General data
General basic values
Speed at maximum performance
Compensation for valve play
Inlet valve stem diameter
Outlet valve stem diameter
Number of spark plugs/glow plugs required
Minimum engine oil pressure when idling
0,80
bar
Test temperature 80° C
Maximum deformation of cylinder head
0,100
mm
Rework (resurfacing) of the cylinder head is not allowed.
Cooling system
Cooling system pressure (radiator cap opening pressure)
Fuel system
Fuel system in general
Mixture processing designation
Exhaust gas test values
General exhaust-gas-relevant values
Diagnostic socket location
behind trim below steering column
Idling speed with manual gearbox
Minimum engine oil temperature at VET
Diesel exhaust gas values
Diesel conditioning speed
4800 - 5200
1/min
from 60° C engine oil temperature 10 gas impulses
Diesel conditioning gas injections
10
from 60° C engine oil temperature
Brake system
Brake dimensions
Front axle brake disc thickness
PR. - number 1ZF
22,00
mm
Front axle brake disc thickness
PR. - number 1ZE
25,00
mm
Front axle brake disc thickness
PR. - number 1LJ
25,00
mm
Front axle brake disc thickness
PR. - number 1ZA
25,00
mm
Front axle brake disc thickness wear limit
PR. - number 1ZF
19,00
mm
Front axle brake disc thickness wear limit
PR. - number 1ZE
22,00
mm
Front axle brake disc thickness wear limit
PR. - number 1LJ
22,00
mm
Front axle brake disc thickness wear limit
PR. - number 1ZA
22,00
mm
Rear axle brake disc thickness
PR. - number 1KD
10,00
mm
Rear axle brake disc thickness
PR. - number 1KZ
12,00
mm
Rear axle brake disc thickness wear limit
Rear axle brake disc thickness wear limit
PR. - number 1KZ
10,00
mm
Front axle brake lining thickness
without backing plate
14,00
mm
Rear axle brake lining thickness
without backing plate
12,00
mm
Front axle brake lining thickness wear limit
without backing plate
2,00
mm
Rear axle brake lining thickness wear limit
without backing plate
2,00
mm
Front axle brake disc diameter
PR. - number 1ZF
280,00
mm
Front axle brake disc diameter
PR. - number 1ZE
288,00
mm
Front axle brake disc diameter
PR. - number 1LJ
312,00
mm
Front axle brake disc diameter
PR. - number 1ZA
312,00
mm
Rear axle brake disc diameter
PR. - number 1KD
255,00
mm
Rear axle brake disc diameter
PR. - number 1KZ
286,00
mm
Front axle brake piston diameter
Rear axle brake piston diameter
Consumables
Filling quantities and specifications
Manual gearbox oil
6 gear DSG 02E, Amount to change
6,00
litres
Manual gearbox oil
6 gear DSG 02E, New filling
7,20
litres
Manual gearbox oil specification
6 gear 02Q
G 052 171 A2
Original oil
Manual gearbox oil specification
6 gear DSG 02E
G 052 182 A2
Original oil
Cooling fluid specification
Cooling fluid specification
up to 2007, Alternative possibility:
TL 774 G
Cooling fluid specification
Brake fluid when changing
Brake fluid specification
from vehicle chassis no. 5P-5-092 800
VW 501 14
Brake fluid specification
up to vehicle chassis no. 5P-5-092 799
DOT 4
Air-conditioning system refrigerant
Refrigerant specification
Air-conditioning system oil
Air-conditioning compressor oil specification
Denso compressor
G 052 300 A2
Original oil
Air-conditioning compressor oil specification
Sanden compressor
G 052 154 A2
Original oil
Air-conditioning compressor oil specification
Compressor Zexel
G 052 200 A2
Original oil
Lighting
Front light sources
Low beam
with halogen headlamp
H7 12V 55W PX26d Longlife
Low beam
with bi-xenon
D1S 85V 35W PK32d-2
High beam
with halogen headlamp
H1 12V 55W P14,5s
High beam
up to vehicle chassis no. 5P-9-053 200, with bi-xenon
H1 12V 55W P14,5s
High beam
from vehicle chassis no. 5P-9-500 000, with bi-xenon
D1S 85V 35W PK32d-2
Daytime running light
from vehicle chassis no. 5P-9-500 000, with bi-xenon
P21W 12V 21W BA15s
Parking light
W5W 12V 5W W2,1x9,5d Longlife
Fog lamps
up to vehicle chassis no. 5P-9-053 200
H3 12V 55W PK22s
Fog lamps
from vehicle chassis no. 5P-9-500 000
HB4 12V 51W P22d
Front direction indicator
PY21W 12V 21W BAU15s yellow
Rear light sources
Tail light
Taillight/brake light
P21W 12V 21W BA15s
Stop lamp
Taillight/brake light
P21W 12V 21W BA15s
Internal light sources
Reading light
front
W5W 12V 5W W2,1x9,5d
Reading light
rear
C5W 12V 5W SV8,5 (11x35)
Change intervals
For service data
Engine control toothed belt change interval
up to 2006
every 120.000 km
Engine control toothed belt change interval
from 2007
every 150.000 km
Engine control toothed belt test mode
not prescribed by the manufacturer
Engine control unit tensioning roller change interval
up to 2006
every 240.000 km
Engine control unit tensioning roller change interval
from 2007
every 300.000 km
Air filter change interval
every 90.000 km / 6 years
Fuel filter change interval
Fuel filter change interval
with bio-diesel
every 30.000 km
Brake fluid change interval
Brake fluid change interval
from 2008
after 3 years for the first time, then every 2 years
Transmission oil change interval
Direct gearbox 02E
every 60.000 km
Gear oil filter change interval
Gearbox 02E
every 60.000 km
Engine oil and filter change interval
every 15.000 km / once a year
Interior filter change interval
every 60.000 km / 4 years
Tyre repair kit change interval
every 4 years
(If present)