Skoda Citigo (2011-2018) - Service Manual / Repair Manual - Wiring Diagrams

SKODA CITIGO (2011-2018) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for cars Skoda Citigo (2011-2018).

 

CONTENTS:


SERVICE MANUAL

1.0-44; 55 kW MPI engine
- 00 – Technical data
- 1 Denomination
- 1.1 Engine number
- 1.2 Engine characteristics
- 2 Safety instructions
- 2.1 Safety precautions when working on the fuel supply system
- 2.2 Safety precautions when working on vehicles with a start/stop system
- 2.3 Safety precautions during road tests in which testing and measuring equipment is used
- 2.4 Safety precautions when working on cooling system
- 2.5 Safety measures to apply when working on the fuel injection and ignition system
- 2.6 General notes on the injection system
- 2.7 General notes on the ignition system
- 2.8 Additional instructions when undertaking assembly work on the air-conditioning system
- 2.9 Safety measures and safety at work when working on vehicles with natural gas system (CNG)
- 3 Repair instructions
- 3.1 Cleanliness rules
- 3.2 Foreign bodies in the engine
- 3.3 Contact corrosion
- 3.4 Installation and fastening of lines
- 3.5 Assembly of radiators and capacitors
- 4 CNG - General
- 4.1 Valid instructions, regulations, standards and recommendations for the service, assembly and repair work on the natural gas system (CNG)
- 4.1.1 Valid instructions, regulations, standards and recommendations for the service, assembly and repair work on the natural gas system (CNG) valid for the Czech Republic
- 4.1.2 Valid instructions, regulations, standards and recommendations for the service, assembly and repair work on the natural gas system (CNG) valid for other countries
- 4.2 Inerting the natural gas fuel tank
- 4.2.1 Inerting the natural gas fuel tank with water
- 4.2.2 Inerting the natural gas fuel tank with nitrogen
- 4.3 Disposing of the natural gas fuel tank
- 4.4 Fuel tank from steel damage assessment
- 10 – Removing and installing engine
- 1 Removing and installing engine
- 1.1 Removing engine
- 1.2 Disconnect engine and gearbox
- 1.3 Securing the engine to the assembly stand
- 1.4 Installing the engine
- 2 Assembly bracket
- 2.1 Unit mounting - summary of components
- 2.2 Support the engine in its installed position
- 2.3 Removing and installing engine mount
- 2.4 Removing and installing gearbox mount
- 2.5 Removing and installing pendulum support
- 2.6 Check assembly bracket setting
- 2.7 Adjusting the unit mounting
- 13 – Crankshaft group
- 1 Cylinder block (pulley end)
- 1.1 Assembly overview - poly V-belt drive
- 1.2 Assembly overview - cylinder block (pulley end)
- 1.3 Removing and installing V-ribbed belt
- 1.3.1 Vehicles with air conditioner compressor
- 1.3.2 Vehicles without air conditioner compressor
- 1.4 Replacing crankshaft sealing ring - belt pulley end
- 2 Cylinder block on gearbox side
- 2.1 Summary of components - cylinder block on gearbox side
- 2.2 Removing and installing flywheel
- 2.3 Removing and installing sealing flange on gearbox side
- 2.3.1 Removing the sealing flange with sender wheel from the crankshaft
- 2.3.3 Attach sealing flange with rotor to the assembly tool -T10134-
- 2.3.4 Attach assembly tool -T10134- with sealing flange to the crankshaft flange and cylinder block
- 2.3.5 Secure assembly tool -T10134- to crankshaft flange
- 2.3.6 Press sender wheel onto crankshaft flange using assembly tool -T10134-
- 2.3.7 Checking sender wheel installation position on crankshaft
- 2.3.8 Re-pressing sender wheel
- 3 Crankshaft
- 4 Pistons and conrods
- 4.1 Assembly overview - piston and conrod
- 4.2 Inspect piston, piston rings and cylinder bore
- 4.3 Separating new conrod
- 15 – Cylinder head, valve gear
- 1 Cylinder head
- 1.1 Summary of components - cylinder head
- 1.2 Removing and installing camshaft housing
- 1.2.1 Removing and installing camshaft housing until 05.2012
- 1.2.2 Removing and installing camshaft housing as of 06.2012
- 1.3 Removing and installing the cylinder head
- 1.4 Testing the compression
- 2 Toothed belt drive
- 2.1 Position crankshaft to “TDC” .
- 2.2 Checking valve timing
- 2.3 Remove the toothed belt from the camshafts
- 2.3.1 Remove the toothed belt from the camshafts up to 05.2012
- 2.3.2 Remove the toothed belt from the camshafts from 06.2012
- 2.4 Removing and installing toothed belt
- 2.4.1 Removing and installing toothed belt up to 05.2012
- 2.4.2 Removing and installing toothed belt as of 06.2012
- 3 Valve gear
- 3.1 Assembly overview - valve gear
- 3.2 Measuring the axial play of the camshafts
- 3.3 Removing and installing camshaft control
- 3.4 Removing and installing camshaft sprocket
- 3.5 Removing and installing gasket ring for camshaft
- 3.5.1 Removing and installing the sealing ring for camshafts on the belt pulley side
- 3.5.2 Removing and installing the gasket ring for camshaft on the belt pulley side
- 3.6 Replacing valve stem seals
- 4 Inlet and exhaust valves
- 4.1 Inspect valve guides
- 17 – Lubrication
- 1 Lubrication system
- 1.1 Summary of components - lubrication system
- 1.2 Removing and installing oil pan
- 1.3 Removing and installing oil pump
- 2 Crankcase ventilation
- 2.1 Summary of components - crankcase ventilation
- 2.2 Removing and installing oil separator
- 3 Oil filter, oil pressure switch
- 3.1 Removing and installing oil filter housing
- 3.2 Removing and installing oil pressure switch -F1-
- 3.3 Testing oil pressure and oil pressure switch -F1-
- 19 – Cooling
- 1 Cooling system
- 1.1 Connection diagram for coolant hoses
- 1.2 Checking the coolant system for leak tightness
- 1.3 Draining and filling up coolant
- 1.3.1 Draining coolant
- 1.3.2 Filling with coolant
- 2 Coolant pump, regulation of cooling system
- 2.1 Assembly overview - coolant pump
- 2.2 Assembly overview - thermostat
- 2.3 Removing and installing coolant pump
- 2.4 Removing and installing coolant regulator
- 2.4.1 Removing and installing thermostat (extended circuit)
- 2.4.2 Removing and installing thermostat (small circuit)
- 2.5 Removing and installing toothed belt for coolant pump
- 2.6 Removing and installing coolant temperature sender
- 2.6.1 Removing and installing coolant temperature sender -G62-
- 2.6.2 Removing and installing radiator fan thermal switch -F18-
- 3 Radiator and radiator fan
- 3.1 Summary of components - Parts of the cooling system fitted to body
- 3.2 Removing and installing radiator
- 3.3 Removing and installing radiator cowling with radiator fan
- 3.4 Removing and installing radiator fan
- 20 – Fuel supply system
- 1 Fuel system
- 1.1 Overview of fitting locations - fuel supply
- 2 Fuel tank/natural gas container
- 2.1 Summary of components - fuel tank for petrol only vehicles
- 2.2 Summary of components - fuel tank for natural gas vehicles (CNG)
- 2.3 Summary of components - Natural gas container
- 2.3.1 Summary of components - Natural gas container 1
- 2.3.2 Summary of components - Natural gas container 2
- 2.3.3 Summary of components - tensioning strap and spring package
- 3 Petrol fuel system
- 3.1 Summary of components - fuel system pressurisation pump -G6-.
