Maintenance 2011.pdf

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Service
Vo l
Maintenance
Passat 2011 ➤
Passat Variant 2011 ➤
Edition 11.2013
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 © 2013 Volkswagen AG, Wolfsburg
D3E8031B2B4
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Passat 2011 ➤ , Passat Variant 2011 ➤
Maintenance - Edition 11.2013
Vo l
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Information reference flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Vehicle diagnosis, testing and information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8 Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.9 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.10 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.11 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Swivel joints, axle bearings, coupling rod bearings and anti-roll bar rubber mountings: Visual
check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Activation of environment monitoring system (Front Assist): Check . . . . . . . . . . . . . . . . . . 31
4.3 Automatic headlight control and static cornering light: Perform functional check . . . . . . . . 31
4.4 Front passenger front airbag: Check key switch and “On/Off function” . . . . . . . . . . . . . . . . 32
4.5 Battery: Checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 33
4.6 Battery: check using battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7 Status of battery: Read - send diagnosis protocol via online . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8 Reducing agent (AdBlue®): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.9 Reducing agent (AdBlue®): Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.10 Checking tyres: Condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 46
4.11 Brake and clutch system: Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.12 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 75
4.13 Thickness of brake pads/linings and condition of brake discs, front and rear: Check . . . . 76
4.14 Brake fluid level: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.15 Checking diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.16 6-speed dual clutch gearbox (DSG) 02E: Changing gear oil and filter . . . . . . . . . . . . . . . . 80
4.17 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 80
4.18 Natural gas tank: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.19 Check condition of natural gas filler connection and sealing cap, clean if necessary and check
seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.20 Reading fault memory of all systems with vehicle diagnostic tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.21 Bonnet: lubricating arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.22 Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage . . . . . . . . 83
4.23 Haldex coupling: Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.24 Interior and exterior body: Performing visual check for corrosion when doors and flaps are
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.25 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.26 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.27 Diesel fuel filter: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.28 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.29 Multi-purpose additive for petrol fuels: add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.30 Memory seat: Perform initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.31 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.32 Engine cover panel “top”: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Contents i
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Passat 2011 ➤ , Passat Variant 2011 ➤
Maintenance - Edition 11.2013
4.33 Removing and installing engine compartment cover (noise insulation) “bottom” . . . . . . . . 100
4.34 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.35 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 101
4.36 Panoramic tilting/sliding roof with rear panorama roof: Check function, clean guide rails and
grease; clean wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.37 Performing road test (driving behaviour, noises, air conditioner, etc.) . . . . . . . . . . . . . . . . 109
4.38 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.39 Reading radio code using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.40 Radio/navigation system: Enter PIN of anti-theft coding and store local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.41 Tyre pressure monitoring : Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.42 Checking tyre repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.43 Window wash/wipe system and headlight washer system: Functional check . . . . . . . . . . 118
4.44 Wiper blade protection: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.45 Headlight adjustment: check halogen headlights and fog lights, adjust if necessary . . . . 124
4.46 Headlight adjustment: check gas discharge headlights without DLA, adjust if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.47 Headlight adjustment: check gas discharge headlights with DLA, adjust if necessary . . . . 132
4.48 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.49 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.50 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.51 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.52 Auxiliary heater: Set weekday in menu of dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . 142
4.53 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 143
4.54 Transportation mode: Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.55 Transportation devices: Remove blocking pieces from front axle springs . . . . . . . . . . . . . . 144
4.56 Transport locks: Remove tie-down rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.57 Door arrester: Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.58 Clock and date: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.59 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of
lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.60 Camshaft drive toothed belt: Renew (diesel engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.61 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.62 Natural gas system: Visual check of natural gas tank for corrosion and leakage. . . . . . . . . 156
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.2 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6
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Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
ii Contents
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Passat 2011 ➤ , Passat Variant 2011 ➤
Maintenance - Edition 11.2013
1 Engine list
(VIGG000652; Edition 11.2013)
This chapter provides information on the following subjects:
Petrol engines ⇒ page 1
Diesel engines ⇒ page 2
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines:
⇒ Petrol engine
Petrol engine
Petrol engine
Petrol engine
Capacity
I
3.6
1.4
2.0
1.8
Engine codes
BWS
CAXA
CCZB
CDAA
No. of cylinders/
valves per cylinder
6/4
4/4
4/4
4/4
Output kW at rpm 220/6500 to 6700
90/5000
155/6200
118/4500 to 6200
Torque
Nm at
rpm
350/3500 to 3750 200/1500 to 4000 280/1700 to 5200 250/1500 to 4500
Bore
∅ mm
89
76.5
82.5
82.5
Stroke
mm
96.35
75.6
92.8
84.2
Compression ratio
11.4
10.0
9.8
9.8
Injection/ignition
Motronic MED 9.1
FSI
Motronic MED 17.5
TSI turbocharger
Motronic MED 17.5
TSI turbocharger
Motronic MED
17.5
TSI turbocharger
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RON
unlea‐
ded, at
least
98
95
95
95
Camshaft drive
Chain
Chain
Chain
Chain
Engines:
⇒ Petrol engine
Petrol engine Petrol engine Petrol engine
Capacity
I
1.8
1.4
1.4
1.4
Engine codes
CDAB
CDGA
CKMA
CTHD
No. of cylinders/valves per
cylinder
4/4
4/4
4/4
4/4
Output
kW at rpm 112/4300 to 6200
110/5500
118/5800
118/5800
Torque
Nm at rpm 250/1500 to 4500 220/1500 to 4500 240/1500 to 4500 240/1500 to 4500
Bore
∅ mm
82.5
76.5
76.5
76.5
Stroke
mm
84.2
75.6
75.6
75.6
Compression ratio
9.6
10.0
10.0
10.0
Injection/ignition
Motronic MED
17.5
TSI turbocharger
Motronic MED
17.1
CNG/TSI twin‐
charger
Motronic
MED17.5
MultiFuel
TSI twincharger
Motronic MED
17.5
TSI twin charger
RON
unleaded,
at least
95
Natural gas and
95
95
95
RON
Ethanol 85
—
---
104
---
1. Engine list 1
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