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Service

Maintenance

Phaeton 2003 ➤

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Service Department. Technical Information

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Edition 03.2021

Service Maintenance

Heading 1. Engine list 2. Service work

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6. Glossary

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5. Exhaust emissions test

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4. Descriptions of work

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3. General information

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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 © 2021 Volkswagen AG, Wolfsburg

K0058951220

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Contents

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1 Engine list . . . . . . . .lk.s.w. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . agen AG. Vo age.n . . . . . . . . . . .A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Service owork ksw not l V gu by ara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d 2.1 Information about flexible or fixed service e nte ris o 2.2 uthService tables . . . . . . . . . . . . . . . . . . . . . . . e.o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ac sa 3 s General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Countries with hot climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 Country overview for diesel not compliant with EN 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Country overview for petrol not compliant with EN 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 Shortened intervals for spark plug replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 Jacking up mode: switching self-levelling suspension off and on . . . . . . . . . . . . . . . . . . . . 4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Removable towing bracket: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Driving light assist: checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Transfer box, front and rear final drive, automatic gearbox: checking oil level . . . . . . . . . . 4.4 Automatic gearbox: checking ATF level and topping up if necessary . . . . . . . . . . . . . . . . 4.5 Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 4.7 Battery: checking with battery tester (always refer to workshop manual) . . . . . . . . . . . . . . 4.8 User profile: allocating to ignition key, entering name of customer . . . . . . . . . . . . . . . . . . 4.9 Tyres: checking condition, wear pattern, tread depth, tyre pressure and age . . . . . . . . . . 4.10 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Brake fluid level (dependent upon brake pad/lining wear): check. . . . . . . . . . . . . . . . . . . . . 4.12 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 4.13 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 4.14 The infotainment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 4.16 Vehicle keys: checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 Fault memory of all systems: reading with vehicle diagnostic tester, correcting possible faults according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18 Front passenger airbag: checking activation/deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 Bonnet catch hook: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 Changed tyre pressure values: storing using infotainment . . . . . . . . . . . . . . . . . . . . . . . . 4.21 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22 Gearbox mounting: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Rear lid: lubricating left and right multi-joint hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24 Dust and pollen filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . 4.25 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26 Poly V-belt: checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27 Diesel fuel filter: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Diesel particulate filter: reading ash loading level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30 Diesel particulate filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents

1 4 4 6 21 21 23 24 25 26 26 27 28 28 29 30 31 31 32 33 36 38 40 43 44 44 45 45 48 49 50 58 62 64 65 67 70 70 71 71 72 73 74 74 76 78 78 78 79 79 85 85

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

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ii Contents

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4.66 5 5.1 5.2 6 7

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4.42 4.43 4.44 4.45 4.46 4.47 4.48 4.49 4.50 4.51 4.52 4.53 4.54 4.55 4.56 4.57 4.58 4.59 4.60 4.61

Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 86 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 87 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Multi-purpose additive for diesel fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Engine cover panel -top-: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Engine cover -bottom- (noise insulation): removing and installing . . . . . . . . . . . . . . . . . . . . 108 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Draining or extracting engine oil, renewing oil filter and replenishing engine oil . . . . . . . . 109 Engine oil: capacities and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 121 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Tyre repair set: checking if bottle is damaged or used; checking shelf life of tyre sealant . . 123 Manual gearbox/final drive: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Service interval display: resetting with diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Service interval display: recoding with diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 125 Sliding sunroof drains: checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 125 Sliding sunroof seal: lubricate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Wiper blades: checking park position, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . 128 Window wash/wipe system and headlight washer system: checking function and settings . .130 Power assisted steering: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Headlight adjustment: checking gas discharge headlights without DLA . . . . . . . . . . . . . . 135 Headlight adjustment: checking gas discharge headlights with DLA . . . . . . . . . . . . . . . . . . 147 Headlight adjustment: checking fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 157 Telematics system: activating and deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Transportation level: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Door arrester: grease. . . . . . . . . . . . . . . . . . . . . . . . . .ge. n. A.G. ..V.ol.ks. w. a.g.e.n .AG . .d. . . . . . . . . . . . 161 oes wa not olks Underbody sealant: inspecting for damage to underbody sealant, underbody panels, V gu y routing of lines and plugs . . . . . . . . . . . . . i.se.d.b . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.ra.n . . . . 162 te r o h Idler pulleys for poly V-belt: renewing (8-cylinder petrol engines) . . . . . . . . . . . . . . . . .e o.r . . 162 ut a a Camshaft drive toothed belt: renewingss(8-cylinder petrol engines) . . . . . . . . . . . . . . . . . . c 162 Central display and control unit (CDCU): setting units of measurement, clock and date . . 162 Central display and control unit (CDCU): determining language for lettering and language version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 ---Change history--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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4.31 4.32 4.33 4.34 4.35 4.36 4.37 4.38 4.39 4.40 4.41