- 3.2 Removing and installing fuel delivery unit only for petrol vehicles
- 3.3 Removing and installing the fuel delivery unit for natural gas vehicles (CNG)
- 3.4 Removing and installing the sender for fuel gauge display -G-
- 3.5 Removing and installing fuel tanks only for petrol vehicles
- 3.6 Removing and installing the fuel tank for natural gas vehicles (CNG)
- 3.7 Fuel filter
- 3.8 Testing fuel pump
- 3.8.1 Checking fuel pressure
- 3.8.2 Testing holding pressure
- 3.8.3 Check fuel flow rate
- 3.9 Drain the fuel tank
- 3.9.1 Emptying fuel tank when fuel pump is intact
- 3.9.2 If the fuel pump has a fault, and the fuel tank is filled by more than 3/4 if there is a fault to the fuel pump.
- 3.9.3 If the fuel pump has a fault, and the fuel tank is filled by less than 3/4 if there is a fault to the fuel pump.
- 4 Quick couplings
- 4.1 Separating quick couplings
- 5 Natural gas fuel system (CNG)
- 5.1 Summary of components - seal fuel tank
- 5.2 Summary of components - filling connection
- 5.3 Mechanically close the tank shut-off valves -N361/N362-
- 5.4 Remove the pressure in the high-pressure line
- 5.5 Removing and installing natural gas container
- 5.5.1 Removing and installing natural gas container 1
- 5.5.2 Removing and installing natural gas container 2
- 5.6 Removing and installing solenoid coil of tank shut-off valve-N361/N362-
- 5.7 Empty the natural gas container
- 5.8 Determine the residual pressure in the natural gas container
- 5.8.1 Check and rework the adapter for the residual pressure test of the natural gas
- 5.8.2 Test (self-test) the cooling system tester -V.A.G 1274 B- and the adapter for the cooling system tester -V.A.G 1274 B/12 A-
- 5.8.3 Residual pressure test of the natural gas
- 5.9 Removing and installing tank shut-off valve -N361/N362-
- 5.10 Removing and installing filling connection
- 6 Accelerator pedal
- 6.1 Assembly overview - accelerator module
- 6.2 Removing and installing accelerator pedal module -GX2-
- 7 Activated charcoal container system
- 7.1 Assembly overview - activated charcoal filter system
- 7.1.1 Summary of components - Activated charcoal filter only for petrol vehicles
- 7.1.2 Summary of components - Activated charcoal filter system for natural gas vehicles (CNG)
- 7.2 Checking the fuel tank venting
- 7.3 Removing and installing activated charcoal filter
- 24 – Mixture preparation - injection
- 1 Fuel Injection System
- 1.1 Summary of components - injection system
- 1.1.1 Summary of components - engine from front
- 1.1.2 Summary of components - engine from rear
- 1.2 Assembly overview - fuel system
- 2 Injectors
- 2.1 Assembly overview - fuel rail with injectors
- 2.2 Removing and installing injection valves
- 2.3 Testing injection valves
- 3 Checking leak-tightness of the natural gas fuel supply system
- 3.1 Differentiating pressure area of the natural gas fuel supply system
- 3.1.1 High-pressure system
- 3.1.2 Low-pressure area
- 3.2 Determine the pressure in the natural gas system
- 3.3 Determining the operating mode of natural gas vehicles
- 3.4 Deactivating/activating natural gas mode
- 3.5 Inspecting the liquefied petroleum gas system (LPG) for leak tightness
- 3.5.1 Checking gas system for leak-tightness, after work on the high-pressure system
- 3.5.2 Checking gas system for leak-tightness, after work in the low-pressure area
- 4 Gas pressure regulator
- 4.1 Summary of components - gas pressure regulator
- 4.2 Removing and installing gas pressure regulator
- 4.3 Removing and installing the tank pressure sensor -G400-
- 5 Gas inlet valves
- 5.1 Summary of components - gas distribution line with gas inlet valves
- 5.2 Removing and installing gas distribution line with gas inlet valves -N366-, -N367-, -N368-
- 5.3 Removing and installing the gas distribution line sensor -G401-
- 6 Air filter
- 6.1 Assembly overview - air filter housing
- 6.2 Removing and installing air filter housing
- 7 Intake manifold
- 7.1 Assembly overview - intake manifold
- 7.2 Removing and installing intake manifold
- 7.3 Removing and installing the throttle valve control unit -GX3-
- 7.4 Clean throttle valve control unit -GX3-
- 8 Senders and sensors
- 8.1 Removing and installing intake manifold pressure sender -G71- with intake air temperature sender -G42-
- 9 Engine control unit
- 9.1 Assembly overview - engine control unit
- 9.2 Removing and installing engine control unit
- 9.2.1 Removing and installing engine control unit -J623-
- 9.2.2 Removing and installing theft-protected engine control unit -J623-
- 9.2.3 Removing engine control unit from bracket
- 10 Lambda probe
- 10.1 Removing and installing lambda probe - catalytic converter on engine
- 10.1.1 Removing and installing Lambda probe 1 after catalytic converter -GX7-
- 10.1.2 Removing and installing Lambda probe 1 after catalytic converter -GX10-
- 10.2 Removing and installing lambda probe - catalytic converter on bottom of vehicle
- 26 – Exhaust system
- 1 Removing and installing parts of the exhaust system
- 1.1 Summary of components - Pre-exhaust pipe with catalytic converter
- 1.1.1 Summary of components - pre-exhaust pipe with catalytic converter on engine
- 1.1.2 Summary of components - pre-exhaust pipe with catalytic converter on bottom of vehicle
- 1.2 Summary of components - Middle and rear part of the exhaust system
- 1.2.1 Replace middle or rear part of the exhaust system on petrol vehicles only
- 1.2.2 Summary of components - Replace middle or rear part of the exhaust system on natural gas vehicles CNG
- 1.3 Removing and installing pre-exhaust pipe with catalytic converter
- 1.3.1 Order of installation for pre-exhaust pipe with catalytic converter on engine
- 1.4 Separating the exhaust pipe
- 1.5 Removing and installing middle and rear silencers
- 1.6 Installation position of clamping sleeve
- 28 – Ignition system
- 1 Ignition system
- 1.1 Assembly overview - ignition system
- 1.2 Removing and installing ignition coils with power output stages
- 1.3 Removing and installing knock sensor 1 -G61-
- 1.4 Removing and installing Hall sender
- 1.5 Removing and installing engine speed sender
Air Conditioning System With Refrigerant R123yf
- 00 – Technical data
- 1 Safety instructions
- 1.1 Safety precautions when working on air Conditioning systems
- 1.2 Safety precautions when handling refrigerants
- 1.3 Safety precautions when working on vehicles with a start/stop system
- 1.4 Safety precautions when handling AC service stations
- 1.5 Safety precautions when handling pressurised containers
- 2 Laws and regulations
- 2.1 Regulations and directives
- 2.2 Filling a refrigerant circuit with other refrigerants
- 2.3 Safety at work
- 3 Repair notes
- 3.1 Cleanliness rules
- 3.2 Seals for the refrigerant circuit
- 3.3 Refrigerant and refrigerant oil
- 3.3.1 Important instructions for repairs involving refrigerant and refrigerant oil
- 3.3.2 Refrigerant machine oil
- 3.4 Handling pressurised containers
- 3.5 Handling refrigerant
- 4 Identification
- 4.1 Information plate for refrigerant circuit
- 5 Technical data
- 5.1 Filling capacities for refrigerant
- 5.2 Filling capacities for refrigerant oil
- 6 Technical and physical principles
- 6.1 Principles of the air-conditioning technology
- 6.1.1 Physical principles of the air conditioning system
- 6.1.2 Pressure and boiling point of the refrigerant
- 6.1.3 Vapour pressure table for the refrigerant
- 6.2 Physical properties
- 6.2.1 Refrigerant R1234yf
- 6.2.2 Potential hazards of refrigerant R1234yf
- 6.2.3 Physical and chemical properties of refrigerant R1234yf
- 6.2.4 Critical point
- 6.2.5 Environmental aspects of refrigerant R1234yf
- 6.2.6 Trade names and designations of refrigerant R1234yf
- 6.2.7 Colour and odour of refrigerant R1234yf
- 6.2.8 Vapour pressure of refrigerant R1234yf
- 6.2.9 Physical properties of refrigerant R1234yf
- 6.2.10 Behaviour of refrigerant R1234yf in contact with metals and plastics
