Volkswagen T-Roc Service Repair Manual

Description

WORKSHOP Service Repair MANUAL Volkswagen T-Roc 2017-2021

Volkswagen T-Roc OFFICIAL WORKSHOP MANUAL
+Wiring Diagrams
FACTORY REPAIR SERVICE MANUAL
SAME AS Volkswagen SERVICES USE

Technical Information
Applies to
Volkswagen T-Roc
2017-2021

MODELS
Volkswagen T-Roc
MODEL YEARS
2017-2021
ENGINES
V8 PETROL, TD6
GEARBOXES
AUTOMATIC
LANGUAGE
ENGLISH
WIRING
YES

Content
Volkswagen T-Roc Manual Contains all the official Volkswagen manufacturer specifications, and repair instructions step by step with illustrations and wiring diagrams.

TABLE OF CONTENTS
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6-speed manual gearbox 02q 0bb installed t roc
8-speed automatic gearbox 09s repair
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fuel system ines dfha djga dgtb dsud dsra dsrb dtsa dtsb dtua
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installed 6-speed manual gearbox 0aj
removed 6-speed manual gearbox 0aj
VW Tiguan 2 prop shaft rear final drive
body repairs exterior
body repairs interior
brake system
electrical system
heating air conditioner
maintenance
running gear axles steering (1)
running gear axles steering
wiring diagrams

TABLE OF Ranges

00 – Technical data
1 Safety information
1.1 General safety provisions
1.2 Safety precautions when using testers and measuring instruments during a road test
1.3 Safety measures when working on vehicles with a start/stop system
2 Identification
2.1 Identification of final drive
3 Repair instructions
3.1 General repair instructions
3.2 Gaskets and seals
3.3 Nuts and bolts
4 Technical data
4.1 Capacities
5 Electrical components
5.1 Overview of fitting locations – electrical components
39 – Final drive – rear differential
1 Final drive
1.1 Assembly overview – final drive
1.2 Removing and installing final drive
2 Assembly mountings
2.1 Assembly overview – assembly mountings
2.2 Removing and installing bonded rubber bush
3 Gear oil
3.1 Overview of fitting locations – oil drain and inspection plugs
3.2 Checking gear oil level
4 Oil seals
4.1 Overview of fitting locations – seals
4.2 Renewing right seal
4.3 Renewing left seal
4.4 Renewing seal for prop shaft flange on the rear final drive
5 All-wheel drive coupling
5.1 Assembly overview – all-wheel drive coupling
5.2 Checking function
5.3 Checking fluid level in all-wheel drive coupling
5.4 Draining and filling high-performance fluid for all-wheel drive coupling
5.5 Removing and installing all-wheel drive coupling pump -V181-
5.6 Removing and installing all-wheel drive coupling
5.7 Removing and installing four-wheel drive control unit -J492-
6 Propshaft
6.1 Assembly overview – prop shaft
6.2 Removing and installing prop shaft
6.3 Removing and installing front flexible coupling
6.4 Removing and installing rear flexible coupling
00 – Technical data
1 Safety information
1.1 Safety regulations for working on fuel supply
1.2 Safety measures when working on vehicles with a start/stop system
1.3 Safety precautions when using testers and measuring instruments during a road test
1.4 Safety precautions when working on the SCR system
2 Identification
2.1 Engine number/engine data
3 General information
3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system
4 Repair notes
4.1 Rules for cleanliness
4.2 Foreign objects in the engine
4.3 Contact corrosion
4.4 Routing and attachment of lines
4.5 Fitting radiator and condensers
20 – Fuel supply system
1 Procedure in event of misfuelling
2 Fuel
2.1 Assembly overview – fuel tank
2.2 Removing and installing fuel tank
2.3 Emptying fuel tank
2.4 Removing and installing misfuelling prevention device
2.5 Deactivating misfuelling prevention device
3 Fuel delivery unit, fuel gauge sender
3.1 Assembly overview – fuel delivery unit/fuel gauge sender
3.2 Removing and installing fuel delivery unit, fuel gauge sender
3.3 Removing and installing fuel gauge sender -G-
3.4 Removing and installing fuel gauge sender 2 -G169-
3.5 Removing and installing assembly opening cover
4 Plug-in connectors
4.1 Separating plug-in connectors
5 Fuel filter
5.1 Assembly overview – fuel filter
5.2 Removing and installing fuel filter
5.3 Fuel hoses in the engine compartment
5.4 Drain water from fuel filter
6 Accelerator pedal
6.1 Assembly overview – accelerator module
6.2 Removing and installing accelerator pedal module -GX2-
7 Fuel pump
7.1 Checking fuel system pressurization pump -G6-
7.2 Removing and installing fuel pump control unit -J538-
7.3 Checking suction-jet pump
7.4 Removing and installing suction-jet pump
8 Senders and sensors
8.1 Removing and installing water separator sender -G63-
9 Lines
9.1 Removing and installing fuel lines
9.2 Removing and installing fuel line for auxiliary/supplementary heater
00 – Technical data
1 Safety information
1.1 Safety precautions when using testers and measuring instruments during a road test
2 Identification
2.1 Allocation of PR number – brakes
2.1.1 Front brakes
2.1.2 Rear brakes
3 Technical data
3.1 Technical data for brakes
3.1.1 Brake master cylinder and brake servo
4 Brake test
4.1 General information