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Engine list

(VIGG001521; Edition 03.2021) This chapter provides information on the following subjects: ♦ Petrol engines ⇒ page 1 ♦ Diesel engines ⇒ page 3 Note

To ease the search for an engine, the engine codes are listed in alphabetical order. Petrol engines

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∅ mm mm

8/5

309/6000 560/4000

246/6200 430/3200

BAN

6/4

12/4

177/6200 315/2400

309/6000 550/3000 to 4750 84.0 90.3 10.8 Motronic ME 7.1.1B PFI

84.0 90.3 10.8 Motronic ME 7.1.1B PFI

84.5 93 11.0 Motronic ME 7.1.1 PFI

98 1

981

Chain

Gear train

84.0 95.9 11.25 Motronic ME 7.1.1 PFI

1) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output. Prote cted by c o p yri gh t. C op yi

Bore Stroke Compression ratio Injection/ignition RON

∅ mm mm

unleaded, at least

Petrol engine 3.2 BKL

8/5

Toothed belt

Petrol engine 3.2 BRK

Petrol engine 6.0 BRN

6/4

12/4

246/6200 430/3200

177/6200 315/2400

84.5 93 11.0

84.0 95.9 10.85

331/6050 550/2750 to 4750 84.0 90.2 10.8

Motronic ME 7.1.1 PFI

981

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No. of cylinders/valves per cylinder Power kW at rpm Torque Nm at rpm

Petrol engine 4.2 BGJ

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Bore Stroke Compression ratio Injection/ignition

12/4

AYT

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BAP

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1. Engine list

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Engines Displacement Engine code

⇒ I

Camshaft drive

Petrol engine 4.2 BGJ

Petrol engine 3.2 BKL

Petrol engine 3.2 BRK

Petrol engine 6.0 BRN

Toothed belt

Chain

Gear train

Petrol engine 3.6 CHNA

Petrol engine 3.6 CMVA

1) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output.

Engines Displacement Engine code

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No. of cylinders/valves per by Volk 12/4 d e cylinder s ri ho ut rpm Power kWs aat 331/6050 s Torque Nm at rpm 550/2750 to 4750

370/3500

206/6300 370/3600

89.0 96.4 12.0 Motronic MED 9.1 FSI

89.0 96.4 11.4 Motronic MED 9.1 FSI

981

Gear train

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RON Camshaft drive

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No. of cylinders/valves per cylinder Power Torque Bore Stroke Compression ratio Injection/ignition

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Engines Displacement Engine code

kW at rpm Nm at rpm ∅ mm mm

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RON

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Chain

Petrol engine 3.0 CPFA

6/4 184/6400 310/3500 84.0 89.5 11.4 Motronic MED 9.1 FSI 95 Chain

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Diesel engines Engines Displacement Engine code

⇒ I

No. of cylinders/valves per cylinder Power kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Injection/ignition Diesel particle filters Camshaft drive

Diesel engine 4.9 AJS

Diesel engine 3.0 BMK

Diesel engine 3.0 CARA

Diesel engine 3.0 CEXA

10/2

6/4

230/4000

165/4000

171/4500

176/4000

750/2000

450/1400 to 3250

450/1750

500/1750

81.0 95.5 18.5 TDI unit injector No Gear train

83.0 91.4 17.0 TDI common rail Yes Chain

83.0 91.4 16.4 TDI common rail Yes Chain

Engines Displacement Engine code

⇒ I

Diesel engine 3.0 CEXB 6/4 180/4000 500/1500 to 3000 83.0 91.4 16.4 TDI common rail Yes Chain

