Chemicals Manual III

Service
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Workshop Manual
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Chemicals Manual
Edition 02.2016
Service Department. Technical Information

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00 - Technical data
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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 © 2016 Volkswagen AG, Wolfsburg D4B8026F7C5

Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , Gol 1995 ➤ , Gol 1999 ➤ , Gol ...
Chemicals Manual - Edition 02.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 List of Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 3M do Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Alba Adesivos Ind. Com. Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Brascola Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Castrol Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Cia Brasileira de Petróleo Ipiranga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.6 Chevron Brasil S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.7 Colauto - Adesivos e Massas Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.8 Cremer S.A. Prod. Têxteis e Cirúrgicos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.9 Dow Corning do Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.10 Dow Automotive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.11 Du Pont S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.12 Elf Lubrificantes do Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.13 Esso Brasileira de Petróleo Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.14 Formiquímica Com. e Repres. de Produtos Químicos Ltda . . . . . . . . . . . . . . . . . . . . . . . . 2
2.15 Gratec System Indústria de Produtos Químicos Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.16 Henkel do Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.17 Klüber Lubrification Lubrificantes Especiais Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.18 Loctite Brasil Ltda . . . . n. A. G. ..V.o.lk.sw. a. g.e.n .A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.19 Lumobrás Imp. Com. wage
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2.20 ExxonMobil isdo ed Brasil Ind. Com. Ltda . . . . . . . . . . .ra.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.21 Motul Synthetic
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Lubricants . . . . . . . . . . . . . . . . . . . . . e.o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.22 Nippondenso
ss Compressores Ltda . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.23 Pentosin do Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.24 Petrobras Distr. S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.25 Promax Prod. Máximos S/A Indústria e Comércio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.26 Repsol - YPF S.A. Divisão Lubrificantes Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.27 Quaker Chemical Industria e Comércio Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.28 Shell Brasil S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.29 Sika S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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2.30 Solplás - Ind. de Plásticos Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.31 Solvay Química . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.32 Three Bond do Brasil Ind. e Com. Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.33 Total Lubrificantes Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.34 Tutela Lubrificantes S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.35 Valvoline Lubrificantes Internacionais Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 List of authorized products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.1 Assembly Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.2 Adhesive for polyurethane and polypropylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.3 Resin adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.4 Polyurethane-based sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.5 Instant adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.6 Adhesive for sealing gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.7 Permanent adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.8 Adhesive for packings and linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.9 Polyurethane adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.10 Polyurethane adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.11 Epoxy adhesive with 2 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.12 Sealing adhesives for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.13 High-resistance locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.14 Low viscosity lock adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.15 Locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.16 Locking adhesive for mechanical seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.17 Medium torque locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.18 Adhesive for plastic cap gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.19 Metal-glass adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.20 Sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.21 2-component adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.22 Universal adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.23 Additives for coolants - G11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.24 Additives for coolants - G13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.25 Additive for the windscreen/rear window washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . 7
3.26 Additives for petrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.27 Activating agent for pre-laminated glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.28 Silicone rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .V.ol.ks.w.a.g.e . . . . . . . . . . . . . . . . . . 8
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3.29 Filling and acoustic isolation foam . . . . . . . . . . o.lk.sw . a. g.e. . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . 8
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3.30 Polyurethane adhesive tape . . . . . . . . . . .ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . . u.ar.a.n . . . . . . 8
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3.31 Cotton tape . . . . . . . . . . . . . . . . . . . . u. th.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e.or. . . . 8
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3.32 Self-adhesive PVC tape . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . 8
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3.33 Transferable adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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3.34 Sealing tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.35 Double-sided adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.36 Double-sided acrylic foam adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.37 Medium density double-sided adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.38 Hydraulic brake fluid (DOT 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.39 Automatic transmission fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.40 Refrigerant gas - R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.41 Multi-purpose grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.42 Semi-fluid grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.45 Special lubrication grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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3.46 Polyalphaolefin-based low temperature grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.47 Lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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3.48 Complex grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.49 Graphite grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.50 Grease for front wheel cylinder support guide pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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3.51 Grease for gearbox side seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3.53 Grease for electrical contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3.54 Polyurea grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3.55 High temperature grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.56 Temperature resistant grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.58 Silicone based grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.59 Windscreen adhesive set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.60 Windscreen adhesive set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.61 Glass adhesion kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.62 Lithium-based lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.63 Adhesive paste and grey sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.64 Adhesive material for glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.65 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.66 Adhesive material for glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.67 Silicone paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.68 Mouldable paste for caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.69 Lubricating paste for high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.70 Lubricating paste for constant velocity joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ii Contents

3.74 Paste for bucket protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.75 Sealing compound for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.77 Sealing compound for engine . . . . . . . . . . . . .g.en. A. G . .. V.o.lk.s.w.ag. e.n.A.G. d. . . . . . . . . . . . . . . . . . . . 13
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3.78 Nyogel . . . . . . . . . . . . . . . . . . . . . . . . y. V.o. . . . . . . . . . . . . . . . . . . . .s.no. t .gu. . . . . . . . . . . . . .
lks 13
b a
3.79 Engine lubricant oil: Petrol, Ethanol ri-seVW d 501 01 . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . 14
ho e
3.80 Engine lubricant oil: Petrol, Ethanol, ut Totalflex and NGV - VW 502 00 . . . . . . . .or .a . . . . . . . 14
sa c
3.81 Lubricating oil for diesel engines - VW 505 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s 15
ce
le
un
3.82 Engine oil lubricant: Diesel - VW 507 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
pt
an
d
3.83 itte
Engine lubricant oil: Petrol and Totalflex - VW 508 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
y li
erm
ab
3.84 Diesel engine lubricant oil - VW 509 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ility
ot p
3.85 Lubricating oil for manual gearbox and steering box - SAE 90, MIL-L-2105B, API-GL5 . . 17
wit
is n
h re
3.86 Lubricating oil for manual gearbox - SAE 80, MIL-L-2105, API-GL4 . . . . . . . . . . . . . . . . . . 17
ole,
spec
3.87 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
t to the co
3.89 Special oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.90 Oil for manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
rrectne
ss
o
cial p
f in
form
mer
atio
m
3.96 Lubricating oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

o
n
c
i
or
n
3.97 Lubricating oil for automatic gearbox and power steering . . . . . . . . . . . . . . . . . . . . . . . . . . 19
thi
te
sd
a
3.98 Lubricating oil for the automatic gearbox differential - SAE 75W90 . . . . . . . . . . . . . . . . . . 19
iv
o
pr
c
3.99 VW ATF oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
um
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ng

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3.101 ATF oil for automatic gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.103 Oil for gear selection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
19
agen
Prote AG.
3.104 Air conditioning compressor oil - R 134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.105 Oil for the air conditioning compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.106 Lubricating oil for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.107 White lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.108 Moly grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.109 Molybdenum bisulphate lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.110 Copper grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.111 Silicon grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.112 High temperature paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.113 Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.114 Glass primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.115 Adhesive remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.116 Cleaning remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.117 Corrosive paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.118 Odourless solvent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.119 Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.120 Engine leak detection spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.121 Cylinder lubricating spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.122 Primer for polyurethane surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.123 Adhesive sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.124 Mixing tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.125 Liquid sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.126 Silicone sealant for engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contents iii
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , Gol 1995
aut ➤ , Gol 1999 ➤ , Gol ... ra
c
s
Chemicals Manual - Edition 02.2016 s
ce
e
nl
pt
du
an
itte
3.127 Sealant for exhaust connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
y li
erm
ab
3.128 Teflon thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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ot p
wit
4 Work Instructions for Handling Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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h re
4.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
hole
spec
5 Application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
es, in part or in w
t to the co
5.1 Application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6 Repair Group 10 - Cylinders, cylinder block, support, protector . . . . . . . . . . . . . . . . . . . . . . 36
rrectness of i
6.1 Cylinder base gasket - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2 Engine housing - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
l purpos
6.3 Engine housing plugs - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4 Cylinder block plugs - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
nf
ercia
or
7 Repair Group 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
m
m
atio
7.1 m
Crankshaft needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o 40
n in
c
7.2 Needle bearing of the fastening hollow screw for the flywheel . . . . . . . . . . . . . . . . . . . . . . 41
or
thi
te
7.3 Flywheel fastening screw - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
sd
iva
o
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8 Repair Group 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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ng
8.1 Intermediate shaft seal - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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8.2 Camshaft valve bearing cover (1st and 5th) - Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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8.3 Cylinder head sealing gasket - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
p by
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8.4 Lower rear threaded pins fastening the cylinder head - rear threaded pin (crankshaft) / lower cted agen
Prote AG.
front threaded pins (flywheel) - Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.5 Cylinder head cover - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9 Repair Group 17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.1 Engine crankcase - Fill / top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.2 Junction between crankcase gaskets and crankshaft front and rear flange gasket - seal . . 51
9.3 Engine crankcase - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10 Repair Group 19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.1 G11 cooling system - fill / adjust additive proportion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.2 G13 cooling system - fill / adjust additive proportion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11 Repair Group 20 - Supply system - tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.1 Fuel tank - add additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.2 Accelerator pedal shaft - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11.3 Accelerator pedal fastening - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.4 Accelerator cable and cable end - accelerator pedal fastening - lubricate . . . . . . . . . . . . . . 58
12 Repair Group 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.1 Exhaust connection - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
13 Repair Group - 28 - Ignition system, pre-ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 60
13.1 Ignition coils with final power stage - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14 Repair Group 30 - Clutch - control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
14.1 Clutch pedal bung - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
14.2 Clutch control cable - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
14.3 Clutch fork, contact with bearing - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
14.4 Clutch fork bungs - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
14.5 Wing nut for clutch control cable adjustment - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
14.6 Sealing ring for the de-clutch bearing guide - lubricate for assembly . . . . . . . . . . . . . . . . . . 66
14.7 Clutch cable - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
14.8 Clutch fork and clutch actuating lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14.9 Clutch pedal fastening - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
14.10 Clutch actuating lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14.11 Input shaft splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.12 Clutch pedal / clutch pedal bung - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14.13 Pedal support - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
iv Contents
14.14 Clutch fork contact with the hydraulically activated cylinder of the gearbox clutch -
lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
14.15 Fastening flange for clutch slave cylinder - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15 Repair Group - 34 - Drive, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15.1 Linkage rod, front/rear section - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15.2 Gear lever bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15.3 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
15.4 Manual gearbox - Fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
15.5 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
15.6 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
15.7 Manual Gearbox - fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
15.8 Plastic sleeves for the linkage rod coupling system / linkage rod / supports (on the gearbox)
- lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
15.9 Gear lever guide plate - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
15.10 Rubber shim for the clutch compartment cover - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
15.11 Clutch compartment cover - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
15.12 Linkage rod bellows for the gear lever assembly - fasten / seal . . . . . . . . . . . . . . . . . . . . . . 87
15.13 Junction of cases and differential cover housing (transfer box / differential) - seal . . . . . . 88
15.14 Gear lever handle - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15.15 Fastening screw for the rear support of the gearbox cushion - seal . . . . . . . . . . . . . . . . . . 90
15.16 Gearbox cushion - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
15.17 Gear selection mechanism - fill up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
15.18 Electric connectors of the gear selection mechanism - apply Nyogel . . . . . . . . . . . . . . . . 93
16 Repair Group 35 - Gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
16.1 Input shaft splines - lubricateAG. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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16.2 Fastening screw forVthe wage
olks clutch assembly / 5th gear
es n synchronizer - lock . . . . . . . . . . . . . . 95
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17 Repair Group r-is37ed - Drive, housing . . . . . . . . . . . . . .ra.n . . . . . . . . . . . . . . . . . . . . . . . . . . .
tee 96
o
17.1 Planetary gearaut
h box (automatic gearbox) - fill / top up oil level or . . . . . . . . . . . . . . . . . . . . . .
ac 96
s
17.2 Planetary gear box (automatic gearbox) - fill / top up oil level . . . . . . . . . . . . . . . . . . . . . .
s 97
ce
le
un
17.3 Planetary gear box (automatic gearbox) - fill / top up oil level . . . . . . . . . . . . . . . . . . . . . . 98
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18 Repair Group - 39 - Gearbox shafts, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

rm
ab
pe
18.1 Gearbox side seals - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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18.2 Planetary and satellite gears - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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18.3 Automatic gearbox differential - top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

hole
spec
18.4 Differential cover with gearbox housing - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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t to the co
19 Repair Group - 40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