4.2 Checking vehicles with front-wheel drive
4.3 Checking vehicles with four-wheel drive
4.3.1 On a regulated roller dynamometer with counter-rotating rollers for four-wheel drive vehicles
4.3.2 Without roller dynamometer for four-wheel drive vehicles
4.4 Checking parking brake
4.4.1 Checking electromechanical parking brake, vehicles with front-wheel drive
4.4.2 Checking electromechanical parking brake, vehicles with all-wheel drive
45 – Anti-lock brake system
1 General information
1.1 Repair instructions for repair work on ABS
2 Overview of fitting locations
2.1 Overview of fitting locations – ABS/ESP
2.1.1 Overview of fitting locations – ABS/ESP
3 Control unit and hydraulic unit
3.1 Assembly overview – control unit and hydraulic unit
3.1.1 Assembly overview – control unit and hydraulic unit, LHD
3.1.2 Assembly overview – control unit and hydraulic unit, right-hand drive
3.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-
3.2.1 Removing and installing control unit and hydraulic unit, left-hand drive, petrol engines
3.2.2 Removing and installing control unit and hydraulic unit, left-hand drive, diesel engine
3.2.3 Removing and installing control unit and hydraulic unit, right-hand drive
3.3 Separating the control unit from the hydraulic unit
3.4 Fitting control unit to hydraulic unit
3.5 Connecting brake lines to the hydraulic unit
3.5.1 Connecting brake lines to the hydraulic unit, LHD
3.5.2 Connecting brake lines to the hydraulic unit, RHD
4 Sensors
4.1 Assembly overview – speed sensor on the front axle
4.2 Assembly overview – speed sensor on the rear axle
4.2.1 Assembly overview – speed sensor on rear axle, front-wheel drive
4.2.2 Assembly overview – speed sensor on rear axle, all-wheel drive
4.3 Removing and installing speed sensors on front axle -G45-/-G47-
4.4 Removing and installing speed sensors on rear axle -G44-/-G46-
4.4.1 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with front-wheel drive
4.4.2 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with all-wheel drive
4.5 Checking ABS sensor ring
4.6 Removing and installing ESP sensor unit -G419-
46 – Brakes – mechanism
1 Front brakes
1.1 Assembly overview – front brakes
1.2 Removing and installing brake pads/linings
1.3 Removing and installing brake caliper
2 Rear brakes
2.1 Assembly overview – rear brakes
2.2 Removing and installing brake pads/linings
2.3 Removing and installing brake caliper
3 Parking brake
3.1 Overview of fitting locations – parking brake
3.2 Removing and installing control unit for electromechanical parking brake -J540-
3.3 Removing and installing parking brake motor -V282-/-V283-
4 Brake pedal
4.1 Assembly overview – brake pedal
4.1.1 Assembly overview – brake pedal, left-hand drive
4.1.2 Assembly overview – brake pedal, right-hand drive
4.2 Removing and installing mounting bracket
4.2.1 Removing and installing mounting bracket, left-hand drive
4.2.2 Removing and installing mounting bracket, RHD
4.3 Separating brake pedal from brake servo
4.4 Connecting brake pedal to brake servo
4.5 Removing and installing brake pedal
4.5.1 Removing and installing brake pedal, left-hand drive vehicles
4.5.2 Removing and installing brake pedal, right-hand drive vehicles
47 – Brakes – hydraulics
1 Front brake caliper
1.1 Assembly overview – front brake caliper
1.2 Removing and installing brake caliper piston
2 Rear brake caliper
2.1 Assembly overview – rear brake caliper
2.2 Removing and installing protective cap
3 Brake servo and brake master cylinder
3.1 Assembly overview – brake servo/brake master cylinder
3.1.1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles
3.1.2 Assembly overview – brake servo/brake master cylinder, right-hand drive
3.2 Removing and installing brake light switch
3.2.1 Removing and installing brake light switch, LHD
3.2.2 Removing and installing brake light switch, right-hand drive
3.3 Removing and installing brake servo
3.3.1 Removing and installing brake servo, LHD
3.3.2 Removing and installing brake servo, right-hand drive with diesel engine
3.3.3 Removing and installing brake servo, right-hand drive vehicles with petrol engine
3.4 Removing and installing brake master cylinder
3.4.1 Removing and installing brake master cylinder, left-hand drive
3.4.2 Removing and installing brake master cylinder, RHD
4 Vacuum system
4.1 Assembly overview – vacuum pump
4.1.1 Vacuum pump for brake servo, diesel vehicles
4.1.2 Assembly overview of vacuum pump for brakes -V192-, vehicles with 2.0 l petrol engine
4.1.3 Assembly overview of vacuum pump for brakes -V192-, vehicles with 1.0 l petrol engine
4.1.4 Assembly overview of vacuum pump for brakes -V192-, vehicles with 1.5 l petrol engine
4.2 Checking non-return valve
4.3 Removing and installing vacuum sender -G608-
4.4 Checking vacuum system
4.4.1 Connecting vacuum gauge for brake servo -VAS 6721-
4.4.2 Checking vacuum generation
4.4.3 Checking for leaks
4.5 Removing and installing electric vacuum pump
4.5.1 Removing and installing electric vacuum pump, vehicles with 1.0 l petrol engine
4.5.2 Removing and installing electric vacuum pump, vehicles with 1.5 l petrol engine
5 Brake lines