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Diesel particle filters Camshaft drive

1. Engine list

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

Service work

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Information about flexible or fixed serv‐ ice

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Flexible service ⇒ page 4 Fixed service ⇒ page 5 Service interval display ⇒ page 5

2.1.1

Service identification

– Referring to vehicle data sticker ⇒ page 26 , check if vehi‐ cle is equipped with following PR numbers: The PR number is decisive for the service intervals ⇒ page 6. Vehicle IDs with the following PR number ► 2012 ► 2012 2013 ► 2013 ►

QG1 QG0, QG2, QG3 QI6 QI1, QI2, QI3, QI4, QI7

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In the past, the PR numbers QG0, QG1 and QG2 determined the type of service. With immediate effect, these PR numbers only denote whether an engine oil level sensor is installed or not and no longer have an influence on the oil change interval.

2.1.2

Flexible service

The flexible service enables long service intervals, depending on individual driving style and the conditions under which the vehicle is used. Note

For the flexible service a special LongLife engine oil is required ⇒ page 6 . Vehicles with PR number “QG1” or “QI6” are set up for flexible service when they leave the factory. This means that these vehicles have a flexible service interval display and are fitted with the following components: ♦ Flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake pad wear indicator (if fitted) For vehicles with flexible service the service interval is deter‐ mined by the control unit and is indicated on service interval display (SID) ⇒ page 5 .

4 2. Service work

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Service identification ⇒ page 4

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Flexible service Fixed service Flexible service Fixed service

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Therefore the service intervals are flexible.

2.1.3

Fixed service

For vehicles with a fixed service, fixed services are calculated. This means that the mileage or time values are already set by Volkswagen. For normal operating conditions achieving these service intervals is technically assured. Therefore the service intervals are fixed. For vehicles ♦ Which have not been delivered with extended servicing in‐ tervals (ESI) (PR numbers “QG0”, “QG2”, “QI1”, “QI2”, “QI3”, “QI4”, “QI7”. ♦ that have had extended servicing interval (ESI) stopped ♦ in which no LongLife engine oil was used

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d These non-flexible service rintervals apply to all types of service rante ise o eo th including an engine oil change. ra au c ss

fixed service applies.

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Vehicles with PR number “QG2” The PR number is valid only to ►2012. For these vehicles the flexible service is not factory-activated. Therefore, these vehicles have a fixed service interval display ⇒ page 5 and for maintenance the fixed service intervals (rigid service intervals) apply. These vehicles are fitted with the following components: ♦ Fixed service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake pad wear indicator (if fitted) Vehicles with PR number “QG3” The PR number is valid only to ►2012. r fo ng

Prote cted by

2.1.4

AG.

♦ Brake pad wear indicator (if fitted)

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♦ Fixed service interval display in dash panel insert

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For these vehicles the flexible service is not factory-activated. Therefore, these vehicles have a fixed service interval display ⇒ page 5 and for maintenance the fixed service intervals apply. These vehicles are fitted with the following components:

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The vehicles are “not” factory-fitted with components for flexible service. Fixed service intervals apply for maintenance.

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Vehicles with PR number “QG0”

Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 6 Flexible service interval display (only vehicles with a flexible service) ⇒ page 6 Fixed service interval display (only vehicles with a fixed service) ⇒ page 6 Service interval display: resetting ⇒ page 124 Service interval display: recoding ⇒ page 124

2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Introduction of extended servicing intervals (ESI) Ask your importer if the extended servicing interval (ESI) is available for your country. Flexible service interval display (only vehicles with a flexible service) Calculation of service intervals: ♦ The service intervals on vehicles with a flexible service is calculated. Input values such as, distance travelled, fuel con‐ sumption, oil temperature and loading on diesel particulate filter are evaluated by the control unit. ♦ The result of the evaluation is a value for the deterioration of the oil due to thermal loading. ♦ The oil deterioration is the deciding factor concerning the distance that can still be driven to the next service. Note

For vehicles with a flexible service but which are serviced ac‐ cording to fixed service intervals, the service interval display must be recoded to “non-flexible” ⇒ page 124 .

