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Removing Remove side panel trim => page 70-51. Remove relay anchorage for front seat belt => page 69-3. Remove door inner seal -2- from B-pillar -4-. Remove handle strap => page 68-51. Unclip B-pillar upper trim -1- to rear off B-pillar -4-. Installing Install in reverse order of removal. Note: Check clips -3- before installing trim and replace as necessary. Make sure door inner seal is seated correctly after installing trim.
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Note: Components depicted here correspond to cylinder bank 1. They are different only as a mirror image of components for cylinder bank 2. 1 – Connecting hose On vehicles with engine code BWF To crankcase ventilation valve Ensure seated tightly 2 – Sealing sleeve On vehicles with engine code BWF Replace if damaged Ensure seated tightly 3 – Bracket On vehicles with engine code BWF For intake hose between air filter and intake manifold flap 4 – Acoustic cover For vehicles with engine code BWF 5 – Cylinder head cover On vehicles with engine code BWF Always clean sealing surfaces of cylinder head cover with a clean cloth before setting in place Replace seal together with cylinder head cover if damaged or leaking Observe tightening sequence of bolts 6 – Acoustic cover For vehicles with engine code BKW 7 – Cylinder head cover For vehicles with engine code BKW Always clean sealing surfaces of cylinder head cover with a clean cloth before setting in place Replace seal together with cylinder head cover if damaged or leaking Observe tightening sequence of bolts 8 – 20 Nm Between control housing and cylinder head 9 – Cylinder head gasket Replace Install new seal of the same strength Imprint of replacement part numbers – A – must be readable After replacing replace entire amount of coolant 10 – Cylinder head Removing and installing 11 – Cylinder head bolt Replace Observe sequence for loosening and tightening head, removing and installing 12 – Sealing sleeve For vehicles with engine code BKW Replace if damaged Check for secure seating 13 – Connection piece For vehicles with engine code BKW To crankcase ventilation valve Check for secure seating Cylinder heads, removing and installing
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Note: Removal and installation of right headlamp is illustrated. Removal and installation of left headlamp is the same. Special tools, testers and auxiliary items required 5 mm hex socket wrench Removing Insert hex wrench into headlamp lock – arrow – . Turn hex socket wrench – 1 – approximately 180 degree in direction of – arrow – (clockwise) in order to release headlamp housing from retainer. Return the headlamp lock – 1 – 90 degree as shown. Note: In order for the headlamp housing to slide in an out freely, the “U” section of the headlamp lock must be in the lowest position (90 degree ). Should the headlamp be difficult to remove from vehicle, turn hex socket wrench – 1 – alternately in both directions while pulling headlamp housing out of retainer. Note: Headlamp retainer – 1 – contains headlamp lock – 2 – position (lock-unlock). Depress lock tab – arrow – while pulling headlamp forward out of retainer. Note: The electrical connection is integrated with both the headlamp and retainer and is disconnected automatically upon removal of headlamp. CAUTION! Headlamp lock on retainer must not be turned while headlamp is removed. . Installing Install in reverse order of removal, noting the following: Note: In order for the headlamp housing to slide in an out freely, the “U” section of the headlamp lock must be in the lowest position (90 degree ). Should headlamp housing be difficult to install in vehicle, turn hex socket wrench – 1 – alternately in both directions while pushing headlamp housing into retainer.
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Special tools, testers and auxiliary items VAG 1598/18 test box Multimeter (Fluke 83 or equivalent) VAG 1527B voltage tester Connector test kit VW 1594 Wiring diagram Checking voltage supply Disconnect 3-pin connector from ignition coil. Connect multimeter using test leads from VW 1594 to measure voltage at terminals 1 and 3 of connector. Turn on ignition. Measure voltage between terminals 1 and 3. Specification: 9-14.5 volts Turn off ignition. If the specification is not attained: Check wire between 3-pin connector contact 1 and Ground for open circuit according to wiring diagram. Wire resistance: Max. 1.5 ohms ( Check wire between 3-pin connector contact 3 and relay plate for open circuit according to wiring diagram. Resistance: max. 1.5 ohms ( If no wiring malfunction is detected and voltage was present between terminals 1 and 3: Replace ignition coil -N152- => Page 28-2, item 7. If no wiring malfunction is detected and no voltage was present between terminals 1 and 3: Replace Engine Control Module (ECM) -J220- => Page 24-9, item 12. Read the readiness code => page 01-32. If DTC memory has been erased, verify repair via appropriate display group => Page 01-34, Readiness code, creating. Checking activation Disconnect the engine harness center connector => Page 24-2, item 11. ) ) Connect VAG 1527B voltage tester with test leads from VW 1594 and adapters VW 1594/15 to terminals 2 and 3 of the connector. Operate starter and check ignition signal from ECM. LED must flicker
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Using the Trim Removal Wedge T10039/1 , pry the front and rear roof rail cover – 1 – in the – direction of the arrow – . Remove the bolt – 3 – on the front and rear roof rail mount – 2 – (20 Nm). Remove the center cover – 1 – from the roof rail – 3 – in the – direction of the arrow – . Remove the bolt – 2 – on the center roof rail mount – 3 – (20 Nm). Installing Installation is performed in the reverse order of removal. Check for the roof railing cover for damage and replace if necessary.