5.1 Repairing brake lines
5.1.1 Assembly overview – flanging tool
5.1.2 Instructions for use of flanging tool
6 Hydraulic system
6.1 General notes on brake fluid
6.1.1 General notes on brake fluid
6.1.2 Changing brake fluid
6.2 Bleeding hydraulic system following standard procedure
6.3 Subsequent bleeding of hydraulic system
6.4 Testing for leaks
00 – Technical data
1 Safety information
2 Identification
3 Technical data
3.1 Allocation gearbox – engine
3.2 Capacities
4 Overview – power transmission
4.1 Overview – power transmission – front-wheel drive
4.2 Overview – power transmission – all-wheel drive
5 Electrical components
6 Repair instructions
6.1 General repair instructions
30 – Clutch
1 Clutch operation
1.1 Assembly overview – clutch release mechanism
1.2 Checking clutch master cylinder and clutch slave cylinder
1.3 Removing and installing clutch slave cylinder together with release bearing
1.4 Repairing clutch release mechanism
2 Clutch
2.1 Assembly overview – clutch
2.2 Removing and installing clutch
34 – Controls, housing
1 Selector mechanism
2 Removing and installing gearbox
3 Bevel box
3.1 Distinguishing between different types of bevel boxes
3.2 Removing bevel box
3.3 Installing bevel box
4 Front differential lock
5 Transporting gearbox
5.1 Transporting manual gearbox
5.2 Transporting front differential lock
6 Gear oil
7 Securing to engine and gearbox support
7.1 Installing manual gearbox to engine and gearbox support
7.2 Installing bevel box or front differential lock to engine and gearbox support
8 Dismantling and assembling gearbox
8.1 Schematic overview – gearbox
8.1.1 Schematic overview – gearbox, front-wheel drive
8.1.2 Schematic overview – front differential lock
8.1.3 Schematic overview – gearbox, all-wheel drive
8.2 Assembly overview – gearbox
8.2.1 Assembly overview – gearbox with front-wheel drive
8.2.2 Assembly overview – gearbox with four-wheel drive, gearbox with front-wheel drive and front differential lock
8.3 Assembly overview – gearbox housing and selector mechanism
8.4 Assembly overview – shafts, differential, selector mechanism
8.4.1 Assembly overview – shafts, differential, selector mechanism, front-wheel drive
8.4.2 Assembly overview – shafts, differential, gear selector, all-wheel drive and front-wheel drive with front differential lock
8.5 Assembly overview – selector forks
8.6 Dismantling and assembling gearbox
8.6.1 Dismantling gearbox
8.6.2 Assembling gearbox
9 Gearbox housing, clutch housing
9.1 Assembly overview – gearbox housing
9.2 Assembly overview – clutch housing
9.3 Repairing gearbox housing
9.4 Repairing clutch housing
35 – Gears, shafts
1 Input shaft
1.1 Assembly overview – input shaft
1.2 Dismantling and assembling input shaft
1.3 Renewing input shaft seal
2 Output shaft
2.1 Assembly overview – output shaft
2.1.1 Assembly overview – output shaft for 1st to 4th gears
2.1.2 Assembly overview – output shaft for 5th, 6th and reverse gears
2.2 Dismantling and assembling output shaft
2.2.1 Dismantling and assembling output shaft for 1st to 4th gears
2.2.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears
2.3 Adjusting output shaft
2.3.1 Adjusting output shaft for 1st to 4th gears
2.3.2 Adjusting output shaft for 5th, 6th and reverse gears
39 – Final drive – differential
1 Oil seals
1.1 Overview of fitting locations – seals
2 Differential
2.1 Assembly overview – differential
2.1.1 Assembly overview – differential, front-wheel drive
2.1.2 Assembly overview – differential, four-wheel drive and front-wheel drive with front differential lock
2.2 Dismantling and assembling differential
2.2.1 Dismantling and assembling differential, front-wheel drive
2.2.2 Dismantling and assembling differential, four-wheel drive, front-wheel drive with front differential lock
2.3 Adjusting differential
3 Adjustment overview
4 Components of bevel box
4.1 Assembly overview – components of bevel box
4.2 Renewing bevel box seals
4.3 Renewing output flange and redetermining thickness of shim
5 Components of front differential lock
5.1 Assembly overview – components of front differential lock
5.2 Checking function
5.3 Renewing seals for front differential lock
5.3.1 Renewing seal between front differential lock and manual gearbox on front differential lock
5.3.2 Renewing oil seal for right flange shaft within front differential lock
5.4 Renewing ball bearing for flange shaft
6 Gear oil
7 Oil for front differential lock
00 – Technical data
1 Safety information
1.1 Safety regulations for working on fuel supply
1.2 Safety precautions when using testers and measuring instruments during a road test
1.3 Safety measures when working on vehicles with start/stop system
2 Identification
2.1 Engine number/engine data
3 General information
3.1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system
4 Repair instructions
4.1 Routing and attachment of lines
4.2 General repair instructions
20 – Fuel supply system
1 Fuel
1.1 Assembly overview – fuel tank
1.1.1 Assembly overview – fuel tank, vehicles with multi-link rear suspension
1.1.2 Assembly overview – fuel tank, vehicles with torsion beam rear suspension