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♦ For normal operating conditions achieving these service in‐ tervals is technically assured.

2.2

Service tables Note

♦ The service tables apply in general with differences depend‐

ing on the vehicle model and equipment level. There is no relation between individual vehicles and identified vehicle identification numbers.

♦ Vehicle-specific time and mileage dependent additional work

Scope of work

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Pre-delivery inspection

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2.2.1

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can only be found in the ⇒ maintenance tables.

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lated in fixed service intervals. This means that the mileage or time values have been previously determined and speci‐ fied by Volkswagen.

– – – –

12V battery: check battery clamp for firm seating. Transportation mode: switch off. Service interval display: reset. Status of 12V battery: read.

•

Runs automatically on vehicles with battery monitor control unit -367- at switching off of transportation mode.

Only applicable to vehicles without battery data module.

6 2. Service work

AG.

•

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– 12V battery: check using -VAS 6161-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Scope of work Event memories of all systems: read. Time and date: set. All switches, electrical consumers, sockets, gauges and other control elements: check function Front passenger airbag: check key switch and ON/OFF function. Window regulators: initialise (activate). Vehicle interior: check for cleanliness. Protective seat covers and protective carpet film: remove. All equipment which has been packed inside vehicle (if part of original equipment): install. Two safety hammers: install according to installation instructions.

•

Applies only to the Netherlands.

– – – – – – – – – – – – – – – – – –

Vehicle exterior: check for cleanliness. Tyre pressure: check. Wheel bolts: tighten to specified torque. Wiper blade protection: remove. Tyre Pressure Loss Indicator: calibrate after tyre pressure has been corrected. Vehicle: inspect for leaks and damage from above and below. Brake system: inspect for leaks and damage. AG. Volkswagen AG d agen o ksw l Transportation devices: remove (if fitted). es not g o yV ua b ran ed Vehicle underside (underbody): inspect for damage. tee ris o h t or u ac a Windscreen wash/wipe system and headlight washer system: check function and settings. ss Engine oil level: check; observe oil specification when topping up. Coolant level: check. Brake fluid: renew, if vehicle is older than 6 months. Brake fluid level: check that it is at maximum. Keys: check number, operation and cleanliness. Service Schedule / Digital Service Schedule: enter pre-delivery inspection. Carry out road test. Charging cable: check that cable is present and check its condition.

•

Applies only to BEV and PHEV

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– – – – – – – – –

– High-voltage battery: charging

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•

2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

2.2.2

Scopes of service

Note ♦ Depending on the time elapsed and the mileage since the

last service, service events may be combined (inspection with oil change).

♦ An extended scope of inspection should be carried out in

combination with an inspection.

♦ The scopes of service work are generally applicable and dif‐

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– High-voltage battery: check charge level, charge as necessary. • X

– Sliding/tilting sunroof: check function.

Vehicle exterior X X X X X X

– – – – – –

– X X

– – – •

8 2. Service work

Applies only to BEV Prote cted by

Applies only to BEV

c o p yri gh t . C op yi

•

AG.

X X

– Interior lights: check function of headliner, luggage compartment and glove compartment lights. – Horn: check function. – Charging cable: check that cable is present and check its condition. do c um en

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Scope of work

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Vehicle interior

Exten‐ ded scope of inspec‐ tion (recom‐ mended in addi‐ tion to regular inspec‐ tion)

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Inspec‐ tion

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Oil change service

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s only in the maintenance tables. ⇒ Maintenance tables

Headlight washer system: check function. Front lighting: check function. Static cornering light (cornering light): check function. Automatic headlight control: check function. Rear lighting: check function. Windscreen wash/wipe system: check function and spray jet settings and adjust if necessary; check for damage. Wiper blades: move blades to service position and check for damage; check park position. Interior and exterior of body: inspect for corrosion. Windscreen: visual check for damage High-voltage charging socket in radiator grille: inspect for soiling and damage. Applies only to PHEV

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Inspec‐ tion

Exten‐ ded scope of inspec‐ tion (recom‐ mended in addi‐ tion to regular inspec‐ tion)

Scope of work

– High-voltage charging socket in radiator grille and tank cap: inspect for soiling and damage. •

– Reducing agent (AdBlue®): replenish only if customer requests. •

If part of equipment

– CSC roof: check for damage and function, clean wind deflector and seals and apply special lubricant to rubber seals. • X

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does ag – Sliding/tilting roof: clean and kswgrease guide rails of glass not panel and slid‐ Vol gu y b ing headliner. ara d e

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Applies only to Golf Cabriolet and Beetle Cabriolet

– Sunroof seal: regrease.