- 6.2.11 Critical temperature/critical pressure of refrigerant R1234yf
- 6.2.12 Water content of refrigerant R1234yf
- 6.2.13 Flammability/decomposition of refrigerant R1234yf
- 6.2.14 Filling factor of refrigerant R1234yf
- 6.2.15 Evidence of leaks in a refrigerant circuit with refrigerant R1234yf
- 6.2.16 Analysis of refrigerant R1234yf
- 6.3 Product features
- 6.4 Function and purpose of the air conditioning system
- 6.4.1 Operating principle
- 6.4.2 Comfort
- 6.4.3 Environmental aspects
- 6.5 Further sources of information
- 87 – Air conditioning system
- 1 Refrigerant circuit
- 1.1 System overview - refrigerant circuit
- 1.2 General description – components of the refrigerant circuit
- 1.2.1 Arrangement and function of the refrigerant circuit
- 1.2.2 AC compressor
- 1.2.3 Condenser
- 1.2.4 Evaporator
- 1.2.5 Fluid reservoir
- 1.2.6 Expansion valve
- 1.2.7 Refrigerant pipe with internal heat exchanger
- 1.2.8 Gaskets
- 1.2.9 Pipes and hoses of the refrigerant circuit
- 1.2.10 Pressure relief valve
- 1.2.11 Connections for quick couplers on refrigerant circuit
- 1.2.12 Connections with valve for switches on refrigerant circuit
- 1.2.15 Regulating valve for compressor of air conditioning system -N280-
- 1.3 Possible complaints
- 1.3.1 Requirements for investigating a complaint
- 1.3.2 Possible complaints
- 1.3.3 Odour from the heating and air conditioning unit
- 1.4 Identifying leaks
- 1.4.1 General information about finding leaks in the refrigerant circuit
- 1.4.2 Detecting leaks on refrigerant circuits with an electronic leak detector
- 1.4.3 Searching for leaks with the UV leak detection system
- 1.4.4 Detecting leaks by means of vacuum testing with the AC service station or pressure testing
- 1.5 Replace components
- 1.5.1 General instructions for replacing components
- 1.5.2 Replacing leaking or damaged components; empty refrigerant circuit (except AC compressor and fluid reservoir)
- 1.5.3 Replacing leaking or damaged components; filled refrigerant circuit (except AC compressor and fluid reservoir)
- 1.5.4 Replacing the AC compressor without needing to clean the refrigerant circuit
- 1.5.5 Replacing the AC compressor because of a leak or internal damage
- 1.6 Clean the refrigerant circuit.
- 1.6.1 General information about cleaning the refrigerant circuit
- 1.6.2 Preparing to clean the refrigerant circuit (to flush with refrigerant R1234yf)
- 1.6.3 Procedure for cleaning the refrigerant circuit
- 1.6.4 Schematic diagrams for cleaning (circuits to be flushed) - refrigerant circuit with expansion valve and fluid reservoir
- 1.6.5 Adapter for setting up the rinsing cycles
- 1.6.6 General information about blowing through with compressed air or nitrogen
- 1.6.7 Blowing through the refrigerant circuit with compressed air and nitrogen
- 1.7 Checking pressures with the pressure gauge
- 1.7.2 Pressure gauges allow to carry out the following inspection and measurement work
- 2 Working with the A/C service station
- 2.1 Working with the A/C service station
- 2.2 Connecting the AC service station to the refrigerant circuit
- 2.3 Performing gas analysis for the refrigerant
- 2.4 Exhaust refrigerant circuit.
- 2.5 Evacuating the refrigerant circuit.
- 2.6 Filling the refrigerant circuit
- 2.7 Operate the air conditioning system after filling
- 2.8 Switching off the AC service station and disconnecting it from the refrigerant circuit
- 2.9 Filling refrigerant into the reservoir
- 2.10 Draining the A/C service station
- 2.11 Clean the refrigerant circuit.
- 2.12 Filling contaminated refrigerant into a recycling cylinder for analysis, treatment or disposal
- 2.13 Check pressures
- 2.13.1 General instructions for checking pressures in a refrigerant circuit
- 2.13.2 Pressures and temperatures in a refrigerant circuit
- 2.13.3 Pressure in a refrigerant circuit when the ignition is switched off
- 2.13.4 Checking pressures when the air conditioning system is switched on
- 3 Test equipment and tools
- 3.1 Tools and materials available from the importer
- 3.2 Tools and materials, which are commercially available
- 3.3 Tools that can be made instead of purchasing
Air Conditioning System With Refrigerant R134a
- 00 – Technical data
- 1 General notes on the air conditioning system
- 1.1 Important instructions
- 1.2 Further documentation and information means
- 1.3 Principles of the air-conditioning technology
- 1.3.1 Physical principles
- 1.3.2 Heat always flows from a warmer substance to a colder substance
- 1.3.3 Pressure and boiling point
- 1.4 Advantages of the air conditioning system - comfort
- 1.5 Operation of the air conditioning system
- 1.6 Refrigerant R134a
- 1.6.1 Physical data of the refrigerant R134a
- 1.6.2 Trade names and designations of the refrigerant R134a
- 1.6.3 Critical point
- 1.6.4 Environmental aspects of the refrigerant R134a
- 1.7 Vapour pressure table for refrigerant R134a
- 1.8 Properties of refrigerant R134a
- 1.8.1 Colour
- 1.8.2 Vapour pressure
- 1.8.3 Air displacement as a result of gaseous refrigerant
- 1.8.4 Behaviour with metals
- 1.8.5 Behaviour with plastics
- 1.8.6 Critical temperature/critical pressure
- 1.8.7 Water content
- 1.8.8 Flammability
- 1.8.9 Filling factor
- 1.9 Evidence of leaks
- 1.10 Refrigerant oil
- 1.10.1 Properties of the refrigerant oil
- 1.11 General occupational safety
- 1.11.1 Product features
- 1.11.2 Using refrigerant R 134a
- 1.11.3 Wear safety goggles
- 1.11.4 Wear protective gloves and apron
- 1.11.5 Do not breath in refrigerant vapours
- 1.11.6 Smoking ban
- 1.11.7 Welding and soldering
- 1.11.8 Pungent odour
- 1.11.9 First Aid
- 1.12 Using pressure tank
- 1.13 Safety precautions when working with extraction and filling systems
- 1.14 Safety measures when working on vehicles with air conditioning system and when using refrigerant R 134a
- 1.15 Basics for working on the refrigerant circuit
- 1.15.1 General points
- 1.15.2 Removing contaminants from the refrigerant circuit
- 1.15.3 Additional work on vehicles with AC compressor without magnetic coupling
- 1.15.5 Work procedure before operating the air conditioning system after a repair
- 2 General instructions for refrigerant circuit
- 2.1 Components of the refrigerant circuit
- 2.1.1 Distribution of the components of the refrigerant circuit and their influence on the high- and low-pressure side
- 2.1.2 AC compressor
- 2.1.4 Fluid reservoir with desiccator
- 2.1.8 O-ring seals
- 2.1.9 Pipes and hoses of the refrigerant circuit
- 2.2 Extractor, filler and measurement valves for quick couplings of the AC service station on the refrigerant circuit
- 2.2.1 Extractor, filler and measurement connections with Schrader valve
- 2.2.2 Extractor, filler and measurement connections with acting head valve
- 2.3 Pressures and temperatures in the refrigerant circuit and its arrangement
- 2.3.1 Pressures, temperatures and arrangement of the refrigerant circuit with expansion valve
- 2.3.2 Pressures, temperatures and arrangement of the refrigerant circuit with throttle
- 2.4 Switch and sender on the refrigerant circuit
- 2.5 Electrical components which are not fitted on the refrigerant circuit
- 2.6 The inspection and measurement work can be performed using the pressure gauge
- 2.6.1 Pressure gauges allow to carry out the following inspection and measurement work
- 2.7 Air conditioning service and recycling equipment
- 2.8 Repair and maintenance instructions for refrigerant circuit
- 3 Legal texts and legal regulations
- 3.1 Laws and regulations
- 3.2 Verification procedure of refrigerant
- 4 Refrigerant circuit
- 4.1 Important repair instructions for air conditioning systems
- 5 Working with the A/C service station
- 5.1 Important instructions for working with the A/C Service station
- 5.2 Connecting the A/C service station to the refrigerant circuit for measuring and testing
- 5.3 Empty the refrigerant circuit with the A/C service station.