1.1.3 Assembly overview – fuel tank, vehicles with fuel tank leak detection
1.1.4 Assembly overview – fuel tank, vehicles with four-wheel drive
1.1.5 Assembly overview – fuel tank, Touran
1.1.6 Assembly overview – fuel tank from below, vehicles with spoiler on fuel tank and torsion beam axle
1.1.7 Assembly overview – fuel tank from below, vehicles with spoiler on fuel tank and all-wheel drive
1.2 Removing and installing fuel tank
1.2.1 Removing and installing fuel tank, vehicles with multi-link rear suspension
1.2.2 Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function
1.2.3 Removing and installing fuel tank, vehicles with torsion beam axle
1.2.4 Removing and installing fuel tank – vehicles with four-wheel drive
1.2.5 Removing and installing fuel tank, Touran
1.2.6 Checking earth cable on filler neck from fuel tank
1.3 Emptying fuel tank
1.3.1 Emptying fuel tank when fuel pump is intact
1.3.2 Emptying fuel tank if it is more than 3/4 full
1.3.3 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with front-wheel drive
1.3.4 Emptying fuel tank with fuel tank less than 3/4 full, vehicles with four-wheel drive
2 Fuel delivery unit, fuel gauge sender
2.1 Assembly overview – fuel delivery unit/fuel gauge sender
2.1.1 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive
2.1.2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive
2.2 Removing and installing fuel delivery unit, fuel gauge sender
2.2.1 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive
2.2.2 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive
2.3 Removing and installing fuel gauge sender -G-
2.3.1 Removing and installing fuel gauge sender -G-, vehicles with front-wheel drive
2.3.2 Removing and installing fuel gauge sender -G-, vehicles with four-wheel drive
2.3.3 Removing and installing fuel gauge sender -G-, Golf 2020
2.4 Removing and installing fuel gauge sender 2 -G169-
2.5 Removing and installing assembly opening cover
2.5.1 Removing and installing assembly opening cover
2.5.2 Removing and installing assembly opening cover, Touran
3 Plug-in connectors
3.1 Separating plug-in connectors
4 Fuel filter
5 Activated charcoal filter with fuel tank leak detection
5.1 Connection diagram – activated charcoal filter system
5.2 Assembly overview – activated charcoal filter system
5.3 Removing and installing activated charcoal filter
5.4 Checking fuel system for leaks
5.5 Removing and installing control unit for fuel tank leak detection -J909-
6 Activated charcoal filter without fuel tank leak detection
6.1 Connection diagram – activated charcoal filter system
6.1.1 Connection diagram – activated charcoal filter system in engine compartment, vehicles with 1.5 l engine and pressure sensor for activated charcoal filter air flushing -GX44-
6.1.2 Connection diagram – activated charcoal filter system in engine compartment, vehicles with 1.0 l engine and pressure sensor for activated charcoal filter air flushing -GX44-
6.1.3 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1.4 l engine from model year 2020
6.2 Assembly overview – activated charcoal filter system
6.3 Removing and installing activated charcoal filter
6.4 Checking fuel tank breather
7 Accelerator pedal
7.1 Assembly overview – accelerator module
7.2 Removing and installing accelerator pedal module -GX2-
8 Fuel pump
8.1 Checking fuel system pressurisation pump -G6-
8.1.1 Checking fuel pressure in engine compartment
8.1.2 Checking fuel pressure on fuel delivery unit -GX1-
8.1.3 Checking fuel delivery rate of fuel system pressurisation pump -G6- in engine compartment
8.1.4 Checking fuel delivery rate at fuel delivery unit -GX1-
8.1.5 Connecting test instrument adapter for voltage measurement at fuel delivery unit
8.1.6 Connecting remote control
8.2 Removing and installing fuel pump control unit -J538-
8.2.1 Removing and installing fuel pump control unit -J538-
8.2.2 Removing and installing fuel pump control unit -J538-, Touran
8.3 Removing and installing suction-jet pump
9 Senders and sensors
9.1 Assembly overview – fuel quality sender -G446-
9.2 Removing and installing fuel quality sender -G446-
9.3 Removing and installing tank pressure sensor -G400-
10 Fuel lines
10.1 Removing and installing fuel lines
10.2 Removing and installing fuel line for auxiliary/supplementary heater
00 – Technical data
1 Safety information
1.1 Safety precautions when working on air conditioning systems
1.2 Safety measures when working on vehicles with a start/stop system
1.3 Safety precautions when using testers and measuring instruments during a road test
1.4 Safety precautions when working on the cooling system
1.5 Safety precautions when handling refrigerants
1.6 Safety precautions for working on vehicles with auxiliary/supplementary heater
1.7 Safety precautions when working on the SCR system
2 Identification
2.1 Identification of heater and air conditioning unit
2.1.1 Identification of heater and air conditioning unit made by Valeo
2.1.2 Identification of Denso heater and air conditioning unit
3 General information
3.1 Type plates
3.2 Notes concerning odours in air conditioned vehicles
