Maintenance

Chapter overview

• 1 Engine list
  1
• 2 Service work
  8
• 2.1 Service tables
  8
• 2.2 Delivery inspection
  11
• 2.3 Oil change service
  12
• 2.4 Inspection service every 12 months for vehicles ►1999
  14
• 2.5 Inspection service every 30,000 km for vehicles ►1999
  16
• 2.6 Additional work / vehicles ►1999
  18
• 2.7 Inspection service for vehicles 2000►
  21
• 2.8 Time or distance dependent additional work, vehicles 2000►
  23
• 3 General information
  28
• 3.1 Sticker
  28
• 3.2 Connecting vehicle diagnostic tester
  29
• 3.3 Severe operating conditions
  32
• 3.4 Raising vehicle
  33
• 3.5 Vehicle identification number
  34
• 3.6 Vehicle data sticker
  34
• 3.7 Information on long-life service or time or distance dependent service 2000►
  34
• 3.8 Countries where diesel has a high sulphur content
  37
• 3.9 Engine code and engine number
  37
• 3.10 RME fuel (biodiesel)
  37
• 3.11 Identification plate
  38
• 4 Descriptions of work:
  39
• 4.1 8-way memory seat: initialising (activation)
  41
• 4.2 Rear final drive: checking oil level
  41
• 4.3 Additive container: extracting and replenishing new additive
  42
• 4.4 Diesel particulate filter: reading ash load level
  47
• 4.5 Swivel joints: inspecting
  48
• 4.6 Automatic gearbox: checking front wheel drive oil level
  48
• 4.7 Automatic gearbox: checking ATF level
  48
• 4.8 Battery: checking battery terminal clamps for secure seating
  48
• 4.9 Battery: checking using battery tester with printer VAS 5097A
  49
• 4.10 Changing brake fluid
  49
• 4.11 Brake fluid level: checking
  54
• 4.12 Tyres: checking condition, wear pattern, inflation pressure, tread depth
  55
• 4.13 Brake system: inspecting for leaks and damage
  62
• 4.14 Front and rear brake pads/linings: checking thickness
  62
• 4.15 Renewing diesel particulate filter
  65
• 4.16 Electric windows: initialising (activation)
  65
• 4.17 Carry out vehicle system test
  66
• 4.18 Boots: inspecting
  67
• 4.19 V-belt: renewing (4-cylinder petrol engine)
  67
• 4.20 Poly V-belt: checking condition
  69
• 4.21 Fuel filter: renewing (diesel engine)
  70
• 4.22 Fuel filter: draining water (diesel engine)
  73
• 4.23 Checking crankcase pressure
  73
• 4.24 Cooling system: checking frost protection and coolant level
  75
• 4.25 Air filter: cleaning housing and renewing filter element
  77
• 4.26 Engine oil level: checking
  79
• 4.27 Engine oil: draining or extracting and replenishing; renewing oil filter
  79
• 4.29 Engine cover panel -top-: removing and installing
  86
• 4.30 Engine cover -bottom- (noise insulation): removing and installing
  90
• 4.31 Road test: performing (driving behaviour, noises, air conditioner etc.)
  91
• 4.32 Wheel securing bolts: tightening to specified torque
  91
• 4.33 Radio/radio-navigation system: activating anti-theft coding
  93
• 4.34 Tyre repair set
  95
• 4.35 Dash panel insert: adapting to required language
  95
• 4.36 Manual gearbox/final drive: checking oil level
  96
• 4.37 Window wash/wipe system and headlight washer system: checking function
  96
• 4.39 Headlight adjustment: checking
  103
• 4.40 Sunroof: checking function, cleaning and greasing guide rails
  112
• 4.41 Sliding sunroof drains: checking for blockage, cleaning if necessary
  113
• 4.42 Power assisted steering: checking fluid level
  114
• 4.43 Service interval display: resetting
  115
• 4.44 Service interval display: recoding
  125
• 4.45 Track rod ends: checking clearance, firm seating and boots
  132
• 4.46 Dust and pollen filter: renewing filter element
  133
• 4.47 Door arrester: lubricating
  133
• 4.48 Track control link front axle: checking
  133
• 4.49 Transport locks: removing blocking pieces from front axle springs (if fitted)
  134
• 4.50 Clock: setting to correct time
  134
• 4.52 Front axle (Passat Protect): renewing
  135
• 4.53 Cleaning plenum chamber
  135
• 4.54 Camshaft drive toothed belt: renewing (4-cylinder TDI engines)
  136
• 4.57 Toothed belt for injection pump: renewing (6-cylinder TDI engines)
  137
• 4.60 Camshaft drive toothed belt: renewing (1.8l 4-cylinder 5-valve petrol engines)
  138
• 4.63 Toothed belt: checking for wear (diesel engine)
  140
• 4.64 Camshaft drive toothed belt: checking (4-cylinder petrol engine)
  140
• 4.65 Spark plugs: renewing
  141
• 4.66 Rear lid: lubricating left and right multi-joint hinge
  152
• 4.67 Driver and front passenger airbags: visual check of airbag units
  154
• 5 Exhaust emissions test
  156
• 5.1 Exhaust emissions test for petrol engines without OBD
  156
• 5.2 Exhaust emissions test for petrol engines with OBD
  172
• 5.3 Procedures for vehicles with diesel engine without OBD
  174
• 5.4 Procedures for vehicles with diesel engine and OBD
  180
• 6 Glossary
  184