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Applies only to Phaeton

– Sliding sunroof drains: check for blockage, clean if necessary.

X X X

AG.

Underside of vehicle X X

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•

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•

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Applies only to Golf Cabriolet and Beetle Cabriolet

– Convertible top: perform water test. •

Applies only to Touran 1T, EOS, Golf Cabriolet, CC and Phaeton

– Convertible top: clean and lubricate locking element. •

Only applies for: CC, Touran 1T, Golf Cabriolet, EOS, Phaeton, Golf 5K1, Golf Plus, Passat 36, Tiguan 5N, Sharan 7N, Touareg 7P

– Door arrester: grease. •

– Bonnet catch hook: grease. •

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Applies only to BEV

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Oil change service

– Drain engine oil and renew oil filter. – Engine and components in engine compartment: inspect for leaks and damage (from below). – Gearbox, final drive and drive shaft boots: inspect for leaks and dam‐ age. – Brakes, front and rear: check thickness of pads/linings and condition of brake discs. – Poly V-belt: check condition. 2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Oil change service

Inspec‐ tion

Exten‐ ded scope of inspec‐ tion (recom‐ mended in addi‐ tion to regular inspec‐ tion)

Scope of work

– Swivel joints, axle mountings, coupling rod bearings and anti-roll bar rubber mountings: perform visual inspection for damage. – Track rod ball joints: check clearance, firm seating and boots. – Brake system and shock absorbers: inspecting for leaks and damage – Exhaust system: inspect for leaks, firm seating and damage. – Underbody: inspect for damage to undercoating, underbody cladding, routing of lines, plugs. – Front and rear coil springs and rubber buffers: inspect for damage. – Warning stickers: check that they are present.

X X X X X X

Applies only to high-voltage vehicles

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– Air suspension: check for leaks and damage.

Applies only to Touareg and Phaeton

– Sunroof: check function, clean guide rails and lubricate with special grease. – Automatic gearbox: checking ATF level •

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• X

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Applies only to Phaeton

Tyres

– – –

Prote cted by

– •

10 2. Service work

AG.

c o p yri gh t. C op yi

X X X

Engine oil: replenish. Oil level: check. Battery and, if fitted, second battery: check with battery tester. Engine and components in engine compartment: inspect for leaks and damage (from above). Brake fluid level (dependent upon brake pad/lining wear): check. Cooling system: check frost protection and coolant level. Window wash/wipe system: check anti-freeze protection; replenish washer fluid. Hybrid components: inspect for damage to high-voltage components and wires. agen lksw Vo by

– – – –

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– Tyre pressure: check. – Tyre mobility set: check for damage and use. – Tyres: check condition and wear pattern of tyre; enter tread depth. in t his d o cu m en

X X X Engine compartment X X X X

Applies only to HEV and PHEV

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Oil change service

Inspec‐ tion

Exten‐ ded scope of inspec‐ tion (recom‐ mended in addi‐ tion to regular inspec‐ tion)

Scope of work

– High-voltage components and high-voltage cables: inspect for damage and correct routing and securing of lines. • X

– Power assisted steering: checking fluid level •

Applies only to BEV

Applies only to Touareg and Phaeton

– Plenum chamber: check for soiling. • X

Applies only to up!

– Plenum chamber: check for soiling. •

Applicable for e-up! only

2.2.3

•

Applies only to PHEV

Service intervals to model year ►2013

NOTICE

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♦ For extremely uneconomical driving style or use under ex‐

treme conditions ⇒ page 27 , the shortest interval for an oil change service is “7,500 km or 1 year”.

