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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.

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The filter is located in the right rear of the instrument panel under a cover. Components of dust and pollen filter: 1 – Frame 3 – Filter element 4 – Plastic nut, 2.5 Nm (20 in lb) 5 – Filter housing with seal Removing Push center cover -1- forward -arrow A- and lift up to remove. Remove screws -arrows-. Lift right plenum panel cover -1- and remove from clips at front and rear edge. Pull cover -1- toward center of vehicle and out of retainer in A-pillar to remove. Remove screws -arrows- and remove right closeout panel -1-. Remove rubber grommet -1-. Press tabs of filter housing in direction of -arrow-. Remove filter element with frame in upward direction -arrow A-. Installing Guide frame -1- into first slot on left and right sides of new filter element. Press frame with filter into housing -2- and engage retainers.

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Note: The procedure for removing and installing the Emergency flasher switch -E3- Rear window defogger switch -E15- Seat heater regulator switches (modules -J131- and -J132-) is essentially the same for all switches. Removing the emergency flasher switch -E3- is illustrated below. Removing CAUTION! Switch off all electrical consumers. Switch off ignition and remove ignition key. CAUTION! Be careful not to damage instrument panel center console trim when removing switch. Protect trim in area of switch with adhesive tape before removing switch. Do Not pry out switches from the side. Only pull out from the top. Carefully loosen and remove switch faceplate using a plastic wedge tool (locally available) or wrapped screwdriver. Using pliers, grasp switch at the top of the frame as illustrated and carefully pull switch from opening. Disconnect electrical connection. Installing Connect electrical connection. Insert switch into opening and push in to engage. Install switch faceplate. Switch blanks, removing Using a plastic wedge tool (locally available) or wrapped screwdriver, carefully pry out blank from the side as illustrated.

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Power Steering Gear Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 Notes for repair work on power steering gear All work on the power steering must be carried out with utmost cleanliness. Thoroughly clean all connections and the surrounding area before disconnecting. If repairs will not be carried out immediately, place removed parts onto a clean surface and cover. Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use parts in their original packing. Removing Remove bolts – 1 – . Remove cover – A – . Remove bolt – 1 – from universal joint. Remove universal joint from steering gear. Clamp off hose from reservoir using hose clamps up to 25 mm dia. 3094 . Clamp off hose on power steering pump using hose clamps up to 25 mm dia. 3094 . Remove sound-deadening pan. Place drip tray underneath. . Press off tie rod from steering knuckle. A – Tie rod puller (standard), e.g. Kukko 128/2 Remove hose lines at steering gear and plug using a plastic bag and tape. Seal threaded holes on power steering gear using plastic screw plugs – 1 – and – 2 – . Remove bolts – 1 – and – 2 – . With TDI Engines Remove bracket for front exhaust pipe at subframe – arrows – and disengage. Continuation for All Support subframe using engine/transmission jack V.A.G 1383 A . Loosen bolts – 1 – . Remove bolts – 2 – and – 3 – . Lower subframe using engine/transmission jack V.A.G 1383 A . Remove bolts – 1 – for power steering gear. Remove power steering gear toward right. Installing Note: . Use new O-rings for hose/line connections. Coat seal on steering gear with lubricant, e.g. lubricating soap, before installing steering gear. After placing steering gear on to universal joint shaft, make sure that seal on steering gear makes contact on assembly plate without kinks and opening to footwell is correctly sealed. Ingress of water and/or noises may result otherwise. Make sure sealing surfaces are clean.