- 5.4 Evacuate the refrigerant circuit with the A/C service station.
- 5.5 Fill the refrigerant circuit with the A/C service station.
- 5.6 Operate the air conditioning system after filling
- 5.7 Fill refrigerant into the reservoir (filling cylinder or reservoir bottle) of the A/C service station
- 5.8 Draining the A/C service station
- 6 Leak detection on the refrigerant circuit
- 6.1 Looking for leaks in the refrigerant circuit - important instructions
- 6.2 Leak detection on the refrigerant circuit with compressed air or nitrogen
- 6.3 Detecting leaks on the refrigerant circuit with the leak detector -VAG1796-
- 6.4 Detecting leaks on the refrigerant circuit with the leak detector -VAS 6196- or -VAS 6201A-
- 7 Removing contaminants from the refrigerant circuit
- 7.1 Cleaning the refrigerant circuit with compressed air and nitrogen
- 7.2 Cleaning refrigerant circuit with refrigerant R134a (flush)
- 7.3 Principle circuit diagrams for different rinsing cycles
- 7.4 Adapter for setting up the rinsing cycles
- 8 Complaints
- 8.1 Possible complaints
- 8.2 Temperature test of cooling capacity
- 8.3 Odour from the heating and air conditioning unit
- 8.3.1 Possible odours coming from the heating and air conditioning unit
- 8.3.2 Spray evaporator with compressed air pistol -VAG 1538- with spray nozzle
- 8.3.3 Ultrasonic air conditioning system cleaning device -VAS 6189B-
- 9 Check the pressure in the refrigerant circuit (with the A/C service station)
- 9.1 Test requirements before the pressure test
- 9.2 Check pressures
- 9.3 Continuation of the test depending on the arrangement of the refrigerant circuit
- 9.4 Pressure test for vehicles with throttle and catch pan (with AC compressor regulated from the inside)
- 9.5 Pressure test for vehicles with expansion valve and fluid reservoir (with AC compressor regulated from the inside)
- 9.6 Pressure test for vehicles with expansion valve, fluid reservoir and with regulating valve for compressor of air conditioning system -N280- (with AC compressor regulated from the outside)
- 9.6.1 Specified values
- 10 Replace components of the refrigerant circuit
- 10.1 Replace parts on the refrigerant circuit - General instructions
- 10.2 Components of the refrigerant circuit leaking or damaged - the refrigerant circuit is absolutely empty
- 10.3 Components of the refrigerant circuit leaking or damaged - refrigerant is still in the refrigerant circuit
- 10.4 Replace AC compressor
- 10.4.1 When there is no need to eliminate impurities in the refrigerant circuit e.g. for external damage after an accident
- 10.4.2 An inner damage (e.g. noise or no performance)
- 10.5 Replace catch pan and throttle/fluid reservoir
- 10.5.1 Because of humidity which has penetrated (the refrigerant circuit was opened over a longer period of time) (e.g. after an accident) or inner damage on the A/C compressor
- 10.5.2 Because of outer damage (e.g. caused by an accident), no refrigerant has flown out and no humidity and no dirt has penetrated into the circuit
- 11 Tools and materials, which are available from the importer
- 11.1 Setting up tools and materials which are available from the importer
- 11.2 A/C service station
- 11.3 Flushing device for the refrigerant circuits -6337/1- or follow-up models (manufacturer Behr)
- 11.4 Flushing device for the refrigerant circuits -6336/1- or follow-up models (manufacturer Waeco)
- 11.5 Leak detector -V.A.G 1796-
- 11.6 Leak detection system -VAS 6196-
- 11.7 Leak detection system -VAS 6201A-
- 11.8 Adapter case of motor car set -VAS 6338/1-
- 11.9 Case of release tools -VAS 6127/3-
- 11.10 Socket insert -T10364-
- 12 Tools and materials, which are commercially available
- 12.1 Setting up tools and materials which are available from a dealer
- 12.2 Filling hoses
- 12.3 Bottle connecting piece for pressure bottle
- 12.4 Valve caps with replacement gaskets
- 12.5 Pressure gauge with pressure reducer for nitrogen
- 12.6 Quick-coupling adapter for service connections
- 12.7 Tools, which you make yourself
Automatic Gearbox 0CT
- 00 – Technical data
- 1 Identification
- 1.1 Gearbox identification
- 2 Technical data
- 2.1 Allocation gearbox - engine
- 2.2 Calculation of gear ratios
- 3 Transmission System - Overview
- 4 Safety instructions
- 4.1 General safety instructions
- 4.2 Safety precautions when working on vehicles with a start/stop system
- 4.3 Notes on tow starting and towing
- 4.4 Safety precautions during road tests in which testing and measuring equipment is used
- 5 Repair instructions
- 5.1 General repair instructions
- 6 Electrical components
- 6.1 Fitting location summary - electrical components
- 30 – Clutch
- 1 Clutch control
- 1.1 Summary of components - clutch actuator
- 1.2 Assembly overview - clutch release mechanism
- 1.3 Check ball pin for wear and renew if necessary.