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Note

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In some countries, diesel has a higher sulphur content. The high sulphur content leads to excessive wear of cylinders and it considerably reduces the cleanliness of pistons. – Change engine oil every 7,500 km in countries where the diesel has a high sulphur content.

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Concluding work . Volkswagen AG gen AG does waService s X X – interval display: k nReset l ot g o yV u b d ran adjust as necessary. X – Headlight adjustment: checkaand ir se tee o h t or X s au – Tyre Pressure Loss Indicator: calibrate after tyre pressure has been ac s corrected. X – Carry out road test. X – High-voltage battery: charge.

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Prote cted by

♦ However, other intervals apply for other countries. Your im‐

porter will inform you about this.

2. Service work

. Volkswagen AG Phaeton 2003 ➤ gen AG does swa k not l o Maintenance - Edition 03.2021 gu yV

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Petrol and diesel: with QG1, QG0/QG2

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2005►2007 Petrol and diesel: all vehicles

Since intro‐ duction 2008►2 012

Oil change service flexible from 15,000 km to max. 30,000 km or 2 years Inspection service every 60,000 km or 4 years Interval service every 30,000 km or 2 years Interval service flexible from 15,000 km to max. 30,000 km or 2 years Interval service inspection every 60,000 km or 4 years

PHAETON 2008►2012 SERVICE INTERVALS 2008►2012 Engine/Engine code/ Service/intervals PR No./Remarks Diesel, in countries where the sulphur content in fuel is high Petrol and diesel: QG0/QG2 or QG1 vehicles coded to non-flexible interval Petrol and diesel: QG1 vehicles

►2010 Petrol and diesel: all vehicles 2011►2 Petrol and diesel: 012 all vehicles

YES YES NO

YES YES YES

Indicated on service interval display SID (includes oil change)

Oil change service every 7,500 km or 1 year

YES

Oil change service every 15,000 km or 1 year Interval service: every 30,000 km or 2 years Interval service: flexible according to SID from 15,000 km or 1 year up to max. 30,000 km or 2 years Inspection service: after 3 years/max. 60,000 km, then every 2 years/60,000 km Inspection service: after 3 years/max. 60,000 km, then every 2 years/60,000 km

YES

Note

For combined kilometre and time display applies: whichever occurs first.

12 2. Service work

YES

do c um en

2005►2007 Petrol and diesel: QG0/QG2 or QG1 vehicles co‐ ded to non-flexible interval 2005►2007 Petrol and diesel: with QG1

from-to

Indicated on service interval display SID (includes oil change)

Oil change service every 7,500 km or 1 year Oil change service every 15,000 km or 1 year

AG.

Diesel, in countries where the sulphur content in fuel is high Petrol and diesel: QG0/QG2 or QG1 vehicles co‐ ded to non-flexible interval Petrol and diesel: with QG1

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►2004

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►2004

PHAETON ►2007 SERVICE INTERVALS ►2007 Engine/Engine code/ Service/intervals PR No./Remarks ss

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Since intro‐ duction Since intro‐ duction

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YES YES

NO NO

Phaeton 2003 ➤ Maintenance - Edition 03.2021

From - to

Indicated on service interval display (includes oil change)

QI1

Oil change service (fixed): every 5,000 km or 1 year QI2 Oil change service (fixed): every 7,500 km or 1 year QI3 Oil change service (fixed): every 10,000 km or 1 year QI4 Oil change service (fixed): every 15,000 km or 1 year QI7 Oil change service (fixed): every 10,000 mi or 1 year QI1, QI2, QI3, QI4, QI7 Interval service (fixed): every 30,000 km or 2 years QI6 Interval service (flexible): from 15,000 km or 1 year up to max. 30,000 km or 2 years QI1, QI2, QI3, QI4, QI6,AG QI7 swagen G service: . VolkInspection n doesor max. 60,000 after 3 Ayears wage s k not l o km, then every 2guyears or yV b ara d nte 60,000 km ise or

Climate and traffic con‐ ditions usual for passen‐ ger vehicles operated on fuels compliant with EN 228 or EN 590

Oil change service

---

YES YES YES YES NO

For operation with fuels that are »NOT« compliant with standards EN 228 ⇒ page 29 or EN 590 ⇒ page 28

QI1 every 5,000 km or 1 year (fixed) 1) --QI2 every 7,500 km or 1 year (fixed) 1) --QI3 every 10,000 km or 1 year (fixed) 1) QI4 every 15,000 km or 1 year (fixed) 1) QI6 --max. 30,000 km or 2 years (flexible) 1) QI7 --every 10,000 mi or 1 year (fixed) 1) do c um en

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YES

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Scope of work

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Service intervals as of model year 2014►

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YES

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1) Whichever occurs first.