4 Repair instructions
4.1 Rules for cleanliness
4.2 General information
4.3 General repair instructions
4.4 Contact corrosion
4.5 Nuts and bolts
4.6 Routing and attachment of lines
4.7 Fitting radiators, coolers and condensers
4.8 Working on refrigerant circuit
4.9 Refrigerant circuit seals
5 Technical data
5.1 Refrigerant capacity
5.1.1 Capacities for refrigerant R134a
5.1.2 Capacities for refrigerant R1234yf
5.2 Refrigerant oil capacities
5.2.1 Refrigerant oil capacities, refrigerant R134a
5.2.2 Refrigerant oil capacities, refrigerant R1234yf
5.3 Oil distribution
80 – Heating
1 Heating
87 – Air conditioning system
1 Overview of fitting locations – air conditioning system
1.1 Overview of fitting locations – components not located in passenger compartment
1.2 Overview of fitting locations – components located in front section of passenger compartment
1.2.1 Overview of fitting locations – components inside of front passenger compartment, left-hand drive vehicles
1.2.2 Overview of fitting locations – components inside of front passenger compartment, right-hand drive vehicles
2 Refrigerant circuit
2.1 System overview – refrigerant circuit
2.2 Assembly overview – condenser
2.3 Removing and installing refrigerant circuit pressure sender -G805-
2.4 Removing and installing refrigerant line with internal heat exchanger
2.5 Removing and installing expansion valve
2.6 Removing and installing condenser
2.7 Removing and installing desiccant bag or cartridge
2.7.1 Removing and installing desiccant bag or cartridge, Denso condenser
2.7.2 Removing and installing desiccant bag or cartridge, Modine condenser
2.7.3 Removing and installing desiccant bag or cartridge, Showa/Keihin condenser
2.8 Removing and installing evacuating and charging valves on low and high-pressure side
2.9 Commissioning air conditioning system after filling refrigerant circuit
2.10 Removing and installing refrigerant line from air conditioner compressor to condenser
2.11 Removing and installing refrigerant line from air conditioner compressor to evaporator
2.12 Removing and installing refrigerant line from evaporator to air conditioner compressor
2.13 Removing and installing damper weight for refrigerant line, low-pressure side
2.14 Commissioning air conditioning system after filling refrigerant circuit
3 Air conditioner compressor
3.1 Assembly overview – drive unit of air conditioner compressor
3.1.1 Assembly overview – drive unit of air conditioner compressor
3.1.2 Assembly overview – drive unit of air conditioner compressor with air conditioning system magnetic clutch -N25-
3.2 Assembly overview – pulley
3.2.1 Assembly overview – pulley, Denso air conditioner compressor
3.2.2 Assembly overview – belt pulley, Sanden air conditioner compressor
3.2.3 Assembly overview – belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25-
3.3 Removing air conditioning compressor from and installing on bracket
3.4 Removing and installing air conditioner compressor
3.5 Checking high-pressure safety valve on air conditioner compressor
3.6 Removing and installing pulley
3.6.1 Removing and installing Denso belt pulley
3.6.2 Removing and installing Sanden belt pulley
3.6.3 Removing and installing belt pulley, air conditioner compressor with air conditioning system magnetic clutch -N25-
4 Control motors
4.1 Overview of fitting locations – control motors at front
4.1.1 Overview of fitting locations – front control motors, air conditioning system, left-hand drive vehicles
4.1.2 Overview of fitting locations – front control motors, air conditioning system, right-hand drive vehicles
4.1.3 Overview of fitting locations – front Climatronic control motors, left-hand drive vehicles
4.1.4 Overview of fitting locations – front Climatronic control motors, right-hand drive vehicles
4.2 Removing and installing temperature flap control motor -V68-
4.3 Removing and installing defroster flap control motor -V107-
4.4 Removing and installing air recirculation flap control motor -V113-
4.5 Removing and installing left temperature flap control motor -V158-
4.6 Removing and installing right temperature flap control motor -V159-
4.7 Removing and installing fresh air/air recirculation, air flow flap control motor -V425-
4.8 Removing and installing front air distribution flap control motor -V426-
4.9 Removing and installing air distribution flap control motor -V428-
4.10 Removing and installing air distribution flap actuator
4.10.1 Removing and installing front air distribution flap actuator, air conditioning system, left-hand drive vehicles
4.10.2 Removing and installing front air distribution flap actuator, air conditioning system, right-hand drive vehicles
4.10.3 Removing and installing front air distribution flap actuator, Climatronic, right-hand drive vehicles
4.10.4 Removing and installing front air distribution flap actuator, Climatronic, right-hand drive vehicles
5 Front heater and air conditioning unit
5.1 Assembly overview – flaps and partitions in air distribution housing
5.2 Assembly overview – heater and air conditioning unit
5.3 Assembly overview – evaporator housing
5.4 Removing and installing evaporator