- 1.4 Removing and installing clutch actuator -VX64-
- 1.4.1 Removing and installing clutch actuator -VX64-, on installed gearbox
- 1.4.2 Removing and installing clutch actuator -VX64-, on removed gearbox
- 1.5 Repairing the clutch release mechanism
- 2 Clutch
- 2.1 Assembly overview - clutch
- 2.2 Removing and installing clutch
- 34 – Controls, housing
- 1 Shift mechanism
- 1.1 Overview - selector mechanism
- 1.2 Summary of components - gearshift knob and cover
- 1.3 Assembly overview of shift mechanism
- 1.4 Summary of components - gear actuator
- 1.5 Removing and installing gear knob
- 1.6 Installing and removing the transmission cover
- 1.7 Remove and install guide for shift lever, adjust
- 1.8 Removing and installing selector mechanism
- 1.8.1 Removing and installing shift mechanism without shift housing
- 1.8.2 Removing and installing shift mechanism and shift housing
- 1.9 Removing and installing gear actuator -VX65-
- 1.9.1 Removing and installing gear actuator -VX65-, on installed gearbox
- 1.9.2 Removing and installing gear actuator -VX65-, on removed gearbox
- 2 Removing and installing the gearbox
- 2.1 Removing the gearbox
- 2.2 Installing the gearbox
- 2.3 Specified torques for gearbox
- 3 Assembly bracket
- 3.1 Unit mounting - summary of components
- 4 Transporting the gearbox
- 5 Disassembling and assembling the gearbox
- 5.1 Schematic overview - Gearbox
- 5.2 Summary of components - Gearbox
- 5.3 Summary of components - Clutch housing
- 5.4 Summary of components - shafts, differential gear, switch
- 5.5 Replacing the spacer bush for the gearshift shaft
- 5.6 Disassembling and assembling the gearbox
- 6 Gearbox housing, clutch housing
- 6.1 Summary of components - Gearbox housing and clutch housing
- 7 Attachment at engine and gearbox mount
- 8 Gear oil
- 8.1 Check gear oil level
- 8.2 Draining and filling gearbox oil
- 35 – Gears, shafts
- 1 Drive shaft
- 1.1 Summary of components - Drive shaft
- 1.2 Disassembling and assembling the drive shaft
- 1.3 Setting drive shaft
- 1.4 Replace gasket ring for drive shaft
- 2 Bevel pinion (output shaft)
- 2.1 Summary of components - Output shaft
- 2.2 Disassembling and assembling the output shaft
- 2.3 Setting output shaft
- 3 Reverse shaft
- 3.1 Removing and installing reverse gear shaft
- 39 – Final drive - differential
- 1 Gasket rings
- 1.1 Installation overview - gasket rings
- 1.2 Replacing left sealing ring
- 1.2.1 Replace left shaft seal for left drive shaft
- 1.3 Replacing right sealing ring
- 1.3.1 Replace right shaft seal for right drive shaft
- 2 Differential gear
- 2.1 Summary of components - Differential
- 2.2 Disassembling and assembling differential gear
- 2.3 Adjusting the differential gear
- 3 Setting overview
- 4 Gearbox control system
- 4.1 Installation overview - gearbox control system
- 4.2 Removing and installing the control unit for electronic transmission -J514-
- 4.3 Removing and installing the gearbox input r.p.m. sender -G182-
Axles Steering
- 40 – Front suspension
- 1 Front axle - Overview
- 1.1 Front axle - Overview of the repair chapter
- 1.2 Lift the wheel bearing in the unladen weight position
- 2 Repairing front axle
- 2.1 Summary of components: Assembly carrier
- 2.2 Repairing thread in longitudinal member
- 2.3 Fixing the assembly carrier
- 2.4 Lower the assembly carrier in the service position
- 2.5 Removing and installing assembly carrier
- 3 Front wheel suspension, suspension link
- 3.1 Summary of components: Front wheel suspension, suspension link
- 3.2 Inspecting the steering joint
- 3.3 Removing and installing the steering joint
- 3.4 Installation position of steering joints
- 3.5 Removing and installing the track control arm
- 3.6 Replacing front rubber-metal bearing for track control arm
- 3.7 Replacing the rear rubber-metal bearing for track control arm
- 4 The wheel bearing
- 4.1 Summary of components of the wheel bearing
- 4.2 Removing and installing the wheel hub with front wheel bearing
- 4.3 Removing and installing wheel bearing housing
- 5 Anti-roll bar
- 5.1 Summary of components anti-roll bar
- 5.2 Removing and installing the anti-roll bar
- 5.3 Removing and installing the rubber bearing for the anti-roll bar
- 6 Suspension strut
- 6.1 Summary of components: Suspension strut
- 6.2 Removing and installing the suspension strut
- 6.3 Repairing front suspension strut
- 7 Drive shaft
- 7.1 Summary of components: Drive shaft with tripod joint
- 7.2 Removing and installing drive shaft
- 7.3 Disassembling and assembling the drive shaft with tripod joint AAR2600i
- 7.4 Inspecting outer CV joint
- 42 – Rear suspension
- 1 Rear axle
- 1.1 Overview of rear axle
- 1.2 Lift the wheel bearing in the unladen weight position
- 1.3 Lowering rear axle
- 1.4 Removing and installing rear axle
- 2 Axle beam
- 2.1 Summary of components: Axle beam
- 2.2 removing and installing rubber-metal bearing
- 2.3 Removing and installing coil spring
- 3 Shock absorber
- 3.1 Summary of components: Shock absorber, spring
- 3.2 Repairing shock absorber
- 3.3 Removing and installing shock absorber
- 3.4 Removing and installing stop buffer
- 4 The wheel bearing
- 4.1 Summary of components: The wheel bearing
- 4.2 Removing and installing the wheel hub with wheel bearing
- 44 – Wheels, tyres, vehicle geometry
- 1 Wheels, Tyres
- 1.1 Tightening torque of the wheel screws
- 1.2 Mounting instructions for wheel change/wheel fitting
- 1.3 Wheel fitting
- 1.4 Protecting wheel centring seat against corrosion
- 1.5 Breakdown set
- 1.6 Tyre sealant
- 1.7 Removing tyre
- 1.8 Mounting the new tyre
- 1.9 Disposing of tyre sealant
- 2 Axle alignment
- 2.1 General points
- 2.2 Measurement preliminaries
- 2.3 Axle alignment
- 2.4 Nominal values for the axle alignment
- 2.5 Overview of the work sequence for the axle alignment
- 2.6 Transversal inclination of the vehicle “straight-ahead position”
- 2.7 Camber correction on the front axle
- 2.8 Checking the camber on the rear axle
- 2.9 Checking the track on the rear axle
- 2.10 Adjusting the track on the front axle
- 2.11 Checking the left and right steering angle
- 2.12 Check position of steering wheel, align if necessary
- 2.13 Vehicle data sticker
- 48 – Steering
- 1 General repair instructions
- 1.1 Steering gear
- 1.2 Gaskets and seals
- 1.3 Nuts and bolts
- 1.4 Electrical components
- 1.5 Targeted fault finding, vehicle self-diagnosis and measuring technique
- 2 Steering wheel
- 2.1 Summary of components: Steering wheel
- 2.2 Removing and installing the steering wheel
- 3 Steering column
- 3.1 Summary of components: Steering column
- 3.1.1 Summary of components: Steering column - left-hand drive
- 3.1.2 Summary of components: Steering column - right-hand drive
- 3.2 Removing and installing steering column
- 3.2.1 Removing and installing steering column - left-hand drive
- 3.2.2 Removing and installing steering column - right-hand drive
- 3.3 Observe handling and transportation of the steering column
- 4 Repairing the steering column
- 4.1 Summary of components
- 4.2 Removing and installing -J500-steering column electronics control unit
- 4.3 Removing and installing assembly aid
- 4.4 Removing and installing drive shaft for steering column
- 5 Steering gear
- 5.1 Summary of components: Steering gear
- 5.1.1 Summary of components: Steering gear - LHD vehicle
- 5.1.2 Summary of components: Steering gear - RHD vehicle
- 5.2 Removing and installing steering gear
- 6 Repairing steering box
- 6.1 Summary of components: Steering gear