19.1 Constant velocity joint spline - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
19.2 Inner and outer constant velocity joint - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
rrectness of i
19.3 Front wheel bearing mounting - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

l purpos
19.4 Axle end - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

20 Repair Group - 42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
nform
ercia
20.1 Inner and outer constant velocity joint - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

m
20.2 Shaft end splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

com
tion in
20.3 Rear torsion bar - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

r
te o
thi
20.4 Rear wheel hub - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

s
iva
do
20.5 Rear wheel hub seal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

r
rp
cum
fo
20.6 Rear wheel bearing - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

en
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21 Repair Group - 46 - Brakes - Mechanical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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21.1 Rear wheel brake shoe ends - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ht
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Vo
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21.2 Handbrake cable terminal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
by lksw
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Prote AG.
21.3 Brake pedal safety pin - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
21.4 Securing pin for the operating rod of the master cylinder plunger - lubricate . . . . . . . . . . . . 122
21.5 Securing pin of the handbrake lever - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
21.6 Handbrake ratchet - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22 Repair Group - 47 - Brakes - Brake servo hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 125
Contents v
22.1 Brake system - fill / top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

22.2 Guide pin for the support of the front disc brake cylinder (manufactured by Varga) -
lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
22.3 Fastening screw for the front disc brake cylinder housing - lock . . . . . . . . . . . . . . . . . . . . 127
23 Repair Group - 48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
23.1 Oil reservoir for the power steering system - Fill / top up oil level . . . . . . . . . . . . . . . . . . . . 128
23.2 Oil reservoir for the power steering system - fill / top up oil level . . . . . . . . . . . . . . . . . . . . 129
23.3 Steering box - Fill / top up level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
23.4 Steering box mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
23.5 Adapter (sleeve) for the upper steering shaft - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
24 Repair Group - 53 - Body - Rear section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
24.1 Bucket sealing membrane - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
24.2 Rear side panel - protect the paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
25 Repair Group - 55 - Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
25.1 Bucket protective cover longitudinal member - glue the finishing . . . . . . . . . . . . . . . . . . . . 135
25.2 Lower latch of the bonnet - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
olkswagen AG
25.3 Damper eyelet for the lkrear en AG. V- lubricate
wagcover .do. e.s.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
o s ot g
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26 Repair Group - s57 d - Front doors / components / central
b ua lock . . . . . . . . . . . . . . . . . . . . . . . .
ran 138
ir e te
26.1 Front door lock
uth - lubricate . . . . . . . . . . . . . . . . . . . . . . . . e.o. . . . . . . . . . . . . . . . . . . . . . . . .
o
ra
138
a
26.2 Lock drivessrod - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . 139
ce
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26.3 Noise insulation for lock operating rod - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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26.4 Inner door seal - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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27 Repair Group - 58 - Rear doors / components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
ility
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27.1 Rear door lock - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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is n
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27.2 Side door lock - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ole,
spec
28 Repair Group - 64 - Windscreens, windows, window mechanism . . . . . . . . . . . . . . . . . . . . 144
t to the co
28.1 Door window activation mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
28.2 Vent window latch - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
28.3 Front door window support - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
rrectne
28.4 Front door window activation mechanism - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

28.5 Window crank fastening screw - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ss
28.6 Windscreen, side window glass and rear window glass - glue . . . . . . . . . . . . . . . . . . . . . . 149
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28.7 Windscreen, side window glass and rear window glass - seal . . . . . . . . . . . . . . . . . . . . . . 150
form
mer
28.8 Glass - engrave chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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28.9 Front and rear door window guide groove - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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28.10 Vent window - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

thi
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va
29 Repair Group - 66 - External equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

i
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pr
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29.1 Roof rack fastening screws - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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30 Repair Group - 68 - Internal equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
t. Cop py
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30.1 Interior rearview mirror support - fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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31 Repair Group - 70 - Lining/insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
by lksw
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Prote AG.
31.1 Door noise insulation - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
31.2 Noise insulation on rear side panel - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
31.3 Roof noise insulation - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
31.4 Door sealing membrane - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
32 Repair Group - 72 - Seat framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
32.1 Front seat central sliding guide - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
32.2 Front seat side sliding guide - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
33 Repair Group - 87 - Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
33.1 Air conditioning system - refill with gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
33.2 Air conditioning system - refill with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
33.3 Air conditioning pressure switch - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
34 Repair Group - 92 - Windscreen, rear window and headlight wiper and washer . . . . . . . . 165
34.1 Windscreen wiper operating rod - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
vi Contents
34.2 Windscreen/rear window washer water tank - fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

35 Repair Group - 94 - Switches, lights, and external bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . 167
35.1 Contact blade for turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
36 Repair Group - 97 - Cables and electrical harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
36.1 Gaskets for the plastic covers that cover the electric harnesses - seal . . . . . . . . . . . . . . . . 168
AG. Volkswagen AG d
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Contents vii
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viii Contents
00 – Technical data
1 Introduction
(VRL008743; Edition 02.2016)
The information in this manual also cover that mentioned in the
⇒ Electronic Replacement Parts Catalogue “ETKA” .
Some products are sold directly by the supplier, and so contacts
are directed to them.
WARNING agen
AG. Volkswagen AG d
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The information contained herein is a reference
rised for the import‐ ara
nte
er, since some of the products cited uint this Manual may not
ho eo
ra
exist on the market. ss a c
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1. Introduction 1
2 List of Suppliers
2.1 3M do Brasil
http://www.3m.com.br
2.2 Alba Adesivos Ind. Com. Ltda

http://www.albaadesivos.com.br/
2.3 Brascola Ltda

http://www.brascola.com.br/
2.4 Castrol Brasil Ltda

AG. Volkswagen AG d
www.castrol.com/pt_br/brazil.html lksw
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2.5 Cia Brasileira de Petróleo Ipiranga d ara
rise nte
tho eo
au ra
http://www.ipiranga.com.br ss c
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nl
pt
2.6 Chevron Brasil S/A
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https://www.chevron.com.br
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2.7 Colauto - Adesivos e Massas Ltda
, is n
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hole
spec
http://bra.sika.com/
es, in part or in w
t to the co
2.8 Cremer S.A. Prod. Têxteis e Cirúrgicos
http://www.cremer.com.br
rrectness of i
2.9 Dow Corning do Brasil Ltda
l purpos
http://www.dowcorning.com/pt_BR
nform
ercia
2.10 Dow Automotive System

m
at
om
io
http://www.dow.com/brasil/
n
c
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2.11 Du Pont S/A

at
do
priv
cum
or
http://www.dupont.com.br
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2.12 Elf Lubrificantes do Brasil
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http://www.elf.com
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2.13 Esso Brasileira de Petróleo Ltda
http://www.exxonmobil.com.br
2.14 Formiquímica Com. e Repres. de Pro‐

dutos Químicos Ltda
http://formiquimica.com.br
2.15 Gratec System Indústria de Produtos

Químicos Ltda
[email protected]
2.16 Henkel do Brasil Ltda

http://www.henkel.com.br/index.htm
2 Rep. gr.00 - Technical data

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Fox 2004 ➤ , Fox 2010ut ➤ , Fox 2014 ➤ , Gol 1995 ➤ , Gol 1999 ➤ o,r aGol ...
ho e
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ss Chemicals Manual - Edition 02.2016 c
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2.17 Klüber Lubrification Lubrificantes Espe‐
itte
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erm
ab
ciais Ltda
ility
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http://www.klueber.com/br/pt/homepage/
h re
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spec
2.18 Loctite Brasil Ltda
t to the co
http://www.loctite.com
2.19 Lumobrás Imp. Com. Ind. Ltda
rrectne
http://www.lumobras.com.br
ss
2.20 ExxonMobil do Brasil Ind. Com. Ltda
o
cial p
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mer
http://www.exxonmobil.com.br
atio
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2.21 Motul Synthetic Lubricants

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c
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https://www.motul.com/br/pt-br
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2.22 Nippondenso Compressores Ltda
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http://www.denso.com.br/ t. C rig
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2.23 Pentosin do Brasil Ltda

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http://www.pentosin.net/
2.24 Petrobras Distr. S/A

http://www.petrobras.com.br
2.25 Promax Prod. Máximos S/A Indústria e

Comércio
http://www.promax.com.br
2.26 Repsol - YPF S.A. Divisão Lubrificantes

Brasil
http://www.ypf.com/brasil/Paginas/Home.aspx
2.27 Quaker Chemical Industria e Comércio

Ltda
http://br.quakerchem.com/
2.28 Shell Brasil S/A

http://www.shell.com/bra.html
2.29 Sika S/A

http://bra.sika.com/
2.30 Solplás - Ind. de Plásticos Ltda

http://www.solplas.com.br
2.31 Solvay Química

http://www.solvay.com/
2.32 Three Bond do Brasil Ind. e Com. Ltda

http://www.threebond.com.br
2. List of Suppliers 3
2.33 Total Lubrificantes Brasil Ltda

http://www.totalbr.com.br/
2.34 Tutela Lubrificantes S/A

http://www.tutela.com.br/
2.35 Valvoline Lubrificantes Internacionais

Ltda
http://www.valvoline.com.br/ AG. Volkswagen AG d
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3 List of authorized products
WARNING
Observe the information in Chapter “Work Instructions for Han‐

dling Chemicals” ⇒ page 23
3.1 Assembly Adhesive

Trade Name Packaging Supplier
D 190 MKD A3 310 ml VOLKSWAGEN
3.2 Adhesive for polyurethane and polypro‐

pylene
MKL.106.113.09
EC 4474 18-L buckets 3M
Brascoplast CE 18-L buckets BRASCOLA
5575VW
3.3 Resin adhesive

DA 001 730 A2 2 Kg VOLKSWAGEN
3.4 Polyurethane-based sealing adhesive

MKL 106,146 83
Trade Name Packaging ASupplier
G. Volkswagen AG d
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3.5 Instant adhesive ho eo
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SB - 416 10 g and 100 g LOCTITE

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TUBES
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TB-1000 E 100 g TUBES THREE BOND

hole
spec
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3.6 Adhesive for sealing gaskets

t to the co

rrectness of i
BRASCOVED 85 ML TUBES BRASCOLA

l purpos
CA-149 V
ADHESIVE FOR 85 ML TUBES BRASCOLA
DIESEL ENGINE
nf
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GASKETS
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3.7 Permanent adhesive

