maitenance cc.pdf

(12360 KB) Pobierz
Service
Maintenance
CC 2010 ➤ , CC 2012 ➤ ,
Passat 2006 ➤ , Passat CC 2009 ➤ ,
Passat Variant 2006 ➤
Edition 12.2011
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Service Department. Technical Information
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Service
Maintenance
Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work
5. Exhaust emissions test
6. Glossary
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2012 Volkswagen AG, Wolfsburg
K0059021420
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CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC 2009 ➤ , Passat Vari ...
Maintenance - Edition 12.2011
Vo l
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Information on long-life service and time or distance dependent service . . . . . . . . . . . . . . 8
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.7 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.8 Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.9 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.10 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.11 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Removable towing bracket: Check and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Swivel joints and axle bearings: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Front passenger front airbag: Check key switch and „On/Off function“ . . . . . . . . . . . . . . . . 34
4.4 Automatic gearbox: Check ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5 Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . . . 39
4.7 Checking tyres: Condition, wear pattern, tyre pressure, tread depth and age of tyres . . . . 39
4.8 Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.9 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.10 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 48
4.11 Thickness of brake pads/linings and condition of brake discs, front and rear: Check . . . . 49
4.12 6-speed dual clutch gearbox (DSG) 02E: Change oil and filter . . . . . . . . . . . . . . . . . . . . . . 51
4.13 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 52
4.14 Reading fault memory of all systems with vehicle diagnosis tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.15 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.16 Interior and exterior body: Performing visual check for corrosion when doors and flaps are
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.17 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.18 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.19 Diesel fuel filter: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.20 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.21 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.22 Removing and installing engine compartment cover -bottom- (noise insulation) . . . . . . . . 73
4.23 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.24 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.25 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 75
4.26 Tyre repair set: Check bottle for damage and if used; check and enter date of tyre sealant
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.27 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 89
4.28 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.29 Reading radio code using vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.30 Radio/navigation system: Enter PIN of anti-theft coding and store local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.31 Tyre pressure monitoring: Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.32 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 95
Contents i
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CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC 2009 ➤ , Passat Vari ...
Maintenance - Edition 12.2011
4.33 Headlight adjustment: checking halogen headlights and fog lights, adjusting if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.34 Headlight adjustment: checking gas discharge headlights without DLA, adjusting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.35 Headlight adjustment: checking gas discharge headlights with DLA, adjusting if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.36 Window wash/wipe system and headlight washer system: Check function, adjustment and
for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.37 Wiper blade protection: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.38 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.39 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.40 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.41 Sliding sunroof drains: Check not blocked, clean if necessary . . . . . . . . . . . . . . . . . . . . . . 118
4.42 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.43 Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.44 Transportation mode: Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.45 Transportation devices: Remove blocking pieces from front axle springs . . . . . . . . . . . . . . 123
4.46 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of
lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.47 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.48 Toothed belt and toothed belt tensioning roller: Renew (TDI unit injector) . . . . . . . . . . . . 125
4.49 Camshaft drive toothed belt: Renew (only 2.0l FSI and TFSI and common rail) . . . . . . . . 125
4.50 Camshaft drive toothed belt: Check (1.6 l, 4-cyl. petrol engine) . . . . . . . . . . . . . . . . . . . . . . 126
4.51 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.52 Compass module: Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.53 Static cornering light (cornering light) and driving light assist: Check function . . . . . . . . . . 138
4.54 Haldex coupling: Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.55 Front and rear final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.56 Auxiliary heater: Set weekday in menu of combi-instrument . . . . . . . . . . . . . . . . . . . . . . . . 143
4.57 Memory seat: Perform initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.58 Checking diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.59 Automatic gearbox: Change ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.60 Reducing agent (AdBlue®): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.61 Reducing agent (AdBlue®): Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.62 Transport locks: Remove fastening rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.63 Gas system test (GAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.64 Check condition of natural gas filler connection, clean if necessary and check O-ring . . . . 162
4.65 Natural gas tank: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.66 Activation of environment monitoring system (Front Assist): Check . . . . . . . . . . . . . . . . . . 163
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1 Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.2 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6
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Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
ii Contents
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CC 2010 ➤ , CC 2012 ➤ , Passat 2006 ➤ , Passat CC 2009 ➤ , Passat Vari ...
Maintenance - Edition 12.2011
1 Engine list
This chapter provides information on the following subjects:
Passat
Petrol engines ⇒ page 1
Diesel engines ⇒ page 3
Passat CC ►2009
CC 2010►
Petrol engines ⇒ page 5
Diesel engines ⇒ page 7
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Passat petrol engines
Engines:
⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Capacity
I
2.0
3.2
1.6
2.0
Engine code
AXX
AXZ
BLF
BLR
No. of cylinders/valves per cylin‐
der
4/4
6/4
4/4
4/4
Output
kW at 1 rpm 147/5700
184/6250
85/5800
110/6000
Torque
Nm at rpm 280/2000
330/3200
155/4000
200/3500
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Bore
∅ mm
82.5
86.0
76.5
82.5
Stroke
mm
92.8
90.89
86.9
92.8
Compression ratio
10.5
12.0
12.0
11.5
Injection/ignition
Motronic MED
9.1
TFSI
Motronic MED
9.1
FSI
Motronic MED
9.5.10
FSI
Motronic MED
9.5.10
FSI
RON
unleaded, at
least
95
95
95
95
Camshaft drive
Toothed belt
Chain
Chain
Toothed belt
Engines:
⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Capacity
I
3.6
2.0
2.0
2.0
Engine code
BLV
BLX
BLY
BPY
No. of cylinders/valves per cylin‐
der
6/4
4/4
4/4
4/4
Output
kW at 1 rpm 206/6200
110/6000
110/6000
147/5700
Torque
Nm at rpm 360/2800
200/3500
200/3500
280/2000
Bore
∅ mm
89.0
82.5
82.5
82.5
Stroke
mm
95.9
92.8
92.8
92.8
Compression ratio
12.0
11.5
11.5
10.5
Injection/ignition
Motronic MED
9.1
FSI
Motronic MED
9.5.10
FSI
Motronic MED
9.5.10
FSI
Motronic MED
9.1
TFSI
RON
unleaded, at
least
98
95
95
95
Camshaft drive
Chain
Toothed belt Toothed belt Toothed belt
1. Engine list 1
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