5.5 Checking auxiliary air heater element -Z35-
5.6 Removing and installing auxiliary air heater element -Z35-
5.6.1 Removing and installing auxiliary air heater element -Z35- (LHD)
5.6.2 Removing and installing auxiliary air heater element -Z35- (RHD)
5.7 Removing and installing heater and air conditioning unit
5.8 Removing and installing holder for heater and air conditioning unit
5.9 Dismantling and assembling heater and air conditioning unit
5.10 Removing and installing air distribution housing
5.11 Removing and installing dust and pollen filter
5.11.1 Removing and installing dust and pollen filter, left-hand drive vehicles
5.11.2 Removing and installing dust and pollen filter, right-hand drive vehicles
5.12 Removing and installing fresh air blower -V2-
5.12.1 Removing and installing fresh air blower -V2-, LHD vehicles
5.12.2 Removing and installing fresh air blower -V2- (RHD)
5.13 Removing and installing fresh air blower control unit -J126-
5.13.1 Removing and installing fresh air blower control unit -J126-, LHD vehicles
5.13.2 Removing and installing fresh air blower control unit -J126-, RHD vehicles
5.14 Removing and installing heat exchanger
5.14.1 Removing and installing Valeo heat exchanger, left-hand drive vehicles
5.14.2 Removing and installing Valeo heat exchanger, right-hand drive vehicles
5.14.3 Removing and installing Denso heat exchanger, left-hand drive vehicles
5.14.4 Removing and installing Denso heat exchanger, right-hand drive vehicles
5.15 Removing and installing coolant pipes on heat exchanger
5.15.1 Removing and installing coolant pipes at heat exchanger (Valeo)
5.15.2 Removing and installing coolant pipes at heat exchanger (Denso)
5.16 Removing and installing evaporator temperature sensor -G308-
5.17 Removing and installing condensation drain
5.17.1 Removing and installing condensation drain, left-hand drive vehicles
5.17.2 Removing and installing condensation drain, right-hand drive vehicles
5.18 Checking condensation drain
5.19 Removing and installing baffle plate
6 Air duct
6.1 Assembly overview – air duct and air distribution in passenger compartment
6.2 Removing and installing driver side footwell vents
6.3 Removing and installing front passenger side footwell vents
6.3.1 Removing and installing front passenger side footwell vents, left-hand drive vehicles
6.3.2 Removing and installing front passenger side footwell vents, right-hand drive vehicles
6.4 Removing and installing rear footwell vent
6.5 Removing and installing air ducts
6.5.1 Removing and installing air duct, for air duct for rear vent in centre console
6.5.2 Removing and installing air duct, for rear vent in centre console
6.6 Removing and installing forced ventilation for passenger compartment
6.7 Checking forced ventilation for passenger compartment
6.8 Removing and installing fresh air intake
6.9 Removing and installing cover for fresh air intake
6.10 Removing and installing air intake duct
6.11 Removing and installing air duct for defroster vent
6.12 Removing and installing air duct for centre vent
7 Operating and display unit
7.1 Overview of operating and display unit
7.1.1 Overview – operating and display unit, air conditioning system
7.1.2 Overview – operating and display unit, Climatronic
7.2 Removing and installing operating and display unit
8 Other controlling and regulating components
8.1 Removing and installing sunlight penetration photosensor -G107-
8.2 Working principles of air quality sensor -G238-
8.3 Removing and installing air quality sensor -G238-
8.4 Removing and installing ambient temperature sensor -G17-
8.5 Removing and installing humidity sender for air conditioning system -G260-
8.6 Removing and installing left vent temperature sender -G150-
8.6.1 Removing and installing left vent temperature sender -G150-, LHD vehicles
8.6.2 Removing and installing left vent temperature sender -G150-, RHD vehicles
8.7 Removing and installing right vent temperature sender -G151-
8.7.1 Removing and installing right vent temperature sender -G151-, LHD vehicles
8.7.2 Removing and installing right vent temperature sender -G151-, RHD vehicles
8.8 Removing and installing footwell vent temperature sender -G192-
00 – Technical data
1 Safety information
2 Repair instructions
3 Evaluating accident vehicles
4 Waste disposal
40 – Front suspension
1 Front axle
2 Subframe
3 Anti-roll bar
4 Suspension strut, upper suspension link
5 Lower suspension link, swivel joint
6 Wheel bearing
7 Drive shaft
42 – Rear suspension
1 Rear axle
2 Axle beam
3 Subframe
4 Anti-roll bar
5 Suspension link, track rod
6 Suspension strut, shock absorber, spring
7 Wheel bearing assembly, trailing arm
8 Drive shaft
43 – Self-levelling suspension
1 Electronically controlled damping system
2 Vehicle level sender
44 – Wheels, tyres, vehicle geometry
1 Wheel alignment
2 Adaptive cruise control
3 Front camera for assist systems
48 – Steering
1 Steering wheel
2 Steering column
3 Steering rack
4 Sensors
00 – Technical data
1 Safety information
2 Repair instructions
3 Battery
27 – Starter, current supply, CCS
1 Battery
2 Alternator
3 Starter motor