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BRASCOVULT 1 L and 3.6 L CANS BRASCOLA

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3. List of authorized products
Chemicals Manual - Edition 02.2016 lkswage es n
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3.8 Adhesive for packings and linings aut
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MKL.106.217.95
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BRASCOFIX 833 900 ML TINS BRASCOLA
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COVULFIX ESPE‐ 900 ML TINS BRASCOLA
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CIAL
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3.9 Polyurethane adhesive
t to the co
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D 180 KD2 A1 50 ml VOLKSWAGEN
l purpos
3.10 Polyurethane adhesive
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3.11 Epoxy adhesive with 2 components
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DA 001 730 A2 37 ML VOLKSWAGEN
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3.12 Sealing adhesives for engines
p by
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ISAVED 2 V 900 ML TINS SOLPLÁS
THREE BOND 900 ML TINS THREE BOND
1,102 A
3.13 High-resistance locking adhesive

LOCTITE 601 50 AND 250 ML LOCTITE
TUBES
THREE BOND 1329 50 AND 250 ML THREE BOND
B TUBES
3.14 Low viscosity lock adhesive

TUBES
THREE BOND 1305 50 AND 250 ML THREE BOND
B TUBES
3.15 Locking adhesive

D 000 600 A2 18 ml VOLKSWAGEN
3.16 Locking adhesive for mechanical seals

THREE BOND 1386 250 ML TUBES THREE BOND
E

AG. Volkswagen AG d
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Fox
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2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , Gol 1995 ra ➤ , Gol 1999 ➤ , Gol ...
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s Chemicals Manual - Edition 02.2016
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3.17 Medium torque locking adhesive
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LOCTITE 649 50 ML TUBES hole
LOCTITE
spec
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3.18 Adhesive for plastic cap gaskets
rrectness of i
l purpos
BRASCOPEN CA 5-LITER TINS BRASCOLA

2800 F
nf
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orm
3.19 Metal-glass adhesive
m
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D 000 703 A1 0.3 g VOLKSWAGEN
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3.20 Sealing adhesive

t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
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Prote AG.
TUBES
3.21 2-component adhesive

(BLUE)
(RED)
3.22 Universal adhesive

D 001 200 M2 420 g VOLKSWAGEN
D 001 210 M2 420 g VOLKSWAGEN
3.23 Additives for coolants - G11

G 052 774 A3 1 litre VOLKSWAGEN
3.24 Additives for coolants - G13

G 013 A8J M1 1.5 litre VOLKSWAGEN
3.25 Additive for the windscreen/rear window

washer reservoir
G 052 164 M1 0.5 litre VOLKSWAGEN
G 052 164 M2 1 litre VOLKSWAGEN
3. List of authorized products 7

3.26 Additives for petrol

APR 020 002 B 375 ml VOLKSWAGEN
3.27 Activating agent for pre-laminated glass

D 181 802 M1 10 ml VOLKSWAGEN
3.28 Silicone rubber

FLEXITE BLACK 85 g TUBES ALBA
BRASCOVED SI-40 85 g TUBES BRASCOLA
- BLACK
SILASTIC 732 RTV 85 g TUBES DOW CORNING
- BLACK
3.29 Filling and acoustic isolation foam

AG. Volkswagen AG d
3.30 Polyurethane adhesive tapeVolkswagen oes
not
by gu
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Trade Name Packaging hoSupplier
ris nte
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MKR 106 260 95 21 MM X 50 M ss a
VOLKSWAGEN c
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3.31 Cotton tape y li

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Trade Name Packaging Supplier wit

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TESABAND IM‐ 19 MM X 50 M CREMER
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PERMEÁVEL 4651 ROLLS

es, in part or in w
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t to the co
3.32 Self-adhesive PVC tape

rrectness of i

l purpos
FITA 470 30 M X 19 MM 3M
ROLLS
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3.33 Transferable adhesive tape

m
at
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in t

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Y-0598 33 M X 16 MM 3M
do
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ROLLS
um
for
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yi Co
3.34 Sealing tape Cop py
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gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
BRASCOVED 2015 BOX CONTAINING BRASCOLA
L 10 TO 20 KG (with
tapes)

3.35 Double-sided adhesive tape

G. Volkswage
gen A n AG d
swa oes
Trade Nameby Volk Packaging Supplier
not
gu
ara
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se n
V 2808thori 6.0 MM X 61 M INDACOtee o
au ROLLS ra
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Y-427 6.3 MM X 10 M 3M
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3.36 Double-sided acrylic foam adhesive
ility
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Y-4205 5 MM X 10 M 3M
ROLLS
rrectne
3.37 Medium density double-sided adhesive
tape
ss o
cial p
f
inform
mer
Y-4210 (SENSOR) 30 X 48 MM UNITS 3 M
atio
m
325 /953 931 1 30 X 48 MM UNITS VOLKSWAGEN

o
n
c
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Y-4210 (GOL GTI 10 X 80 MM UNITS 3 M n thi

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ROOF SPOILER)
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3.38 Hydraulic brake fluid (DOT 4)

en
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t.
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Cop py
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pyri by
Vo
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B 000 750 M1 Prote 0.25 litre
cted AG. VOLKSWAGEN
agen
3.39 Automatic transmission fluid

3.40 Refrigerant gas - R134a

SUVA® 134A DU PONT
SOLKANE® 134A SOLVAY QUÍMICA
3.41 Multi-purpose grease

ESSO MULTI H ESSO
LITHOLINE MP IPIRANGA
LUBRAX G-MA-2 PETROBRÁS
RETINAX WB SHELL
MULTIFAK 2 CHEVRON BRASIL
3.42 Semi-fluid grease

G 052 168 A1 10 g VOLKSWAGEN

3.43 Multi-purpose grease

LITHOLINE EP 2 IPIRANGA
CASTROL GRAXA CASTROL
EPL 2
EXXON BEACON ESSO
EP-2
LUBRAX - GMA-2 PETROBRÁS
MULTIFAK PREMI‐ CHEVRON BRASIL
UM EP2
3.44 Multi-purpose ogrease AG. Volkswagen AG

agen does
lksw not
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Trade Name Packaging
or
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G 052 735 A2 ss a120 g VOLKSWAGEN c
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un
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3.45 Special lubrication grease
an
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G 000 450 02 90 g VOLKSWAGEN
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3.46 Polyalphaolefin-based low temperature
t to the co
grease
ISOFLEX TOPAS KLÜBER rrectne
L32 (WHITE)
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3.47 Lubricating grease

inform
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atio

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VARILUB 745 BR 1 KG KLÜBER

or
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3.48 Complex grease

i
o
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Co
Cop py
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MOBILPLEX 47 MOBIL
ht
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Vo
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3.49 Graphite grease
Prote AG.

ISAGRAFITE IPIRANGA
KLÜBER ST 25/300 KLÜBER
G-8
PROFASA HD G-1 WAL
3.50 Grease for front wheel cylinder support

guide pin
SYNTHESO GLK 1 KLÜBER

3.51 Grease for gearbox side seals

GRAXA VARILUB KLÜBER
AH 70-222 BR

3.53 Grease for electrical contacts

UNIMOLY AC MET‐ KLÜBER
ALLIC
MOLYKOTE HSC LUMOBRÁS
3.54 Polyurea grease

3.55 High temperature grease

Trade Name Packagingn AG. VolkswagSupplier
en AG
ge does
swa
G 052 133 A2 90
by
Vog
lk VOLKSWAGEN
not
gu
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G 052 133 A3 or
ise 120 g VOLKSWAGENntee
th or
au ac
3.56 Temperature resistant grease
ss
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nl
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G 000 650 100 g VOLKSWAGEN

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G 000 100 80 g VOLKSWAGEN

rrectness of i
3.58 Silicone based grease

l purpos

UNISILKON GLK 1 Kg KLÜBER
nf
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112 BR
rm
m
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3.59 Windscreen adhesive set

o
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or c
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DA 004 660 M2 Comp. A - 207 ml VOLKSWAGEN

o
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f
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and Comp. B - 193

t.
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op
ml
C py
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pyri by
Vo
co lksw
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cted agen
Prote AG.

3.60 Windscreen adhesive set

DA 004 556 M2 Comp. A - 200 ml VOLKSWAGEN
and Comp. B -
200ml en AG. V
olkswagen AG
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3.61 Glass adhesion kit yV
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Trade Name au ra
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BETASEAL BOX WITH PRI‐ DOW AUTOMO‐

nl
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du
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U-400HV MER AND TUBE TIVE SYSTEMS
itte
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OF ADHESIVE
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3.62 Lithium-based lubricant
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3.63 Adhesive paste and grey sealant
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D 511,500 A2 290 ML VOLKSWAGEN
nf
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3.64 Adhesive material for glass
rm
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Trade Name Packaging Supplier n in

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DH 009 100 300 ML VOLKSWAGEN

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3.65 Sealing compound

f
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Cop py
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D 174,003 A2 83 ML VOLKSWAGEN
c by lksw
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Prote AG.
3.66 Adhesive material for glass

DH 009 100 03 300 ml VOLKSWAGEN
3.67 Silicone paste

3.68 Mouldable paste for caulking

BRASCOVED 1051 BOX WITH 20 KG BRASCOLA
(20 1-KG BAGS)
191 BOX WITH 20 KG HENKEL
(20 1-KG BAGS)
3.69 Lubricating paste for high temperatures


3.70 Lubricating paste for constant velocity

joints

D 154,103 A1 100 g VOLKSWAGEN

VEDANTE 245/78 85 ML TUBES HENKEL
SQV - 337 85 ML TUBES BRASCOLA
3.73 Sealing compound agen

AG. Volkswagen AG d
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Trade Name Packaging Supplierise d b ara
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AMV 188 200 03 100 g TUBES VOLKSWAGEN
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3.74 Paste for bucket protection

nl
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STOP NOISE 20 KG PAILS HENKEL
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STOP NOISE 5 KG TINS HENKEL
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6979B
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3.75 Sealing compound for engines
rrectness of i
l purpos
D 454,300 A2 125 g TUBES VOLKSWAGEN
nform
ercia

m
at
om
Trade Name Packaging Supplier ion

c
in t
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7X0 898,539 100 g TUBES VOLKSWAGEN

his
ate
do
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3.77 Sealing compound for engine

um
for
en
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op
Trade Name Packaging Supplier C py
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AMV 188 001 02 - 100 g TUBES VOLKSWAGEN
p by
co Vo
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(EA 111 - 8V en‐ Prote
cted AG.
agen
gines)
D 154 103 A1 - (EA 100 g TUBES VOLKSWAGEN
111 - 8V engines)
D 188,003 A1 - (EA 100 g TUBES VOLKSWAGEN
111 - 16V engines)
3.78 Nyogel
G 052 817 A1 10-g SACHET VOLKSWAGEN

3.79 Engine lubricant oil: Petrol, Ethanol -

VW 501 01
CASTROL 1 litre G 052 167 A1 VOLKSWA‐
MAGNATEC 200 litres G 052 167 M1 GEN
EXCLUSIVE
(SAE 10 W 40)
MOTUL 4100 MOTUL
TURBOLIGHT
(SAE 10 W 40)
PENTOLUB PENTOSIN
PERFORM‐
ANCE (SAE 10
W 40)
3.80 Engine lubricant oil: Petrol, Ethanol, To‐

talflex and NGV - VW 502 00
PROFESSIO‐
NAL MF (SAE
5 W 40)
EDGE PRO‐ GEN
FESSIONAL
A3 (SAE 0 W
30) agen
AG. Volkswagen AG d
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ELAION F50 YPF by Vo gu
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ELAION SUV YPF s au ra
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HAVOLINE CHEVRON
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IPIRANGA F1 IPIRANGA
wit
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SYNTHETIC
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SN 502 (SAE
es, in part or in w
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5 W 40)
MOBIL SU‐ MOBIL
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MOTUL 6100 MOTUL