- 6.2 Removing and installing track rod
- 6.3 Checking and adjusting the length of the track rod
- 6.4 Removing and installing track rod ends
- 6.5 Checking play, tightness and bellows of track rod ball joints
- 6.6 Allocation of track-rod ends
- 6.7 Determining the centre position of the gear rack
- 6.8 Adjusting steering box
Body Repairs
- 00 – Technical data
- 1 Vehicle identification data
- 1.1 Vehicle identification number
- 1.2 Identification plate
- 1.3 Vehicle data sticker
- 2 Safety instructions
- 3 Moulded foam parts
- 4 Galvanized body parts, high/ultra high-strength and hot-formed body panels
- 4.1 Body
- 4.2 Overview
- 5 Anti-corrosion measures
- 6 Gap sizes
- 6.1 Front body
- 6.2 Middle body
- 6.3 Rear body
- 7 Vehicle body dimensions
- 7.1 Front body
- 7.2 Middle body
- 7.2.1 5-door
- 7.3 Rear body
- 7.4 Body platform at the front
- 7.5 Body platform in the middle
- 7.6 Body platform at the rear
- 8 Tools
- 9 Straightening bench
- 9.1 Overview
- 10 Portal gauge
- 50 – Body - front
- 1 Replacing console - right
- 1.1 Removing
- 1.2 Install
- 1.2.1 Part welding
- 2 Replacing console - left
- 2.1 Removing
- 2.2 Install
- 2.2.1 Preparing the new part
- 2.2.2 Part welding
- 3 Replacing the support block (for assembly carrier)
- 3.1 Removing
- 3.2 Install
- 3.2.1 Preparing the new part
- 3.2.2 Part welding
- 4 Replacing the front bumper holder
- 4.1 Removing
- 4.2 Install
- 4.2.1 Part welding
- 5 Replacing the wheelhouse frame side rail at the top
- 5.1 Removing
- 5.2 Install
- 5.2.1 Preparing the new part
- 5.2.2 Part welding
- 6 Replacing the front wheelhouse
- 6.1 Removing
- 6.2 Install
- 6.2.1 Preparing the new parts
- 6.2.2 Part welding
- 7 Replacing the front frame side rail
- 7.1 Removing
- 7.2 Install
- 7.2.1 Preparing the new part
- 7.2.2 Part welding
- 8 Repairing the thread for the attachment of the assembly carrier
- 8.1 Contents of the thread repair set
- 8.2 Repairing thread
- 8.2.1 Drilling thread
- 8.2.2 Cutting the thread
- 8.2.3 Inserting the threaded insert
- 51 – Body - centre
- 1 Replacing the roof ▶ vehicle without sliding/tilting roof Open Sky
- 1.1 Tools
- 1.2 Removing
- 1.3 Install
- 1.3.1 Preparing the new part
- 1.3.2 Setting the depth gauge for the roof
- 1.3.3 Glueing in the roof
- 1.3.4 Part welding
- 2 Replacing the roof - vehicle with sliding/tilting roof Open Sky
- 2.1 Tools
- 2.2 Removing
- 2.3 Install
- 2.3.1 Preparing the new part
- 2.3.2 Setting the depth gauge for the roof
- 2.3.3 Glueing in the roof
- 2.3.4 Part welding
- 3 Replacing the roof rail ▶ 3-door
- 3.1 Removing
- 3.2 Install
- 3.2.1 Preparing the new part
- 3.2.2 Part welding
- 4 Replacing the roof rail ▶ 5-door
- 4.1 Removing
- 4.2 Install
- 4.2.1 Preparing the new part
- 4.2.2 Part welding
- 5 Replacing the front roof cross member
- 5.1 Removing
- 5.2 Install
- 5.2.1 Part welding
- 6 Replacing the front roof cross member ▶ Vehicle with sliding/tilting roof Open Sky
- 6.1 Removing
- 6.2 Install
- 6.2.1 Part welding
- 7 Replacing the roof reinforcement ▶ Vehicle with sliding/tilting roof Open Sky
- 7.1 Removing
- 7.2 Install
- 7.2.1 Part welding
- 8 Replacing the rear roof cross member
- 8.1 Removing
- 8.2 Install
- 8.2.1 Part welding
- 9 Replacing the A-pillar
- 9.1 Removing
- 9.2 Install
- 9.2.1 Preparing the new part
- 9.2.2 Part welding
- 10 Replacing reinforcement of A-pillar - cutoff part
- 10.1 Removing
- 10.2 Install
- 10.2.1 Preparing the new part
- 10.2.2 Part welding
- 11 Replacing B-pillar ▶ 5-door
- 11.1 Removing
- 11.2 Install
- 11.2.1 Preparing the new part
- 11.2.2 Mark the areas in which welding is permitted
- 11.2.3 Part welding
- 12 Replacing the reinforcement of the B-pillar ▶ 3-door
- 12.1 Removing
- 12.2 Install
- 12.2.1 Preparing the new part
- 12.2.2 Marking the prohibited welding zones
- 12.2.3 Part welding
- 13 Replacing the reinforcement of the B-pillar ▶ 5-door
- 13.1 Removing
- 13.2 Install
- 13.2.1 Preparing the new part
- 13.2.2 Marking the prohibited welding zones
- 13.2.3 Part welding
- 14 Replacing the outside bottom side rail ▶ 3-door
- 14.1 Removing
- 14.2 Install
- 14.2.1 Preparing the new part
- 14.2.2 Part welding
- 15 Replacing reinforcement of bottom side rail- centre cutoff part
- 15.1 Removing
- 15.2 Install
- 15.2.1 Preparing the new part
- 15.2.2 Part welding
- 16 Replacing the front bottom side rail ▶ 3-door vehicle
- 16.1 Removing
- 16.2 Install
- 16.2.1 Preparing the new part
- 16.2.2 Part welding
- 53 – Body - rear
- 1 Replacing rear apron
- 1.1 Removing
- 1.2 Install
- 1.2.1 Part welding
- 2 Replacing the reinforcement of the sealing channel
- 2.1 Removing
- 2.2 Install
- 2.2.1 Preparing the new part
- 2.2.2 Part welding
- 3 Replacing front cover plate
- 3.1 Removing
- 3.2 Install
- 3.2.1 Preparing the new part
- 3.2.2 Part welding
- 4 Replacing the support of the tail light
- 4.1 Removing
- 4.2 Install
- 4.2.1 Preparing the new part
- 4.2.2 Part welding
- 5 Replacing the luggage compartment floor
- 5.1 Removing
- 5.2 Install
- 5.2.1 Preparing the new part
- 5.2.2 Part welding
- 6 Replacing reinforcement of C-pillar - cutoff part
- 6.1 Removing
- 6.2 Install
- 6.2.1 Preparing the new parts
- 6.2.2 Part welding
- 7 Replacing top part of rear frame side rail
- 7.1 Removing
- 7.2 Install
- 7.2.1 Preparing the new parts
- 7.2.2 Part welding
- 8 Replacing the bracket for the rear axle
- 8.1 Removing
- 8.2 Install
- 8.2.1 Preparing the new part
- 8.2.2 Part welding
- 9 Replacing rear frame side rail - cutoff part
- 9.1 Removing
- 9.2 Install
- 9.2.1 Part welding
- 10 Replace rear lateral part ► 3-door vehicles
- 10.1 Removing
- 10.2 Install
- 10.2.1 Preparing the new part
- 10.2.2 Mark the areas in which welding is permitted
- 10.2.3 Part welding
- 11 Replace rear lateral part ► 5-door vehicles
- 11.1 Removing
- 11.2 Install
- 11.2.1 Preparing the new part
- 11.2.2 Part welding
- 12 Replacing the outer wheelhouse liner
- 12.1 Removing
- 12.2 Install
- 12.2.1 Preparing the new part
- 12.2.2 Part welding
Body Work
- 00 – Technical data
- 1 Technical data
- 1.1 Vehicle identification data
- 50 – Body - front
- 1 Lock carrier
- 1.1 Summary of components - Lock carrier
- 1.2 Service position
- 1.3 Removing and installing lock carrier
- 2 Wing
- 2.1 Summary of components
- 2.2 Removing and installing the wing
- 2.2.1 Removing and installing the wing
- 2.2.2 Removing and installing wing strut
- 3 Front wall
- 3.1 Summary of components
- 3.2 Summary of components of the water box cover
- 3.3 Removing and installing the plenum chamber cover
- 55 – Bonnet, rear lid
- 1 Front flap
- 1.1 Summary of components - Front flap
- 1.1.1 Summary of components
- 1.1.2 Summary of components - Lock and unlock components of front flap
- 1.1.3 Summary of components - Operating lever and bearing bracket
- 1.2 Removing and installing the front flap
- 1.2.1 Removing and installing the locking clamp
- 1.3 Adjusting the front flap
- 1.3.1 Adjusting the flap lock
- 1.3.2 Adjusting the locking clamp
- 1.4 Removing and installing the hinges
- 1.5 Removing and installing the support bar
- 1.6 Removing and installing the gaskets for the front flap
- 1.7 Removing and installing front flap lock
- 1.7.1 Routing the control cable for the lid release
- 1.8 Removing and installing the operating lever for the front flap
- 2 Tailgate
- 2.1 Summary of components
- 2.1.1 Summary of components - Pressurized gas strut
- 2.1.2 Summary of components - Lock and unlock components
- 2.2 Removing and installing tailgate
