS 3122B Note n Spark plug identification and tightening torque Emissions Test n Observe disposal regulations Install new spark plugs using spark plug removal tool VAS 3122B Connect spark plug connectors using assembly tool T10029 Check ignition wir
64. stem is leak free top up with G 002 000 oil http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Page 62 of 83 Screw cap on hand tight Fluid at operating temperature from approx 50 Perform following work procedure With engine not running bring front wheels into straight ahead position Unscrew reservoir cap with fitted dipstick Clean off dipstick with a clean rag Tighten cap by hand and remove again Note n Fluid level is only valid if cap has been screwed on Check oil level Fluid level must be between MIN and MAX markings Note n If oil level is above MAX marking oil must be extracted n If oil level is below MIN marking then hydraulic system must be checked for leaks repair measure It is not enough to simply top off with fluid If hydraulic system is leak free top up with G 002 000 oil Screw cap on hand tight Brake fluid changing Required special tools and equipment http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 63 of 83 VAS 5234 n Brake filling and bleeding tool VAS 5234 or V A G 1869 n brake filling and bleeding tool V A G 1869 or n Brake filling and bleeding tool V A G 1869 with upgrade kit V A G 1869 4 V A G 1869 2 n Brake pedal depressor V A G 1869 2
65. t checking condition and tension Check condition of V belt Checking n Sub surface cracks cracks core ruptures cross sectional breaks n Layer separation top layer cord strands n Base break up n Fraying of cord strands n Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks n Traces of oil and grease Note n It is essential to replace V belt if malfunctions are found This will avoid possible break downs or operating problems replacement of ribbed belt is a repair measure V belt tension checking and adjusting http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 26 of 83 Check V belt tension by strong thumb pressure depth of impression approx 5 mm and adjust if necessary For following adjustment torque wrench V A G 1410 in connection with ring insertion tool A F 22 mm V A G 1410 2 A is particularly suitable Loosen bolts 1 and 2 clamping screw 3 and mounting nut 4 for clamps if available at least one turn Tension V belt to 4 Nm by turning tension nut using torque wrench run in belt and tighten clamping screw 3 of tension nut to 25 Nm Tighten mounting bolt 1 for pump to 45 Nm Tighten mounting bolt 2 for pump and mounting nut 4 for clamps if available to 25 Nm Ribbed belt Check condition and tension engines w
66. t Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 20 of 83 V A G 1307 A n Oil extractor V A G 1307 A or V A G 1358A amp n Oil extractor V A G 1358 A V A G 1331 i n Torque wrench V A G 1331 5 50 Nm Note n If oil is drained and not extracted using oil extractor V A G 1307 A or oil extractor V A G 1358 A replace gasket for oil drain plug n Observe disposal regulations http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id V W B4 ME01 01 5 12 7 2004 Work descriptions Capacities with filter change for emissions test Tightening torque for drain plug n 4 cyl engines 30 Nm n 6 cyl engines 50 Nm Oil filter replacing 4 cyl engine Note n Observe disposal regulations Loosen oil filter using tension strap e g Hazet 2171 1 and remove oil filter Clean engine sealing surface Lubricate rubber seal lightly with oil Install new filter element and tighten hand tight 6 cyl engine Note n Observe disposal regulations Drain oil at drain plug Remove filter lower part using tool Install new filter element and new O ring oiled Tighten filter lower part with 25 Nm and drain plug with new sealing ring with 10 Nm Engine oil filling Oil capacities with filter change Emissions test Due to positive properties of oils 01 5 Oil properties use only following ap
67. t and rear checking thickness Underbody sealant checking Tie rod ends checking Ball joints checking Cooling system anti freeze protection and coolant level checking Spark plugs replacing Dust and pollen filter element replacing Toothed belt for camshaft drive Diesel engine code AAZ Ccheck condition and tension Toothed belt and toothed belt tensioning roller Diesel engine codes AFN and 1Z replacing Toothed belt for camshaft drive gasoline engine check condition and tension Toothed belt check wear TDI engines Fuel filter replacing diesel engine Fuel filter draining water Diesel engine Automatic transmission Checking ATF level Automatic transmission changing ATF Power steering fluid level checking Brake fluid changing Brake fluid level checking Battery checking Idle speed Diesel engine code AAZ Checking Headlight setting checking Road test performing Engine overview Engine overview Engines gt Code letters Manufactured Number of cylinders valves per cylinder from Liters kW RPM Nm RPM mm mm Compression ratio Fuel injection ignition system RON On Board Diagnostic OBD Catalytic converter Oxygen sensor control Exhaust Gas Recirculation EGR Exhaust turbocharging system at least 1 240 Nm when using Super plus unleaded RON 98 with catalytic converter unleaded Engines Code letters Manufactured Number of cylinders valves per cylinder fro
68. tte lighter horn and warning lamps Checking function 01 5 Driver amp apos s Airbag for driver and passenger Perform a visual check of and front passenger airbag units for outer damage airbags visual check of airbag units 01 5 On Board On Board Diagnostic OBD Check DTC memory of all Diagnostic OBD systems checking DTC memory of all systems Vehicle exterior 01 5 Door check Door arrester and securing bolts Lubricate straps and securing bolts lubricate 01 5 Windshield Windshield wiper washer system and headlight cleaning wiper washer system http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 3 12 7 2004 Inspection service system Check function and setting Windshield wiper blades Check for damage check rest position only for juddering wiper blades Check pitch angle Tires Spare wheel Check condition wear pattern tread depth mm Front left tire Check condition wear pattern tread depth mm Rear left tire Check condition wear pattern tread depth mm Rear right tire Check condition wear pattern tread depth mm Front right tire Check condition wear pattern tread depth mm Vehicle from below Engine oil Drain or extract replace oil filter Engine and components in engine compartment from below Visual check for leaks and damage Transmission final drive and joint protective bellows boots Visual check for
69. ugs Electrolyte level too high Note n If electrolyte level is too high above max marking electrolyte a mixture of sulfuric acid and water escapes and causes damage outside battery for example to functional parts in engine compartment Unscrew battery sealing plugs At an acid level that is too high overfilling i e it lies above inner acid level marking plastic plug or above exterior max marking Use hydrometer to extract off electrolyte until its level has reached mark on plastic peg 1 or max mark Note http ebahn bentleypublishers com vw servlet Display action Goto amp type repair amp id VW B4 ME01 01 5 12 7 2004 Work descriptions Page 76 of 83 n Observe disposal regulations Screw in battery sealing plugs Checking battery batteries with magic eye and without battery cell plugs These batteries can be recognized by magic eye 1 and a cover 2 as shown in illustration Note n magic eye can be located at various positions on battery Caution Cover is used only for filling during production Cover must not be removed under any circumstances otherwise battery may be damaged battery becomes unusable magic eye gives information regarding acid level and charge level of battery Before performing a visual check lightly and carefully tap onto magic eye using a screwdriver handle Air bubbles which can affect display are dispersed by doing this Reading

Engine oil level, checking - Volkswagen Technical Site

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