SYNERGIE +
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nf
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en
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MOTUL 8100 MOTUL C py
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gh
X Clean (SAE
ht
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5 W 40)
co Vo
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Prote
PENTO‐ PENTOSIN
AG.
SYNTH (SAE
5 W 40)


SHELL HELIX SHELL
HX7 (SAE 5 W
40)
SHELL HELIX SHELL
ULTRA (SAE
5 W 40)
3.81 Lubricating oil for diesel engines - VW

505 00 AG. Volkswagen
agen AG do
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Trade Name y Vol Packaging Supplierot g
ua
db ran
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CASTROL 1tholitre
r
G 052 167 A1 VOLKSWA‐ tee o
MAGNATEC ss 200 litres au
G 052 167 M1 GEN
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PROFESSIO‐
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NAL (SAE 5 W
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ELAION F50 YPF
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ELAION SUV YPF
rrectness of i
(SAE 5 W 40)
l purpos
HAVOLINE CHEVRON
ULTRA S BRASIL
(SAE 5 W 40)
nf
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m
atio
MASTER
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SYNTHETIC
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SN 502 (SAE
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MOBIL SU‐ MOBIL

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PER 3000 X1
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(SAE 5 W 40) C py
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MOTUL 4100 yri
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TURBO‐ by c lksw
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LIGHT (SAE
Prote AG.
10 W 40)
MOTUL 6100 MOTUL
SYNERGIE +
(SAE 5 W 40)
MOTUL 6100 MOTUL
SYNERGIE +
(SAE 10 W
40)
MOTUL 8100 MOTUL
X Cess (SAE
5 W 40)
MOTUL 8100 MOTUL
X Clean (SAE
5 W 40)
PENTOLUB PENTOSIN
PERFORM‐
ANCE (SAE
10 W 40)
PENTO‐ PENTOSIN
SYNTH (SAE
5 W 40)


SHELL HELIX SHELL
HX7 (SAE 5 W
40)
SHELL HELIX SHELL
ULTRA E
(SAE 5 W 30)
3.82 Engine oil lubricant: Diesel - VW 507 00

CASTROL 1 litre G 052 195 R2 VOLKSWA‐
EDGE PRO‐ GEN
gen AG
. Volkswagen AG
d
FESSIONAL Vol
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not
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du
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SHELL HELIX SHELL
ULTRA EX‐
TRA (SAE 5
rrectness of i
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l purpos
SHELL HELIX SHELL

ULTRA ECT
(SAE 5 W 30)
nform
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MOBIL 1 ESP MOBIL

m
FORMULA at
om
ion
c
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3.83 Engine lubricant oil: Petrol and Totalflex

o
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ate
- VW 508 88
do
priv
cum
for
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t.
Trade Name Packaging Cop
yi
Supplier Co
py
t. rig
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gh by
ht
MAGNATEC GEN
cop Vo
by lksw
PROFESSIO‐ cted agen
Prote AG.
NAL 508 88
(SAE 5 W 40)
ELAION F50 YPF
PLUS (SAE 5
W 40)
MASTER
SYNTHETIC
SN (SAE 5 W
40)
MOTUL SPE‐ MOTUL
CIFIC 508 88
509 99 (SAE 5
W 40)
PENTO‐ PENTOSIN
SYNTH R
(SAE 5 W 40)
MOBIL SU‐ MOBIL
PER 3000 X3


HAVOLINE CHEVRON
ULTRA W
3.84 Diesel engine lubricant oil - VW 509 99

MAGNATEC GEN
PROFESSIO‐
NAL 508 88
(SAE 5 W 40)
ELAION F50 YPF
PLUS (SAE 5
W 40)
MASTER
SYNTHETIC
SN (SAE 5 W
40)
MOTUL SPE‐ MOTUL
CIFIC 508 88
509 99 (SAE 5
W 40)
PENTO‐ n AG. Volkswagen
PENTOSIN
AG do
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SYNTH R by Vol ot g
ua
(SAE 5 W 40) ir se
d ran
tee
ho
MOBIL SU‐ s aut
MOBIL or
ac
PER 3000 X3 s
ce
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nl
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HAVOLINE CHEVRON
du
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ULTRA W
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ab
ility
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3.85 Lubricating oil for manual gearbox and

wit
, is n
steering box - SAE 90, MIL-L-2105B,

h re
hole
spec
API-GL5
es, in part or in w
t to the co

CASTROL MAX‐ CASTROL
rrectness of i
TRON 90
l purpos
ESSO GEAR OIL ESSO

GX
IPIRGEROL SP 90 IPIRANGA
nf
ercia
orm
MOBILUBE HD 90 MOBIL
m
atio
m
LUBRAX TRM 5 PETROBRÁS

o
n in
or c
SHELL SPIRAX A SHELL

thi
te
sd
a
90
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MULTIGEAR EP 90 TEXACO
o
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f
en
ng
t.
yi Co
op
3.86 Lubricating oil for manual gearbox - SAE
C py
t. rig
gh ht
yri
80, MIL-L-2105, API-GL4
p by
co Vo
by lksw
cted agen
Prote AG.
IPIRGEROL EP 80 IPIRANGA
CASTROL UNI‐ CASTROL
TRON 80 W
ESSO GEAR OIL ESSO
GP 80 W
MOBILUBE GX 80 MOBIL
W


AG. Volkswagen AG d
agen
LUBRAX TRM -4 PETROBRÁS olksw
oes
not
byV gu
SHELL SPIRAX G SHELL rised ara
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80 W ut
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UNIVERSAL EP TEXACO ss
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un
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an
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75W90
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wit
is n
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spec
G 005 000 1 litre VOLKSWAGEN
t to the co
75W90
rrectne
ss
G 052 157 A2 0.5 litre VOLKSWAGEN
o
cial p
f inform
3.89 Special oil
mer
atio
om
n
c
i
or
n thi
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G 052 172 A1 30 ml VOLKSWAGEN

t
sd
iva
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G 052 172 M2 100 ml VOLKSWAGEN

p
cum
r
fo
en
ng
t.
yi
3.90 Oil for manual gearbox
Co
Cop py
ht. rig
rig ht
py by
Trade Name Packaging Supplier co Vo
by lksw
cted agen
Prote
AG.

75W90

75W90

75W90

75W90

AG. Volkswagen AG d
agen
3.95 Lubricating oil for Vmanual gearbox - SAE
w es n o
olks ot g
by ua
75W90 ed ran
ris tee
tho
u or
sa ac
Trade Name Packaging
s Supplier
ce
e
nl
pt
du
an
itte
y li
erm
ab
3.96 Lubricating oil for power steering
ility
ot p
wit
, is n
h re
hole
spec
G 004 000 M2 1 litre VOLKSWAGEN
es, in part or in w
t to the co
3.97 Lubricating oil for automatic gearbox
and power steering
rrectness of i
l purpos
325 029 901 1 20 litre VOLKSWAGEN
nf
ercia
o
3.98 Lubricating oil for the automatic gearbox
rm
m
atio
m
differential - SAE 75W90

o
n in
or c
thi
e

t
sd
iva
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rp
cu
G 052 145 S2 1 litre VOLKSWAGEN
o
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f
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ng
t.
yi Co
3.99 VW ATF oil for power steering Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
3.100 VW ATF oil for power steering

3.101 ATF oil for automatic gearboxes

3.102 VW ATF oil for power steering

3.103 Oil for gear selection mechanism

G 052 512 S1 1 litre VOLKSWAGEN
3.104 Air conditioning compressor oil - R 134a

3.105 Oil for the air conditioning compressor


3.106 Lubricating oil for assembly

AG. Volkswagen AG d
agen
3.107 White lubricating grease
oes
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y V gu
d b ara
rise nte
utho eo
ra
s a c
DUOTEMPI KLÜBER
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PMY-45
nl
pt
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MOLYKOTE D LUMOBRÁS
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erm
ab
ility
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3.108 Moly grease
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.109 Molybdenum bisulphate lubricating
rrectness of i
grease
l purpos

UNIMOLY R 55/10 KLÜBER
nform
ercia
MOLYKOTE G LUMOBRÁS
m
at
PASTE
om
ion
c
in t
or
3.110 Copper grease
his
ate
do
priv
cum
or

f
en
ng
t.
yi
MOLIKOTE (r) LUMOBRÁS
Co
Cop py
CU-7439 PLUS
t. rig
gh ht
pyri by
Vo
co lksw
by
3.111 Silicon grease cted agen
Prote AG.

3.112 High temperature paste

3.113 Primer
D 181,711 A1 10 ml VOLKSWAGEN
3.114 Glass primer

D 009 200 02 10 ML VOLKSWAGEN
3.115 Adhesive remover

D 002 000 A2 900 ML VOLKSWAGEN

3.116 Cleaning remover

LVM 020 100 A5 2.5 litres VOLKSWAGEN
3.117 Corrosive paste

GRATECRIL ACTI‐ 125 g TUBES GRATEC SISTEM
VATED TLB 1012
3.118 Odourless solvent

RUTILOS 40 20-LITER CON‐ QUAKER CHEMI‐
TAINERS CAL
FORMISOLV 710 20-LITER CON‐ FORMIQUIMICA
TAINERS
3.119 Cleaning solution

AG. Volkswagen AG d
Trade Name Packaging lksw
agenSupplier oes
not
Vo gu
y
D 009 401 04 250 ML ised b VOLKSWAGEN ara
nte
or eo
th
3.120 Engine leak detection spray au ra
ss c
ce
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un
pt
an
d
itte
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erm
G 001 800 A1 200 ML VOLKSWAGEN

ab
ility
ot p
3.121 Cylinder lubricating spray wit

is n
h re
ole,
spec
t to the co
G 052 778 A2 50 ML VOLKSWAGEN
3.122 Primer for polyurethane surface

rrectne

ss o
# 2287 1-LITER JARS VOLKSWAGEN

cial p
f inform
P.8220 0.9-LITER JARS VOLKSWAGEN

mer
atio
m
3.123 Adhesive sealant

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
3.124 Mixing tube C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
D 001 001 50 ml VOLKSWAGEN
Note
Can be used with D 001 730 A2

3.125 Liquid sealant

3.126 Silicone sealant for engines

D 176 404 M2 80 ML TUBES VOLKSWAGEN
3.127 Sealant for exhaust connections

AG. Vo lkswagen AG
TMX 386 3.6-LITER TINS SOLPLÁS agen does
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UV-93 3.6-LITER TINS BRASCOLA
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AIR DRYING SEAL‐ 3.6-LITER TINS thoHENKEL
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3.128 Teflon thread sealant
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VIBRA-SEAL 503 15 g and 250 g LOCTITE
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TUBES
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4 Work Instructions for Handling

Chemicals
4.1 General considerations
4.1.1 Solvent Handling

♦ Description of the Material
Solvents and their mixtures, e. g. hydrocarbons, halogens, alco‐
hols, esters, ketones are liquid organic materials. This Safety
Information applies to all solvents and water-free cleaning prod‐
ucts, and hardeners, primers, separators, and all preparations
used for this purpose as well.
Solvents can be classified as follows:
A - Irritant
B - Noxious
C - Toxic
D - Easily flammable
AG. Volkswagen AG d
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♦ Applications Prote
cted AG.
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painting, cleaning and maintenance of parts.