4 Cruise control system (CCS)
5 Start/stop system
6 Adaptive cruise control
90 – Gauges, instruments
1 Dash panel insert
2 Horn
92 – Windscreen wash/wipe system
1 Windscreen wiper system
2 Windscreen washer system
3 Rear window wiper system
4 Rear window washer system
5 Washer fluid lines
94 – Lights, bulbs, switches – exterior
1 Headlights
2 Fog lights
3 Lights in exterior mirror
4 Tail lights
5 High-level brake light
6 Number plate light
7 Entry and start authorisation system
8 Steering column switch module
9 Parking aid
10 Park assist steering
11 Automatic headlight range control
12 Blind Spot Monitor
96 – Lights, bulbs, switches – interior
1 Lights
2 Controls
3 Anti-theft alarm
4 Immobiliser
5 Front camera for assist systems
6 Towing bracket
7 Cigarette lighter, socket
97 – Wiring
1 Relay carriers, fuse holders, electronics boxes
2 Control units
3 Connectors
4 Releasing and dismantling connector housings
5 Repairing aerial wires
6 Fibre optic cables
7 Vehicle diagnosis, testing and information systems
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
21 – Turbocharging/supercharging
24 – Mixture preparation – injection
26 – Exhaust system
28 – Ignition system
001 – Basic equipment
002 – Convenience system , (L0L)
003 – Convenience system , (L0R)
004 – Anti-lock brake system (ABS) , (L0L)
005 – Anti-lock brake system (ABS) , (L0R)
006 – Airbag systems , (L0L)
007 – Airbag systems , (L0R)
008 – Fuses in engine compartment
009 – Earthing concept
010 – LED headlights , (8IT)
011 – Electromechanical steering , (1N3),(1N5),(1N7)
012 – Seat heating , (4A3)
013 – Entry and start authorisation , (4F2),(4I3)
014 – Window wash/wipe system , (8N6),(8N8),(8M1)
015 – Dual clutch gearbox 0GC , (0IJ)
016 – Dual clutch gearbox 0CW , (0EG)
017 – Multifunction steering wheel , (1XX),(2FW),(2PK),(2PU),(2ZD),(2ZH),(2ZW@2FW)
018 – Climatronic , (9AK)
019 – Air conditioning system , (KH6)
020 – Anti-theft alarm system , (7AL),(7AS)
021 – Parking aid (PDC) , (7X2),(7X5)
022 – Dynamic Chassis Control , (2H4)
023 – Radio navigation system
024 – Reversing camera (Rear Assist) , (KA1)
025 – Auxiliary heater , (9M9)
026 – Radiator fan
027 – All-wheel drive , (1X1)
028 – Data bus network
029 – Trailer coupling , (1D2),(1M5)
030 – Sound system , (9VG),(I8C),(I8F)
031 – Adaptive cruise control , (6K3),(6K4),(8T7),(8T8)
032 – Sliding/tilting sunroof , (3FU)
033 – 12 V sockets , (9JA),(7B6)
034 – Front camera for driver assist systems , (QK1)
035 – Steering column electronics for heated steering wheel , (2ZD),(2ZW)
036 – Mobile telephone systems , (9IJ)
037 – Emergency call module , (EL2),(EL5),(NZ4),(I8F)
038 – Tail light clusters with LEDs , (8SK),(8SQ)
039 – 1.0l petrol engine , CHZJ
040 – 1.5l petrol engine , DADA,DPCA
041 – 2.0l petrol engine , CZPB,DKZA
042 – 2.0l diesel engine , DFFA,DFHA
043 – Fuses in interior
044 – 1.6l diesel engine , DGTE
045 – Lane change assist , (7Y8),(7Y9)
046 – 1.0l petrol engine , DKRA,DKRF
047 – Basic equipment
048 – Steering column electronics for heated steering wheel , (2ZD),(2ZW)
049 – Anti-theft alarm system , (7AL),(7AS)
050 – 2.0l petrol engine , DNUE
051 – Engine sound generator , (A9R)
052 – TV tuner, card reader unit (Japan) , (ER5)
053 – Radio and navigation system (South Korea) , (ER7)
054 – 1.0l petrol engine , DLAA
055 – 1.4l petrol engine , DJKA
056 – 2.0l diesel engine , CRVC
057 – 2.0l diesel engine , DTRD,DTTA,DTTC
058 – USB connections for data transfer , (U9B),(U9C)
059 – Emergency call module , (EL2),(EL5),(EL6),(NZ2),(NZ4),(NZ5),(8AR),(I8I)
060 – Sound system , (8AR),(9VG)
061 – Dual clutch gearbox 0D9 , (0ES)
062 – 8-speed automatic gearbox 09S , (0IH)
063 – 2.0l petrol engine , DNFC
064 – 2.0l petrol engine , DNNA
830 – -Connector views: parts with prefix A to D – 3
831 – -Connector views: parts with prefix E – 3
832 – -Connector views: parts with prefix F – 3
833 – -Connector views: parts with prefix G – 3
834 – -Connector views: parts with prefix H to I – 3
835 – -Connector views: parts with prefix J – 3
836 – -Connector views: parts with prefix K to M – 3
837 – -Connector views: parts with prefix N – 3
838 – -Connector views: parts with prefix O to Q – 3
839 – -Connector views: parts with prefix R – 3
840 – -Connector views: parts with prefix S to U – 3
841 – -Connector views: parts with prefix V – 3
842 – -Connector views: parts with prefix W to Z – 3
00 – Technical data
1 Safety information
2 Repair instructions
68 – Interior equipment
1 Compartments/covers
2 Equipment
3 Centre console
4 Front centre armrest
5 On inside
69 – Passenger protection
1 Seat belts
2 Child seat anchors
3 Airbag system
4 Airbag control unit
5 Driver’s airbag
6 Front passenger side airbag
7 Side airbags
8 Curtain airbags
9 Airbag crash sensors
10 Seat belt verification
70 – Trim, insulation
1 Front door trims
2 Rear door trims
3 Dash panel
4 Central tube for dash panel
5 Interior trims
6 Luggage compartment trims
7 Roof trims
72 – Seat frames
1 Overview of seat variants
2 Front seats
3 Rear seats
74 – Seat – padding, covers
1 Front seat covers and padding
2 Rear seat covers and padding
00 – Technical data