- 2.3 Adjusting tailgate
- 2.3.1 Adjusting the locking clamp
- 2.4 Removing and installing the hinges
- 2.5 Removing and installing the pressurized gas strut
- 2.5.1 Degassing the pressurized gas strut
- 2.6 Removing and installing the control
- 2.7 Removing and installing flap lock
- 2.7.1 Removing and installing the locking clamp
- 2.8 Removing and installing the gasket
- 3 Fuel tank lid unit
- 3.1 Removing and installing fuel tank lid unit
- 57 – Front doors, door components, central locking
- 1 Front door
- 1.1 Summary of components - door
- 1.2 Removing and installing the door
- 1.2.1 Installing after replacing the A pillar
- 1.3 Door adjustment
- 1.4 Adjusting the locking clamp
- 2 Installation parts
- 2.1 Summary of components - Component parts
- 2.1.1 Summary of components - Fabric strap
- 2.1.2 Summary of components - Adhesive pad
- 2.2 Summary of components - Door handle and door lock
- 2.3 Removing and installing installation parts
- 2.3.1 Removing and installing the door cover
- 2.3.2 Removing and installing the door retaining strap
- 2.3.3 Removing and installing the locking clamp
- 2.4 Removing and installing the door handle
- 2.4.1 Removing and installing cap for lock cylinder
- 2.4.2 Removing and installing cap (without lock cylinder)
- 2.4.3 Removing and installing lock cylinder
- 2.4.4 Removing and installing bearing bracket
- 2.5 Removing and installing the door lock
- 2.6 Central locking system
- 2.6.1 Summary of components - Central locking system
- 2.7 Removing and installing the battery for the foldable radio control key
- 2.8 Door windows
- 2.8.1 Front door window - Summary of components
- 2.8.2 Removing and installing the front door window
- 2.9 Window lifter
- 2.9.1 Removing and installing front window lifter
- 2.9.2 Removing and installing front window lifter motor
- 2.9.3 Removing and installing window lifter drive
- 2.9.4 Removing and installing front window crank
- 2.10 Window run and strips
- 2.11 Removing and installing front window run
- 2.12 Guide rail
- 2.12.1 Removing and installing guide rail
- 2.12.2 Removing and installing the additional window run
- 2.13 Removing and installing the front window channel strip
- 2.13.1 Removing and installing the inner front window channel strip
- 2.13.2 Removing and installing the outer front window channel strip
- 2.14 Removing and installing door seal
- 2.14.1 Removing and installing the inside door seal
- 58 – Rear doors, door components
- 60 – Sunroof
- 63 – Bumpers
- 1 Front bumper
- 1.1 Summary of components - Front bumper
- 1.1.1 Summary of components - Component parts
- 1.1.2 Summary of components - Front bumper bracket
- 1.2 Removing and installing the front bumper
- 2 Rear bumper
- 2.1 Summary of components - Rear bumper cover
- 2.1.1 Summary of components - Guides for rear bumper cover
- 2.1.2 Summary of components - Rear bumper bracket
- 2.1.3 Summary of components - Foam part of bumper bracket
- 2.2 Removing and installing the rear bumper
- 64 – Glazing
- 1 Repair instructions
- 1.1 Minimum hardening time for glued windows
- 1.2 Window repair
- 1.3 Installation instructions for glued windows
- 1.3.1 Installation instructions
- 1.3.2 Materials
- 1.4 Preparing new windows for fitting
- 1.5 Preparing new windows for fitting
- 1.6 Prepare body flange for fitting
- 1.6.1 Eliminating paint damage
- 1.7 Cleaning necessary due to soiling through glue
- 2 Windscreen
- 2.1 Windscreen - Summary of components
- 2.2 Removing and installing windscreen
- 2.2.1 Removing undamaged windscreen
- 3 Rear window
- 3.1 Rear window - Summary of components
- 3.2 Removing and installing the rear window
- 3.2.1 Remove damaged rear window
- 4 Side windows
- 4.1 Summary of components - Rear side windows
- 4.2 Removing and installing rear side window
- 4.2.1 Remove damaged side window
- 66 – Exterior equipment
- 1 Strips / trims / extensions / trim panels
- 1.1 Summary of components - Trim of A-pillar
- 1.2 Removing and installing the trim of the B-pillar
- 2 Underfloor trim panel
- 2.1 Removing and installing the tunnel bridge
- 3 Exterior mirror
- 3.1 Exterior rear-view mirror - Summary of components
- 3.1.1 Summary of components - Electrically adjustable outside mirror
- 3.1.2 Summary of components - Manually adjustable outside mirror
- 3.2 Removing and installing mirror glass
- 3.3 Removing and installing the mirror housing
- 3.3.1 Removing and installing the mirror housing
- 3.3.2 Removing and installing the trim
- 3.4 Removing and installing the mirror adjustment unit
- 3.5 Removing and installing outside mirror
- 3.5.1 Removing and installing outside mirror with electrical adjustment
- 3.5.2 Removing and installing outside mirror with manual adjustment
- 4 Wheelhouse liner
- 4.1 Summary of components - Wheelhouse liner
- 4.2 Removing and installing the wheelhouse liner
- 4.2.1 Removing and installing the sill cover
- 5 Letterings and emblems
- 5.1 Dimensions - Letterings and emblems
- 5.1.1 Dimensions of letterings on the tailgate
- 5.2 Removing and installing the emblems
- 5.2.1 Removing and installing the front emblem
- 5.2.2 Removing and installing the emblem on the tailgate
- 68 – Interior equipment
- 1 Storage areas/covers
- 1.1 Overview of fitting location - Storage areas/covers
- 1.2 Summary of components - Dash panel cover on driver's side
- 1.3 Summary of components - Steering column trim panel
- 1.4 Summary of components - Glove compartment
- 1.5 Summary of components - Covering for the hand brake lever
- 1.6 Removing and installing dash panel cover on driver's side
- 1.6.1 Removing and installing dash panel cover on driver's side, „Basic“
- 1.6.2 Removing and installing dash panel cover on driver's side, „High“
- 1.7 Removing and installing the gap cover of the dash panel insert
- 1.8 Removing and installing dash panel cover on front passenger's side
- 1.9 Removing and installing top steering column trim panel
- 1.10 Removing and installing bottom steering column trim panel
- 1.11 Removing and installing the glove compartment
- 1.12 Removing and installing glove compartment opener
- 1.13 Removing and installing brake element of glove compartment cover
- 1.14 Removing and installing the covering of the handbrake lever
- 2 Equipments
- 2.1 Summary of components - Sun visors
- 2.2 Removing and installing the sun visor
- 2.3 Removing and installing middle bearing of sun visor
- 2.4 Removing and installing the recessed handles of the roof
- 3 Centre console
- 3.1 Summary of components - Centre console
- 3.2 Removing and installing front ashtray
- 3.3 Removing and installing the insert of the centre console
- 3.4 Removing and installing centre console
- 3.4.1 Removing and installing top part of centre console
- 3.4.2 Removing and installing bottom part of centre console „High“
- 3.4.3 Removing and installing bottom part of centre console „Basic“
- 3.5 Removing and installing the bracket of the centre console
- 3.5.1 Summary of components - Attachment angle
- 3.5.2 Removing and installing the front attachment angle
- 3.5.3 Removing and installing the centre attachment angle
- 3.5.4 Removing and installing the rear attachment angle
- 4 Interior rear-view mirror
- 4.1 Summary of components - Interior rear-view mirror
- 4.2 Removing and installing the interior rear-view mirror
- 4.2.1 Removing and installing the interior rear-view mirror
- 4.2.2 Glueing the retaining plate for the interior rear-view mirror
- 4.3 Removing and installing sensor unit for emergency brake