♦ Storage
4. Work Instructions for Handling Chemicals 23

Solvents must be stored in closed, identified safety containers.

Storing solvents in beverage bottles is strictly prohibited. Keep
only a volume sufficient to carry out the work in one shift in the
workplace. Volumes exceeding the daily requirement must be
stored in well ventilated, explosion-proof rooms.
♦ Work
Work with solvents requires the use of exhaust fans or environ‐
ments with good ventilation. Greater quantities of easily flamma‐
ble or flammable materials must be handled only in explosion-
proof locations. To prevent spontaneous combustion, solvents
must not come into contact with highly corrosive substances (e.g.
chromic acid, organic peroxides, etc.).
Thus, the following should be observed: agen
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1 - prevent contact with hot surfaces, alkalis, such as caustic ed bso‐
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2 - prevent contact with hot surfaces, alkalis, such ass caustic so‐
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3 - protect the material against sunlight.
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4 - do not use open flames, such as welding torches.
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In case of prolonged use or storage, mixtures of halogen and
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flammable solvents, such as cold cleaning products, classified as
spec
less flammable, may become flammable solutions, due to evap‐
es, in part or in w
oration of the halogen component.
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♦ Maintenance in confined spaces
rrectness of i
Solvent vapours are heavier than air. Thus, they concentrate in
wells and tanks. Accordingly, before starting work in these places,
l purpos
an "authorization for confined space" must be requested.

♦ Operational failures
nform
ercia
Spilt solvent must be collected using appropriate absorption prod‐

m
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ucts. The products should be stored in closed containers with
com
tion in
material identification and information on the content for future
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disposal.
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♦ Protection against fire

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When handling solvents, open flames, exposed lighting and

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smoking are prohibited. For fire extinguishers, use CO2 and dry
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♦ Health protection, hygiene at work
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1- When inhaled, most solvents have a narcotic effect and re‐

duce ethanol tolerance. Some solvents, even in small con‐
centrations, are noxious.
2- In case of severe intoxication, remove the person to an out‐
side or a well-ventilated location, until an ambulance arrives.
3- Work uniforms heavily-stained with solvent should be
changed and thoroughly cleaned.
4- Workers who have handled solvents and later complain
about health problems should consult a doctor immediately.
The doctor must be informed about the solvents handled by
the worker.
5- Solvents have a degreasing effect on the skin. Using sol‐
vents to clean the skin is prohibited. In case contact with the
skin is inevitable, treat the skin beforehand with protective
cream.
6- In workplaces where solvents are used, eating, drinking and
storing food, especially close to chemicals, are prohibited.

7- Smoking while handling solvents is prohibited, since there

is risk of fire or formation of products that cause toxic reac‐
tions in atmospheres with high hydrocarbon and halogen
contents.
♦ Personal protective equipment
In compliance with Standard 6 (NR-6) Ordinance 3214 of the
Ministry of Labour, handling solvents requires the use of personal
protective equipment, such as the following:
1 - gloves olkswage es n
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2 - safety goggles ir se
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3 - protective clothing ss
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♦ Environmental protection, waste treatment

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Solvents must not be disposed of in the sewer network. These
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closed and identified, for future disposal or recycling.
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4.1.2 Work instruction - Flammable material
hole
spec
handling
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Flammable liquids are liquids, liquid mixtures or liquids with solid
particles in solution or suspension (including substances classi‐
rrectness of i
fied in a different way, based on their hazardous characteristics)
producing flammable vapours at temperatures up to 60.5 °C, in
l purpos
open vessel tests.

Flammable materials may be solid, liquid or gaseous. As they re‐
nform
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lease oxygen, these materials burn and, under certain circum‐

stances, may ignite explosively. Flammable materials cause
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irritations, corrosion, and noxious and toxic reactions.
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In accordance with legislation, flammable materials are classified
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♦ Extremely flammable: Substances or liquid mixtures, of which

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♦ Easily flammable:
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substances or mixtures that may warm and ignite in the air at room
temperature, without interference from any energy source;
substances or solid mixtures that may easily ignite after a brief
contact with an ignition source and that keep burning after the
source is removed;
For liquid substances, the flash point is lower than 21 °C. In con‐
tact with water or humid air, extremely flammable gases are
released in dangerous volumes;
♦ Flammable: substances or liquid mixtures, the flash point of
which is equal to or higher than 21 °C and lower than or equal
to 55 °C.
Handling these materials requires that the following be observed:
1- In places of work and storage, floors, desks or racks made
of wood should not be used. The floor must be kept clean.
2- Eating, drinking, smoking, and storing food or cigarettes are
prohibited at the workplace and areas close to it.
3- The required personal protective equipment, such as safety
goggles, gloves, and, where applicable, aprons and rubber
boots, must be used.
4- Wet or excessively dirty clothing must be promptly changed.
This clothing must not be dried. Work clothes - even those

slightly dirty - must be sorted and marked with the following

warning before being sent to laundry: "CLOTHING CON‐
TAMINATED WITH FLAMMABLE MATERIALS". These
clothes must be washed in water.
5- Contaminated or wet personal clothes must also be washed
in water at home.
6- Flammable materials must not come into contact with or‐
ganic substances, such as oil, grease, and solvent, since
there is risk of fire.
7- While handling flammable materials, prevent spillage and
dust. In case of leaks, spilt products must not be adsorbed
by sawdust or disposed of in trash cans.
8- Solid flammable materials must be swept or wet with ab‐
sorption products. These materials must be collected into
proper containers and sent, with indication of content, for
disposal.
9- In case flammable materials come into contact with the skin
or eyes, wash them promptly with plenty of water (for at least
15 minutes). Then, consult a doctor. Inform about the prod‐
uct affecting the person.
4.1.3 Handling used engine oil

♦ Description of the material
Oils for four-cylinder engines comprise basically superior hydro‐
carbons with additives. At temperatures that can reach over 450
ºC on the bottom of the piston, oxidation and other chemical re‐
actions take place. In these processes reactive products are
formed, such as "polycyclic aromatic hydrocarbons".
♦ Applications
Used engine oil is produced mostly in engine test workshops after wage
es n
long-running operational tests. It is also produced during yoil Volks ot g
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change, for example, at a customer service centre, and edfrom ve‐
b ran
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hicles undergoing durability tests. For sealing quality
uth control,
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or
these engine oils are submitted to thermal load.ss a ac ce
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♦ Storage
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Used engine oil must be collected and temporarily stored into

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metal containers with locks and the following warning:

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“Caution. Used engine oil.” Prevent contact with skin.

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♦ Work
spec
es, in part or in w
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Production-scale work at recovery facilities, unproductive appli‐

cation in used oil coagulation.
♦ Maintenance
rrectness of i
Observe the following items during maintenance activities: Oper‐

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ating failures - Leaks, Fire protection and Occupational hygiene

and health preservation.
nform
ercia
♦ Operational failures - Leaks

m
at
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In case spilt oil absorption is required, the spilt product must be

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stored in closed containers for future disposal.

in t
or
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ate
♦ Protection against fire

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Engine oils are not classified as flammable materials, since their

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flash points are above 100 ºC. To prevent spontaneous ignition,
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fire or explosion, cloths or other absorbent materials impregnated
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with oil must be stored in non-flammable containers with a cover.
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♦ Health protection and hygiene at work
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Prote AG.

Prolonged or repetitive contact with any type of engine oil results

in skin degreasing. Skin drying, irritation or inflammation may oc‐
cur. In addition, used engine oils contain hazardous substances
classified as "polycyclic aromatic hydrocarbons". The following
work hygiene precautions should be observed:
1- Before handling used engine oils, apply appropriate skin
protection.
2- Preferentially, use warm water and soap to remove engine
oil from skin.
3- Solvents, cold cleaners, thinners, diesel oil should not be
used for cleaning skin contaminated with engine oil.
♦ Personal protection equipment
The following equipment should be used:
- Goggles
- Sleeves
- Aprons
♦ Environmental protection, waste treatment
. Volkswagen AG
a gen AG d
Used oils are classified as liquids hazardous
Vol
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oes
not
gu
pose of used oil in the sewer system
ed by or the soil. ara
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5 Application guide
5.1 Application guide

Repair group - 10 - Cylinders, Cylinder block, Support, Protector
APPLICATION VALIDITY
Cylinder base gasket - lubri‐ 1.6-litre, air-cooled engine
cate ⇒ page 36
Air-cooled engine housing - 1.6-litre, air-cooled engine
seal ⇒ page 37
Cylinder block plugs - fasten Water-cooled engines
⇒ page 39
Cylinder block plugs - seal 1.6-litre engine ⇒ page 38
Repair group - 13 - Crankshaft group
Needle bearing of the fasten‐ Air-cooled engines ⇒ page 41
ing hollow screw for the fly‐
wheel - lubricate
Crankshaft needle bearing - Engines - 1.6 , 1.8 and 2.0 L EA
lubricate 827 , 2.0 L 16 V , 1.0 , 1.4 and
1.6 L - EA 111 , 1.0 16 V -AG
EA
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111 , 1.8 and 2.0 oLlks-wEA does
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⇒ page 40 ed by V gu
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Flywheel fastening screw - Air-cooleduth engines ⇒ page 42
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lock ss
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Repair group - 15 - Cylinders, Cylinder block, Support, Protector pt

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APPLICATION VALIDITY ab
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Intermediate shaft seal - lu‐ Engines - 1.6, 1.8 and 2.0 L EA

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bricate for assembly 827 ⇒ page 43

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spec
Camshaft valve bearing cov‐ Engines - 1.0-litre - EA 111

es, in part or in w
er (1st and 5th) - Seal (Tasse) ⇒ page 44

t to the co
Cylinder head sealing gasket Air-cooled engines ⇒ page 45

- glue
rrectness of i
Lower rear threaded pins fas‐ Air-cooled engines ⇒ page 46

tening the cylinder head - rear
l purpos
threaded pin (crankshaft) /

lower front threaded pins (fly‐
wheel) - Seal
nform
ercia
Cylinder head cover - seal Engines - 1.0 L - EA 111 , 1.0 16

m
V - EA 111 ⇒ page 49
com
tion in
Cylinder head cover - seal 8 V engine RSH - ⇒ page 48

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Cylinder head cover - seal 8 V Tasse Engine - ⇒ page 47

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Repair group - 17 - Lubrication system

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APPLICATION VALIDITY t. C rig
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Engine crankcase - Fill / top Engines - all ⇒ page 50
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up oil level
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Prote AG.
Engine crankcase - Fill / top 2.4 L Engine - Caravelle and Eu‐

up oil level rovan ⇒ page 50
Engine crankcase - Fill / top 2.0-litre engine - Amarok
up oil level ⇒ page 50