1 Safety information
2 Identification
3 Repair notes
10 – Removing and installing engine
1 Removing and installing engine
2 Assembly mountings
3 Motor cover
13 – Crankshaft group
1 Cylinder block (pulley end)
2 Cylinder block, gearbox end
3 Crankshaft
4 Balancer shaft
5 Pistons and conrods
15 – Cylinder head, valve gear
1 Cylinder head
2 Timing chain cover
3 Chain drive
4 Valve gear
5 Inlet and exhaust valves
17 – Lubrication
1 Sump, oil pump
2 Engine oil cooler
3 Crankcase ventilation
4 Oil filter, oil pressure switch
19 – Cooling
1 Cooling system/coolant
2 Coolant pump/thermostat assembly
3 Coolant pipes
4 Radiator, radiator fan
21 – Turbocharging/supercharging
1 Exhaust turbocharger
2 Charge air system
24 – Mixture preparation – injection
1 Injection system
2 Injectors
3 Air filter
4 Intake manifold
5 Senders and sensors
6 Engine (motor) control unit
7 High-pressure pump
8 Lambda probe
26 – Exhaust system
1 Exhaust pipes, silencers
2 Exhaust gas cleaning
3 Exhaust gas temperature regulation
28 – Ignition system
1 Ignition system
00 – Technical data
1 Safety information
2 Identification
3 Repair instructions
10 – Removing and installing engine
1 Removing and installing engine
2 Assembly mountings
13 – Crankshaft group
1 Cylinder block (pulley end)
2 Cylinder block, gearbox end
3 Crankshaft
4 Pistons and conrods
15 – Cylinder head, valve gear
1 Cylinder head
2 Toothed belt drive
3 Valve gear
4 Inlet and exhaust valves
17 – Lubrication
1 Sump, oil pump
2 Engine oil cooler
3 Crankcase ventilation
4 Oil filter, oil pressure switch
19 – Cooling
1 Cooling system/coolant
2 Coolant pump, regulation of cooling system
3 Coolant pipes
4 Radiator, radiator fan
21 – Turbocharging/supercharging
1 Turbocharger
2 Charge air system
24 – Mixture preparation – injection
1 Injection system
2 Injectors
3 Air filter
4 Intake manifold
5 Sensors
6 Engine (motor) control unit
7 High-pressure pump
8 Lambda probe
26 – Exhaust system
1 Exhaust pipes, silencers
2 Exhaust gas cleaning
28 – Ignition system
1 Ignition system
00 – Technical data
1 Safety information
2 Identification
3 Repair notes
10 – Removing and installing engine
1 Removing and installing motor
2 Assembly mountings
13 – Crankshaft group
1 Cylinder block (pulley end)
2 Cylinder block, gearbox end
3 Crankshaft
4 Pistons and conrods
15 – Cylinder head, valve gear
1 Cylinder head
2 Toothed belt drive
3 Valve gear
4 Inlet and exhaust valves
17 – Lubrication
1 Sump, oil pump
2 Engine oil cooler
3 Crankcase ventilation
4 Oil filter, oil pressure switch
19 – Cooling
1 Cooling system/coolant
2 Coolant pump, regulation of cooling system
3 Coolant pipes
4 Radiator, radiator fan
21 – Turbocharging/supercharging
1 Turbocharger
2 Charge air system
24 – Mixture preparation – injection
1 Injection system
2 Injectors
3 Air filter
4 Intake manifold
5 Senders and sensors
6 Engine control unit
7 High-pressure pump
8 Lambda probe
26 – Exhaust system
1 Exhaust pipes and silencers
2 Emission control
28 – Ignition system
1 Ignition system
00 – Technical data
1 Safety information
2 Repair notes
50 – Body – front
1 Lock carrier
2 Wings
3 Plenum chamber bulkhead
55 – Bonnet, rear lid
1 Bonnet
2 Tailgate
3 Tank flap unit
57 – Front doors, door components, central locking
1 Door
2 Door components
3 Central locking
58 – Rear doors, door components
1 Door
2 Door components
60 – Sunroof
1 Sliding sunroof
2 Water drain hoses
63 – Bumpers
1 Bumper, front
2 Bumper, rear
64 – Glazing
1 Repair notes
2 Windscreen
3 Rear windscreen
4 Door windows
66 – Exterior equipment
1 Radiator grille and front trim
2 Spoiler
3 Mouldings, trims, extensions
4 Noise insulation
5 Underbody cladding
6 Roof moulding and roof railing
7 Trim film and protective film
8 Exterior mirror
9 Wheel housing liner
10 Lettering and emblems
11 Towing bracket
12 Heat shields

ABOUT THE MANUAL & IMPORTANT INFORMATION
The workshop manual is the same as used in official and authorized Dealer services and professional automotive services
You can follow all processes exactly as the car manufacturer recommended – maintain your car in the same way as professional and official services do
The PDF file is compatible with all systems i.e. Android, iOS, Windows, Linux
The PDF file is compatible with all devices like Notebooks, laptops, tablets, smartphones, PC, etc.
You can find any keywords in the Workshop Manual by search option
The Workshop Manual contains a Table of Contents
Any page, chapter, or whole manual can be printed out at every moment

The manual contains:
All official manufacturer specifications (for example Tightening torques, parts/ tools numbers, and specifications)
Repair instructions and information step by step
Maintenance guidance
A lot of diagrams
Ilustrations and tables
Why PDF instead of CD-ROM or Printable version?
You save the environment
You are able to recover the manual every time, you will not lose it.
You can download and save the Workshop Manual on every device
You can print out every page, chapter, or whole manual if you need -every time
Ilustrations and tables.

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