- 69 – Passenger protection
- 1 Safety instructions
- 1.1 Safety precautions when working with pyrotechnical components
- 1.2 Storage, transport and disposal of airbag, belt tensioner and battery separation units (pyrotechnical components)
- 1.3 Safety instructions of airbag
- 1.4 Additional safety instructions for side airbag
- 1.5 Seat belts
- 1.6 Safety instructions for crash sensors (pressure sensors) for front side airbag
- 1.7 Exchanging pyrotechnical, mechanical and electrical components of the restraint system after an accident
- 1.8 Checking airbag fixing parts after an accident
- 1.9 Accident without deployment of airbag
- 1.10 Inspecting seat belts
- 1.11 Checking the seat belt
- 1.12 Checking automatic belt retractor (locking effect)
- 1.13 Seat belt buckle - visual inspection
- 1.14 Seat belt buckle - functional check
- 1.15 Check deflection fittings and buckle latch
- 1.16 Checking fixing parts and fixing points after an accident
- 1.17 Checking the child seat anchorages after an accident
- 2 Seat belts
- 2.1 Overview of fitting location - Seat belts and fixing points
- 2.2 Removing and installing the front three-point seat belt
- 2.3 Removing and installing front belt end fitting
- 2.4 Removing and installing front belt guide
- 2.5 Removing and installing the front seat belt buckle
- 2.6 Removing and installing the rear three-point seat belt
- 2.7 Removing and installing the outer rear belt end fitting
- 2.8 Removing and installing the rear seat belt buckle
- 3 Airbag system
- 3.1 Overview of fitting location - Airbag System
- 4 Airbag control unit
- 4.1 Summary of components - Airbag control unit
- 4.2 Removing and installing airbag control unit
- 5 Airbag on driver side
- 5.1 Summary of components - Airbag on driver side
- 5.2 Removing and installing airbag unit with igniter
- 6 Airbag front passenger side
- 6.1 Summary of components - Airbag on front passenger side
- 6.2 Removing and installing airbag unit on front passenger side with igniter
- 6.3 Removing and installing key switch for deactivation of airbag on front passenger side
- 6.4 Removing and installing airbag warning light on front passenger side
- 7 Side airbags
- 7.1 Summary of components - front side airbag
- 7.2 Removing and installing front side airbag with igniter
- 8 Crash sensors for airbag
- 8.1 Overview of fitting location - Crash sensors for airbag
- 8.2 Removing and installing the crash sensor for front airbag
- 8.3 Removing and installing the crash sensor for side airbag
- 9 Belt use recognition
- 9.1 Removing and installing seat occupation sensor
- 70 – Trim, insulation
- 1 Door trim panels
- 1.1 Summary of components - Front door trim panel
- 1.1.1 Summary of components - Front door trim panel, vehicles without window crank
- 1.1.2 Summary of components - Front door trim panel, vehicles with window crank
- 1.2 Removing and installing the front door trim panel
- 1.2.1 Removing and installing door trim panel
- 1.2.2 Removing and installing loudspeaker damping
- 1.2.3 Removing and installing mirror cover trim panel
- 1.3 Removing and installing trim button
- 1.4 Removing and installing the inner door control
- 1.4.1 Removing and installing the front inner door control
- 1.4.2 Removing and installing the rear inner door control
- 1.5 Summary of components - Rear door trim panel
- 1.6 Removing and installing the rear door trim panel
- 1.6.1 Removing and installing door trim panel
- 1.6.2 Removing and installing loudspeaker damping
- 2 Dash panel
- 2.1 Summary of components - dash panel
- 2.2 Removing and installing lateral cover of dash panel
- 2.3 Removing and installing the decorative trim of the dash panel
- 2.3.1 Removing and installing the middle decorative trim „Basic“
- 2.3.2 Removing and installing the middle decorative trim „High“
- 2.4 Removing and installing mounting frame of radio/navigation system
- 2.4.1 Removing and installing the trim for the air conditioning operating unit
- 2.4.2 Vehicles with radio/navigation system
- 2.4.3 Removing and installing mounting frame with preinstallation for radio/navigation system
- 2.4.4 Removing and installing mounting frame of radio/navigation system with storage compartment
- 2.5 Removing and installing the dash panel
- 2.5.1 Removing and installing the dash panel
- 2.5.2 Aligning the dash panel in the vehicle
- 3 Central tube of dash panel
- 3.1 Summary of components - central tube of dash panel
- 3.2 Removing and installing the central tube of dash panel
- 3.2.1 Removing and installing the central tube of dash panel
- 3.2.2 Removing and installing pin screws of bearing bracket
- 4 Interior trim panels
- 4.1 Overview of fitting location - Interior trim panels
- 4.1.1 Floor dampings
- 4.1.2 Dampings of inner front wall
- 4.2 Summary of components - Sill panel
- 4.3 Summary of components - A-pillar trim panel
- 4.4 Summary of components - B-pillar trim panel
- 4.5 Summary of components - C-pillar trim panel
- 4.6 Removing and installing sill panel
- 4.6.1 Removing and installing sill panel, 4-door vehicle
- 4.6.2 Removing and installing sill panel, 2-door vehicle
- 4.7 Removing and installing A-pillar trim panel
- 4.7.1 Removing and installing top trim panel of pillar A
- 4.7.2 Removing and installing bottom trim panel of pillar A on the driver's side
- 4.7.3 Removing and installing bottom trim panel of pillar A on the front passenger side
- 4.7.4 Removing and installing the parking ticket holder on the driver's side
- 4.8 Removing and installing B-pillar trim panel
- 4.8.1 Removing and installing B-pillar trim panel, 4-door vehicle
- 4.8.2 Removing and installing B-pillar trim panel, 2-door vehicle
- 4.8.3 Removing and installing B-pillar trim panel, 4-door vehicle
- 4.8.4 Loosening and attaching the B-pillar trim panel, 2-door vehicle
- 4.9 Removing and installing trim panel of pillar C
- 4.9.1 Removing and installing top C-pillar trim panel, 4-door vehicle
- 4.9.2 Removing and installing C-pillar trim panel, 2-door vehicle
- 4.9.3 Removing and installing bottom C-pillar trim panel, 4-door vehicle
- 4.10 Removing and installing side trim panel
- 4.11 Removing and installing foot rest
- 4.12 Removing and installing floor covering
- 4.12.1 Removing and installing floor covering
- 4.12.2 Removing and installing the floor damping
- 4.12.3 Removing and installing dampings of inner front wall
- 4.13 Removing and installing the rear window shelf
- 5 Luggage compartment trim panels
- 5.1 Overview of fitting location - Luggage compartment trim panels
- 5.2 Summary of components - luggage compartment side trim panel
- 5.3 Removing and installing the tailgate trim panel
- 5.4 Removing and installing luggage compartment side trim panel
- 5.5 Removing and installing luggage compartment floor
- 5.5.1 Removing and installing covering for luggage compartment floor
- 5.5.2 Removing and installing luggage compartment floor support CNG vehicles
- 5.5.3 Removing and installing variable luggage compartment floor
- 5.6 Removing and installing bracket for luggage compartment floor covering
- 6 Roof trim panels
- 6.1 Overview of fitting location - Roof trim panel
- 6.2 Summary of components - Moulded headliner
- 6.3 Removing and installing moulded headliner
- 6.3.1 Removing and installing moulded headliner without sliding/tilting roof
- 6.3.2 Removing and installing moulded headliner with sliding/tilting roof
- 6.3.3 Removing and installing moulded headliner without sliding/tilting roof

And more....