Engine crankcase - seal Engines - 1.6 , 1.8 and 2.0 L EA
827 , 1.0 , 1.4 and 1.6 L - EA 111 ,
1.0 16 V - EA 111 , ⇒ page 52
Junction between crankcase Engines - 1.6, 1.8 and 2.0 L EA
gaskets and crankshaft front 827 - UNF, UPQ, UDH, UQG -
and rear flange gasket - seal 2.0L 16 V ⇒ page 51
Repair group - 19 - Cooling system
Cooling system (G11) - fill / Engines - all until 05/01/2000
adjust additive proportion. ⇒ page 53
Cooling system (G13) - fill / Engines - all from 05/02/2000
adjust additive proportion. ⇒ page 54
Repair group - 20 - Fuel tank, fuel pump
Fuel tank - add additive All petrol-only models
⇒ page 55
Accelerator pedal shaft - lu‐ All (except Kombi and E-gas ve‐
bricate hicles) ⇒ page 56
Accelerator pedal fastening - Kombi ⇒ page 57
lubricate
Accelerator cable and cable Kombi ⇒ page 58
end - accelerator pedal fas‐
tening - lubricate
Repair group - 26 - Exhaust system
Exhaust connection - seal All ⇒ page
AG. 59
Volkswagen AG
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Repair group - 28 - Ignition ed system,
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APPLICATION aut
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VALIDITY ra
ss c
Ignition coils with final power All ⇒ page 60
ce
le
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stage - lubricate
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Repair group - 30 - Clutch - control system

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Clutch pedal bung - lubricate Gol GTI 16 V and Parati GTI 16

spec
V ⇒ page 61
t to the co
Clutch control cable - lubri‐ Gol, Parati, Saveiro and Santana

cate ⇒ page 62
Clutch fork, contact with bear‐ Gearboxes - 013 ⇒ page 63
rrectne
ing - lubricate
Clutch fork bungs - lubricate Gearboxes - 013 ⇒ page 64
ss o
cial p
Wing nut for clutch control ca‐ Gearbox - 081 ⇒ page 65

f in
ble adjustment - lubricate

form
mer
Sealing ring for the clutch Gearboxes - MQ 200 and 250

atio
m
bearing guide - lubricate for ⇒ page 66

o
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i
or
assembly
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Clutch cable - lubricate Kombi ⇒ page 67

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Clutch fork and clutch actuat‐ Gearbox -081 ⇒ page 68

fo
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ing lever - lubricate

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Clutch pedal fastening - lubri‐ Kombi ⇒ page 69
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5. Application guide 29
Clutch actuating lever - lubri‐ Gearbox -081 ⇒ page 70
cate
Input shaft splines - lubricate Gearboxes - 013 1.0 L , 013 -
1.6 , 1.8 E 2.0 L ⇒ page 71
Clutch pedal / clutch pedal All (except Kombi) ⇒ page 72
bung
Pedal support - seal Gol , Parati, and Saveiro - 98 ►
⇒ page 73
Clutch fork contact with the Gearbox - CNX ⇒ page 74
hydraulically activated cylin‐
der of the gearbox clutch -
lubricate
Fastening flange for clutch Gearbox - CNX ⇒ page 75
slave cylinder - seal
Repair group - 34 - Drive, housing
Linkage rod, front/rear sec‐ Kombi ⇒ page 76
tion - lubricate
Gear lever bearing - lubricate All (except Kombi) ⇒ page 77
Manual gearbox - Fill / top up Gearbox - CNX ⇒ page 78
level
Manual gearbox - Fill / top up Gearboxes - 013 - 1.0 L 013 -
level 1.6 , 1.8 E 2.0 L ⇒ page 79
Manual gearbox - Fill / top up Gearbox - MQ 250 ⇒ page 80
level
Manual gearbox - Fill / top up Gearbox - MQ 200 ⇒ page 81
level
Manual gearbox - Fill / top up eGearbox AG. Volks-w081
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Kombi
level ag n
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does
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Plastic sleeves forristhe
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rod coupling system
utho / linkage ⇒ page 83 eo
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rod / supportsss a(on the gear‐ c
box)
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Gear lever guide plate - lubri‐ Kombi ⇒ page 84

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Rubber shim for the clutch Gol, Parati, Saveiro and Santana
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compartment cover - glue ⇒ page 85

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Clutch compartment cover - Gol, Parati, Saveiro and Santana

hole
spec
seal ⇒ page 86
es, in part or in w
t to the co
Linkage rod bellows for the Gol, Parati, Saveiro and Santana
gear lever assembly - fasten / ⇒ page 87
seal
rrectness of i
Housing junction (transfer Gearbox - CNX ⇒ page 88

box / differential) and differ‐
l purpos
ential cover housing - seal

Gear lever handle - fasten Gol, Parati, Saveiro and Santana
nform
ercia
⇒ page 89
m
Gearbox cushion - lubricate Polo and Fox manual gearbox

com
tio
⇒ page 91
n in
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Fastening screw for the rear Gearboxes - 013 - 1.0 L 013 -

s
iva
support of the gearbox cush‐ 1.6 , 1.8 E 2.0 L ⇒ page 90

do
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Gear selection mechanism - Automated gearboxes SQ 200
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fill up ⇒ page 92
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Electric connectors of the Automated gearboxes SQ 200
gear selection mechanism - ⇒ page 93
apply nyogel AG. Volkswagen AG d
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Repair group - 35 - Gears d b and shafts
y gu
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APPLICATION s a ut
VALIDITY ra
c
s
Input shaft splines - lubricate Gearbox - 081 ⇒ page 94
ce
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nl
pt
du
an
Fastening screw for the 5th Gearboxes - 013 - 1.0 L , 013 -
itte
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gear synchronizer / clutch as‐ 1.6 , 1.8 E 2.0 L ⇒ page 95
erm
ab
sembly - lock
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Repair group - 37 - Drive, housing
h re
hole
spec
es, in part or in w
t to the co
Planetary gear box (automat‐ Gearbox - 01M ⇒ page 96
ic gearbox) - Fill / top up oil
level
rrectness of i
Planetary gear box (automat‐ Gearbox - 09A ⇒ page 97
l purpos

level
nform
ercia
Planetary gear box (automat‐ Gearbox - 09G ⇒ page 98

m
at
level
om
ion
c
in t
or
Repair group - 39 - Gearbox shafts, differential

his
ate
do
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p
cum
for
en
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Gearbox side seals - lubricate Gearboxes - 013 - 1.0 L 013 - 1.6,

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1.8 and 2.0 L 081 ⇒ page 99 C py
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Planetary and satellite gears Gearbox - 081 ⇒ page 100 pyri by
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- lubricate for assembly
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Automatic gearbox differen‐ Gearbox - 01M ⇒ page 101
tial - top up oil level
Differential cover with gear‐ Gearboxes - 013 - 1.0 L , 013 -
box housing - seal 1.6 , 1.8 E 2.0 L ⇒ page 102
Repair group - 40 - Front suspension
Constant velocity joint spline Gol, Parati, Saveiro and Santana
- lubricate ⇒ page 103
Inner and outer constant ve‐ Gol, Parati, Saveiro and Santana
locity joint - lubricate ⇒ page 104
Front wheel bearing mount‐ Gol, Parati, Saveiro and Santana
ing - lubricate ⇒ page 105
Axle end - lubricate Kombi ⇒ page 106
King pin bearing - lubricate Kombi ⇒ page 108
Front axle beam - lubricate Kombi ⇒ page 109
Suspension arms - lubricate Kombi ⇒ page 110
Front wheel bearing - lubri‐ Kombi ⇒ page 111
cate
Passage hole for the speed‐ Kombi ⇒ page 112
ometer cable in the wheel hub
protector - seal
Repair group - 42 - Rear suspension AG. Volkswagen AG d

agen oes
lksw not
APPLICATION VALIDITY d by Vo gu
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Inner and outer constant ve‐ Kombi ⇒ page 104 utho eo
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locity joint - lubricate ss a c
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le
Shaft end splines - lubricate Kombi ⇒ page 114
un
pt
an
d
Rear torsion bar - lubricate Kombi ⇒ page 115
itte
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ab
Rear wheel hub - lubricate Kombi ⇒ page 116
pe
ility
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Rear wheel hub seal - lubri‐ Kombi ⇒ page 117
wit
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cate
h re
hole
spec
Rear wheel bearing - lubri‐ Kombi ⇒ page 118
cate es, in part or in w
t to the co
Repair group - 46 - Brakes - Mechanical systems
rrectness of i
l purpos
Rear wheel brake shoe ends Gol, Parati, Saveiro, Santana

- lubricate and Kombi ⇒ page 119
nform
ercia
Handbrake cable terminal - Gol, Parati, Saveiro and Santana

lubricate ⇒ page 120
m
a
com
t
Brake pedal safety pin - lubri‐ Gol, Parati, Saveiro and Santana
ion in
cate ⇒ page 121
r
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thi
Securing pin for the operating Kombi ⇒ page 123
s
iva
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rod of the master cylinder
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plunger - lubricate
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ng
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Securing pin of the hand‐ Gol, Parati, Saveiro and Santana Cop py
brake lever - lubricate ⇒ page 123
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Handbrake ratchet - lubricate Kombi ⇒ page 124
co Vo
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cted agen
Prote AG.
Repair group - 47 - Brakes - Brake servo hydraulic system
Brake system - fill / top up All ⇒ page 125
Guide pin for the support of Gol, Parati, Saveiro and Santana
the front disc brake cylinder ⇒ page 126
(manufactured by Varga) - lu‐
bricate
Fastening screw for the front Gol, Parati, Saveiro and Santana
disc brake cylinder housing - with Vargas brake system
lock ⇒ page 127
Repair group - 48 - Steering
Oil reservoir for the power Santana, Gol, Parati, Saveiro,
steering system - Fill / top up Polo and Fox. ⇒ page 128
oil level
Oil reservoir for the power Santana, Golf, Passat, Polo
steering system - Fill / top up Classic, Fox, Polo and Saveiro
oil level ⇒ page 129
Steering box - Fill / top up oil Kombi ⇒ page 130
level
Steering box mechanism - lu‐ Gol , Parati , Saveiro (Genera‐
bricate tion II , III and IV) and Santana
⇒ page 131
Adapter (sleeve) for the up‐ Gol, Parati, Saveiro and Santana
per steering shaft - lock ⇒ page 132

Repair group - 53 - Body - Rear section

Bucket sealing membrane - Saveiro Generation II , III and IV
glue ⇒ page 133
Rear side panel - protect the Saveiro Generation II , III and IV
paint ⇒ page 134
Repair group - 55 - Covers, Protector
Bucket protective cover lon‐ Saveiro ⇒ page 135
gitudinal member - glue the
finishing
Lower latch of the bonnet - lu‐ Gol, Parati, Saveiro and Santana
bricate ⇒ page 136
Damper eyelet for the rear All ⇒ page 137
and front lid
Tailgate buffer - lubricate Saveiro 2013 ► ⇒ page 10
Repair group - 57 - Front doors / components / central lock
Front door lock - lubricate Gol, Parati, Saveiro and Santana
⇒ page 138
Lock drive rod - lubricate Kombi ⇒ page 139
Noise insulation for lock op‐ All (except vehicles with cable
erating rod - glue operation) ⇒ page 140
Inner door seal - glue Kombi ⇒ page 141
Repair group - 58 - Rear doors / components
Rear door lock - lubricate Gol, Parati, Saveiro and Santana
AG. Volks⇒
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Repairuthgroup - 64 - Windscreens, windows, windowemechanisms
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wit
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Vent window latch - lubricate Kombi ⇒ page 145

h re
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spec
Front door window support - Kombi ⇒ page 146

lubricate
t to the co
Front door window activation Kombi ⇒ page 146

mechanism - lubricate
rrectne
Window crank fastening All (fastened with screw)

screw - lock ⇒ page 147
s
Windscreen, side window All (except windows with finish‐

s o
glass and rear window glass ing) ⇒ page 149

cial p
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- glue
form
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Windscreen, side window All (except glued windows)

atio
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glass and rear window glass ⇒ page 150

o
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5. Application guide
Repair group - 66 - External equipment

Roof rack fastening screws - Santana, Quantum and Parati
lock ⇒ page 154
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APPLICATION VALIDITY hor eo
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ce
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port - fasten
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Door noise insulation - glue All ⇒ page 156
hole
spec
Noise insulation on rear side All ⇒ page 157
es, in part or in w
t to the co
panel - glue
Roof noise insulation - glue All ⇒ page 158
Door sealing membrane - All ⇒ page 159
rrectness of i
glue
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Repair group - 72 - Seat framework
nf
ercia
orm
m
Front seat central sliding Gol, Parati, Saveiro and Santana
atio
m
guide - lubricate ⇒ page 160

o
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te
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- lubricate ⇒ page 161

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Air conditioning system - refill All ⇒ page 163

with oil
Air conditioning pressure Gol, Parati, Saveiro and Santana
switch - seal ⇒ page 164
Repair group - 90 - Instrument case, indicators
Windscreen ultrasound sen‐ Santana ► 12.01, Gol and Parati
sor - fasten ► 04.99
Repair group - 92 - Windscreen, rear window and headlight wiper
and washer
Windscreen wiper operating Kombi ⇒ page 165
rod - lubricate
Windscreen/rear window All ⇒ page 166
washer water tank - fill
Repair group - 94 - Switches, lights, and external bulbs
Contact blade for turn signal All ⇒ page 167
switch - lubricate

Repair group - 97 - Cables and electric harnesses

Gaskets for the plastic covers All ⇒ page 168
that cover the electric har‐
nesses - seal
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6 Repair Group 10 - Cylinders, cylinder

block, support, protector
WARNING
Check the regulations on the disposal of each product and

packaging as per manufacturer's guidelines and current legis‐
lation at local, state and federal level.
dling Chemicals ”.
6.1 Cylinder base gasket - lubricate
- Air-cooled engines
- Product used
- Multi-purpose grease
⇒ page 10
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6.2 Engine housing - seal
- Product used
- Sealing adhesive ⇒ page 7
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6. Repair Group 10 - Cylinders, cylinder block, support, protector 37

AG. Volkswagen AG d
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6.3 Engine housing plugs - fasten
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AG. V kswagen AG d
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6.4 Cylinder block plugs - fasten
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chanical seal ⇒ page 6
h re
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6. Repair Group 10 - Cylinders, cylinder block, support, protector 39

7 Repair Group 13 - Crankshaft group
WARNING

dling Chemicals”.
7.1 Crankshaft needle bearing
- All, except automatic gearbox

- Product used
⇒ page 10 agen
AG. Volkswagen AG d
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7.2 Needle bearing of the fastening hollow screw for the flywheel
- Product used
⇒ page 10
AG. Volkswagen AG d
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7. Repair Group 13 - Crankshaft group 41

7.3 Flywheel fastening screw - lock
- All
- Product used AG. Volkswagen AG d
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⇒ page 6 rise
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8 Repair Group 15 - Cylinder head,

valve gear
WARNING

dling Chemicals”.
AG. Volkswagen AG d
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olksw not
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8.1 Intermediate shaft seal - lubricate for assembly orised ara
nte
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- AP engines, 1.6, 1.8 and 2.0
ce
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y li
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- Lubricating paste for constant
ot p
velocity joints ⇒ page 13
wit
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8. Repair Group 15 - Cylinder head, valve gear 43

8.2 Camshaft valve bearing cover (1st and 5th) - Seal
- AT engines, except RSH

- Product used
- Sealing compound for en‐
gines ⇒ page 13
AG. Volkswagen AG d
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8.3 Cylinder head sealing gasket - glue
- Product used
- Sealing gasket adhesive
⇒ page 5
AG. Volkswagen AG d
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8.4 Lower rear threaded pins fastening the cylinder head - rear threaded pin
(crankshaft) / lower front threaded pins (flywheel) - Seal
- Product used
- Sealing adhesive ⇒ page 7
AG. Volkswagen AG d
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8.5 Cylinder head cover - seal
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gines ⇒ page 13 Volksw
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Chemicals Manual - Edition hor02.2016
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- 8V engine - RSH
pe
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9 Repair Group 17 - Lubrication system
WARNING

dling Chemicals”.
9.1 Engine crankcase - Fill / top up oil level
- Product used
- Engines - All up to 11/2002 ,
except Passat 2001 ►
- Multi-purpose engine lubri‐
cating, as per VW 501 01
standard ⇒ page 14
- Engines - For Passat 2001 ►
and all as of 12/2002 ►
12/2014
- Engine lubricating oil with
high lubricating capacity, as
per VW 502 00 standard
⇒ page 14
- Engines - all totalflexo2015age
lksw ► es n
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- Engine lubricating
ris
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au
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ac
per VW 508 ss 88 standard
⇒ page 16
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- Lubricating oil for diesel en‐

wit
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gines - according to standard

ole,
VW 505 00 ⇒ page 15
spec
- Engines - 2.0 T Amarok (with‐

t to the co
out diesel particulate filter -

DPF)
rrectne
- Lubricant oil for diesel en‐

gines, according to standard
s
VW 509 99 ⇒ page 17
s o
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- Engines - 2.0 T Amarok (with

nform
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mer
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i
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9.2 Junction between crankcase gaskets and crankshaft front and rear flange
gasket - seal
- AP engines with solid crank‐

case gasket
- Product used
- Engine sealing adhesive
⇒ page 6
AG. Volkswagen AG d
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9. Repair Group 17 - Lubrication system 51

9.3 Engine crankcase - seal
- Engines without solid crank‐

case gasket
- Product used
- Silicone sealant for engine
⇒ page 22
AG. Volkswagen AG d
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10 Repair Group 19 - Cooling system
WARNING

lation at local, state and federal
olkswagelevel. es n
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Observe the information
ris
ed in Chapter “Work Instructions for Han‐
ara
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10.1 G11 cooling system - fill / adjust additive proportion
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rrectness of i
⇒ page 7
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10. Repair Group 19 - Cooling system 53

10.2 G13 cooling system - fill / adjust additive proportion.
- Water-cooled engines
*Forvehicles manufactured as
from 05/02/2000
- Product used
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⇒ page 7
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11 Repair Group 20 - Supply system -

tank, fuel pump
WARNING

dling Chemicals”.
11.1 Fuel tank - add additive
- Petrol-only vehicles
- Product used
- Petrol additive ⇒ page 8
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11. Repair Group 20 - Supply system - tank, fuel pump 55

11.2 Accelerator pedal shaft - lubricate
- All (except Kombi and E-gas

vehicles)
- Product used
- White lubricating grease
⇒ page 20
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en AG. V
olkswagen AG Chemicals Manual - Edition 02.2016
ag does
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11.3 Accelerator pedal fastening - lubricate
b ara
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au ra
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11. Repair Group 20 - Supply system - tank, fuel pump 57

11.4 Accelerator cable and cable end - accelerator pedal fastening - lubricate
- Kombi
- Product used
⇒ page 9
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12 Repair Group 26 - Exhaust system
WARNING

dling Chemicals”.
12.1 Exhaust connection - seal

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12. Repair Group 26 - Exhaust system 59

13 Repair Group - 28 - Ignition system,

pre-ignition system
WARNING

packaging as per manufacturer's guidelines and. Vcurrent legis‐
olkswagen AG
lation at local, state and federal level. kswagen AG does
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⇒ page 20
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AG. Volkswagen AG d
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14 Repair Group 30 - Clutch - control
oes
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14.1 Clutch pedal bung - lubricate
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16 V
nf
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14. Repair Group 30 - Clutch - control system 61

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Fox 2004
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Chemicals
s Manual - Edition 02.2016
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un
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14.2 Clutch control cable - lubricate
itte
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Note
ss o
Lubrication of the cable end fitted in
cial p
f in
the clutch lever, in the gearbox, is
form
mer
only valid for 1.6, 1.8 and 2.0 L en‐
atio
gines manufactured until 12/02/98
om
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14.3 Clutch fork, contact with bearing - lubricate
- Gearboxes
013 - 1.0 L
013 - 1.6, 1.8 and 2.0 L
- Product used
AG. Volkswagen AG d
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14.4 Clutch fork bungs - lubricate
- Gearboxes
013 - 1.0 L
013 - 1.6 L , 1.8 L and 2.0 L
- Product used
olkswagen AG
en AG. V
- Lubricating paste for constant ksw
ag does
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Vol
velocity joints ⇒ page 13 ed
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or e
h
Fox 2004aut ➤ , Fox 2010 ➤ , Fox 2014 ➤ , Gol 1995 ➤ , oGol ra
c
1999 ➤ , Gol ...
s
s Chemicals Manual - Edition 02.2016
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un
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d
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14.5 Wing nut for clutch control cable adjustment - lubricate
y li
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- Gearbox
h re
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spec
081
t to the co
- Product used
rrectne
⇒ page 10
ss o
cial p
f inform
mer
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14.6 Sealing ring for the de-clutch bearing guide - lubricate for assembly
- Gearboxes
❑ MQ 200
❑ MQ 250
- Product used
⇒ page 10
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14.7 Clutch cable - lubricate
- Kombi
- Product used
⇒ page 9
AG. Volkswagen AG d
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14.8 Clutch fork and clutch actuating lever - lubricate
- Gearbox
❑ 081
- Product used
⇒ page 9
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14.9 Clutch pedal fastening - lubricate
- Kombi
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⇒ page 9
AG. Volkswagen AG d
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14.10 Clutch actuating lever - lubricate
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⇒ page 9 db
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14.11 Input shaft splines - lubricate n AG. Volkswagen AG do

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❑ 013 - 1.0 L ss
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ce
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2.0 L
an
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⇒ page 9 hole
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14.12 Clutch pedal / clutch pedal bung - lubricate
- All (except Kombi)

- Product used
⇒ page 20
AG. Volkswagen AG d
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14.13 Pedal support - seal
- Product used
- Sealing compound
⇒ page 13
-7X0 898 539-
AG. Volkswagen AG d
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14.14 Clutch fork contact with the hydraulically activated cylinder of the gearbox
clutch - lubricate
- Gearbox -
- Product used
- Copper grease ⇒ page 20
AG. Volkswagen AG d
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Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , gGol 1995
n AG. Volks➤
wa,ge
Gol
n AG1999 ➤ , Gol ...
wa e does
Vo Chemicals Manual - Edition
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g
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14.15 Fastening flange for clutch slave cylinder - seal tho
or
au ac
ss
ce
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un
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an
- Gearbox - ⇒ Item (page 74)
d
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15 Repair Group - 34 - Drive, housing

agen
AG. Volkswagen AG d
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WARNING ho
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Check the regulations on the disposal s
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15.1 Linkage rod, front/rear section - lubricate
t to the co
- Kombi
rrectness of i
- Product used
l purpos
⇒ page 10
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15.2 Gear lever bearing

tana
- Product used
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⇒ page 10
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15. Repair Group - 34 - Drive, housing 77

15.3 Manual Gearbox - fill / top up level
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- Product used
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15.4 Manual gearbox - Fill / top up level
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- Gearbox - MQ 250
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75W90 ⇒ page 18
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AG. Volkswagen AG d
♦ -G 052 512 A2- - 1 liter ksw
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- Gearbox - MQ 200
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75W90 ⇒ page 19
♦ -G 052 512 A2- - 1 liter
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- Gearbox - 081 - Kombi

- Product used
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gearbox and steering box -
SAE 90, MIL-L-2105B, API-
GL5 ⇒ page 17
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15.8 Plastic sleeves for the linkage rod coupling system / linkage rod / supports
(on the gearbox) - lubricate

tana gen AG
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20. Repair Group - 42 - Rear suspension 113

20.2 Shaft end splines - lubricate
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⇒ page 9
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20.3 Rear torsion bar - lubricate
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20.5 Rear wheel hub seal - lubricate
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21. Repair Group - 46 - Brakes - Mechanical systems 119

21.2 Handbrake cable terminal - lubricate

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21.3 Brake pedal safety pin - lubricate
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21.4 Securing pin for the operating rod of the master cylinder plunger - lubricate
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⇒ page 9
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21.5 Securing pin of the handbrake lever - lubricate

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21.6 Handbrake ratchet - lubricate
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22 Repair Group - 47 - Brakes - Brake

servo hydraulic system
WARNING

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22.1 Brake system - fill / top up
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⇒ page 9
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22. Repair Group - 47 - Brakes - Brake servo hydraulic system 125

22.2 Guide pin for the support of the front disc brake cylinder (manufactured by
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22.3 Fastening screw for the front disc brake cylinder housing - lock

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22. Repair Group - 47 - Brakes - Brake servo hydraulic system 127

23 Repair Group - 48 - Steering
WARNING

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23.2 Oil reservoir for the power steering system - fill / top up oil level
- Santana (1), Gol (2) , Golf,

Passat, Polo Classic, Fox (3),
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(1)From
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(2)
Export to Russia and Ka‐
zakhstan.
(3)With electric power steering.
(4)As
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000 M2- ⇒ page 19
AG. Volkswagen AG d
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23. Repair Group - 48 - Steering 129

23.3 Steering box - Fill / top up level
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MIL-L-2105B, API-GL5
⇒ page 17
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23. Repair Group - 48 - Steering 131

AG. Volkswagen
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23.5 Adapter (sleeve) forssthe upper steering shaft - lock au ra
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24. Repair Group - 53 - Body - Rear section 133

24.2 Rear side panel - protect the paint
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⇒ page 8
❑ 1 - Polyurethane adhe‐
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nl
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25. Repair Group - 55 - Covers 135

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25.2 Lower latch of the bonnet - lubricate ss
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25.3 Damper eyelet for the rear cover - lubricate or ac
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25. Repair Group - 55 - Covers 137

26 Repair Group - 57 - Front doors /

components / central lock
WARNING

dling Chemicals”.
26.1 Front door lock - lubricate

tana agen
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26.2 Lock drive rod - lubricate ed
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26. Repair Group - 57 - Front doors / components / central lock 139

26.3 Noise insulation for lock operating rod - glue
- All (except vehicles with cable

operation)
- Product used
ing ⇒ page 6
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26.4 Inner door seal - glue
- Kombi
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ing ⇒ page 6
AG. Volkswagen AG d
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26. Repair Group - 57 - Front doors / components / central lock 141

27 Repair Group - 58 - Rear doors / com‐

ponents
WARNING
AG. Volkswagen AG d
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ol not
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⇒ page 9
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27.2 Side door lock - lubricate
- Kombi
- Product used
⇒ page 9
AG. Volkswagen AG d
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27. Repair Group - 58 - Rear doors / components 143

Chemicals Manual - Edition
AG. Vo02.2016
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28 Repair Group - 64 - Windscreens,
thoris tee
or
au
swindows, window mechanism
s ac
ce
e
nl
pt
du
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WARNING
erm
ab
ility
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es, in part or in w
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rrectness of i
28.1 Door window activation mechanism - lubricate
l purpos
nform
ercia
tana
m
at
om
i
- Product used
on
c
in t
or
his
ate
⇒ page 9
do
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28.2 Vent window latch - lubricate
- Kombi
- Product used
⇒ page 9
AG. Volkswagen AG d
agen oes
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28. Repair Group - 64 - Windscreens, windows, window mechanism 145

AG. Volkswagen AG d
agen oes
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28.3 Front door window support - lubricate ol not
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pe
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⇒ page 9
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l purpos
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te o
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28.4 Front door window activation mechanism - lubricate
- Kombi
- Product used
⇒ page 9
AG. Volkswagen AG d
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28.5 Window crank fastening screw - lock
- All (fastened with screw)

- Product used
sive ⇒ page 7
AG. Volkswagen AG d
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28.6 Windscreen, side window glass and rear window glass - glue
- All (except windows with

packing)
- Product used
- Glass adhesion kit
AG. Volkswagen AG d
❑ Total drying time: agen oes
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U-400 HVBN Adhesive :orpartial
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3 h , total 72 h / 5500SA
aut Pri‐
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28.7 Windscreen, side window glass and rear window glass - seal
- All (except glued windows)

- Product used
- Sealing compound
⇒ page 13
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28.8 Glass - engrave chassis number
- All
- Product used
- Corrosive paste ⇒ page 21
❑ The destructible labels -
VIS are only supplied
exclusively to the gov‐
ernmental traffic-related
bodies (Detrans / Cire‐
trans) or Security bodies
(Police Station). On the
Network Website, under
“After Sales Service ” ,
“Services Information
System” Memorandum
no. 98/09 of 06/16/2009
can be found “Engrav‐
ing the chassis number
(VIS) on windows ”.
lkswage es n
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28.9 Front and rear door window guide groove - glue
- Kombi
- Product used
ing ⇒ page 6
AG. Volkswagen AG d
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28.10 Vent window - seal
AG. Volkswagen AG d
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agen oes
not
ol
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or eo
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s aut ra
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⇒ page 13 s
ce
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❑ -7X0 989 539-
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29 Repair Group - 66 - External equip‐

ment
WARNING

dling Chemicals”.
29.1 Roof rack fastening screws - lock
- Santana, Quantum and Par‐

ati
- Product used
⇒ page 6
AG. Volkswagen AG d
agen oes
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rise nte
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30 Repair Group - 68 - Internal equip‐

ment
WARNING

AG. Volkswagen AG d
agen oes
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30.1 Interior rearview mirror support - fasten ol not
V gu
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- 2-component adhesive
ility
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⇒ page 7
wit
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❑ First mix the blue and
h re
hole
red adhesives, in equal
spec
parts. Then, apply this
es, in part or in w
mixture onto the interior
t to the co
rearview mirror support
(detail A), leaving a
small protrusion of ad‐
rrectness of i
hesive (not more than
l purpos
0.5 mm) to ensure con‐

tact with the wind‐
screen. Surfaces must
nf
ercia
be free of oil residues.
orm
m
atio
1 - Adhesive
om
n in
or c
2 - Adhesive applied in em‐
thi
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30. Repair Group - 68 - Internal equipment 155

31 Repair Group - 70 - Lining/insulation
WARNING

dling Chemicals”.
31.1 Door noise insulation - glue

AG. Volkswagen AG d
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ing ⇒ page 6
du
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31.2 Noise insulation on rear side panel - glue
- All
- Product used
ing ⇒ page 6
AG. Volkswagen AG d
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31. Repair Group - 70 - Lining/insulation 157

31.3 Roof noise insulation - glue
- All
- Product used
ing ⇒ page 6
AG. Volkswagen AG d
agen oes
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or eo
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31.4 Door sealing membrane - glue
- All (except Golf and Polo)

- Product used
- Transferable adhesive tape
⇒ page 8
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31. Repair Group - 70 - Lining/insulation 159

32 Repair Group - 72 - Seat framework
WARNING

32.1 Front seat central sliding guide - lubricate

tana agen
AG. Volkswagen AG d
o
w es n
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- Product used d byV ua
ran
ise tee
or
- Lubricating paste au
thfor constant or
ac
velocity joints ⇒ss page 13
ce
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32.2 Front seat side sliding guide - lubricate
- Gol, Parati, Saveiro and San‐ AG. Volkswagen AG d

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32. Repair Group - 72 - Seat framework 161

33 Repair Group - 87 - Air conditioning
WARNING

33.1 Air conditioning system - refill with gas
- All
- Product used
- Refrigerant gas ⇒ page 9
AG. Volkswagen AG d
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d b ara
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Rep. gr.00 - Technical data
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , Gol o1995 ➤ , Gol 1999 ➤ , Gol ...
lkswagen AG
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agChemicals Manual d-oeEdition 02.2016
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33.2 Air conditioning system - refill with oil tho
ris tee
or
au ac
ss
ce
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un
- All
pt
an
d
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ab
pe
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ot
wit
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compressor ⇒ page 19
h re
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r
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33. Repair Group - 87 - Air conditioning 163

33.3 Air conditioning pressure switch - seal

tana
- Product used
sive ⇒ page 7
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34 Repair Group - 92 - Windscreen, rear

window and headlight wiper and
washer
WARNING

34.1 Windscreen wiper operating rod - lubricate
- Kombi
⇒ page 9
AG. Volkswagen AG d
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Chemicals Manual III

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Service

Gol 1995 ➤ , Gol 1999 ➤ , Gol 2006 ➤ ,

Golf 1999 ➤ , Golf 2007 ➤ ,

Parati 1999 ➤ , Parati 2006 ➤ ,

Polo Sedan 2012 ➤ , Santana 1991 ➤ ,

Saveiro 2000 ➤ , Saveiro 2006 ➤ ,

Saveiro 2010 ➤ , Saveiro 2014 ➤ ,

Saveiro 2017 ➤ , SpaceFox 2006 ➤ ,

SpaceFox 2011 ➤ , Voyage 2009 ➤ ,

Voyage 2013 ➤ , Voyage 2017 ➤ ,

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg D4B8026F7C5

2.23 Pentosin do Brasil Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.24 Petrobras Distr. S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.25 Promax Prod. Máximos S/A Indústria e Comércio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.26 Repsol - YPF S.A. Divisão Lubrificantes Brasil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.27 Quaker Chemical Industria e Comércio Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.28 Shell Brasil S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.29 Sika S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.30 Solplás - Ind. de Plásticos Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.32 Three Bond do Brasil Ind. e Com. Ltda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.34 Tutela Lubrificantes S/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 List of authorized products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Assembly Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Adhesive for polyurethane and polypropylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3 Resin adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Polyurethane-based sealing adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.5 Instant adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.15 Locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.33 Transferable adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.36 Double-sided acrylic foam adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.37 Medium density double-sided adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.38 Hydraulic brake fluid (DOT 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.39 Automatic transmission fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.44 Multi-purpose grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.46 Polyalphaolefin-based low temperature grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.48 Complex grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.49 Graphite grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.50 Grease for front wheel cylinder support guide pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.51 Grease for gearbox side seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.71 Sealing compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.95 Lubricating oil for manual gearbox - SAE 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.96 Lubricating oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.100 VW ATF oil for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.3 Flywheel fastening screw - lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8.1 Intermediate shaft seal - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

18 Repair Group - 39 - Gearbox shafts, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

18.1 Gearbox side seals - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

18.2 Planetary and satellite gears - lubricate for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

18.3 Automatic gearbox differential - top up oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

18.4 Differential cover with gearbox housing - seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

19 Repair Group - 40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

19.3 Front wheel bearing mounting - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

19.4 Axle end - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

20.1 Inner and outer constant velocity joint - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

20.2 Shaft end splines - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

20.3 Rear torsion bar - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

20.4 Rear wheel hub - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

20.5 Rear wheel hub seal - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117