YES

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2.2.4

PR No.

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2013

PHAETON 2013 Service intervals Service events: Intervals

2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Scope of work

Climate and traffic con‐ ditions usual for passen‐ ger vehicles operated on fuels compliant with EN 228 or EN 590

For operation with fuels that are »NOT« compliant with standards EN 228 ⇒ page 29 or EN 590 ⇒ page 28

Inspection

---

QI1 every 10,000 km or 1 year 1) QI2 every 15,000 km or 1 year 1) QI3 every 10,000 km or 1 year 1) QI4 every 15,000 km or 1 year 1)

----QI4 30,000 km or 2 years then every 30,000 km or 1 year 1) QI6 30,000 km or 2 years then every 30,000 km or 1 year 1) QI7 Every 20,000 mi or 2 years 1)

---

1) Whichever occurs first.

Scope of work

Climate and traffic con‐ ditions usual for passen‐ ger vehicles operated on fuels compliant with EN 228 or EN 590

For operation with fuels that are »NOT« compliant with standards EN 228 ⇒ page 29 or EN 590 ⇒ page 28

Extended scope of in‐ After 60,000 km or . Volkswagen AG spection years AG n3 does wage (recommended in addition Vthen not olks every 60,000 km or gu y ara to regular inspection) ed b 2 years 1)

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Air filter

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ris tho u 1) Whichever occurs a ss first.

2.2.5

After 30,000 km or 2 years or after 20,000 km or 2 years 1)

Scope of work

Climate and traffic conditions usu‐ al for passenger vehicles

Countries with high levels of dust ⇒ page 31

Air filter: cleaning housing and re‐ newing filter element • Applies only to Polo (except for 1.0 TSI) and up! with PFI

Every 60,000 km or 4 years 1)

Every 30,000 km or 2 years 1)

Air filter: cleaning housing and re‐ newing filter element

Every 90,000 km or 6 years 1)

Every 30,000 km or 2 years 1)

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c o p yri gh t. C op yi

14 2. Service work

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1) Whichever occurs first.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

2.2.6

Dust and pollen filter Scope of work

Climate and traffic conditions usu‐ al for passenger vehicles

Countries with high levels of dust ⇒ page 31

Dust and pollen filter (cabin filter): renew. • Applies only to Polo (6R1 and 6C1) and up!

Every 30,000 km or 2 years 1)

Max. 1 year or 30,000 km 1)

Dust and pollen filter (cabin filter): renew.

Every 60,000 km or 2 years 1)

Max. 1 year or 30,000 km 1)

Scope of work

Climate and traffic conditions usu‐ al for passenger vehicles

Countries with high levels of dust ⇒ page 31

Toothed belt and camshaft drive tensioning roller: renew. • Applies only to TDI biturbo and V8 PFI

Every 120,000 km

1) Whichever occurs first.

2.2.7

Toothed belt

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Toothed belt drive for coolant pump: renew. • Applies to all petrol engines with toothed belt for coolant pump 1) Whichever occurs first.

---

Every 120,000 km

---

Every 120,000 km

Countries with high levels of dust ⇒ page 31

--Every 90,000 km

Every 60,000 km Every 60,000 km

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Poly V-belt: renewing Poly V-belt for compressor: re‐ new • Applies only to Touareg

Climate and traffic conditions usu‐ al for passenger vehicles c o p yri gh t. C op yi

Scope of work

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Poly V-belt

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2.2.8

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Unlisted engines do not have a toothed belt inspection or re‐ placement interval.

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Toothed belt and camshaft drive tensioning roller: renew. • Applies to all petrol engines with toothed belt

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Toothed belt and camshaft drive tensioning roller: renew. • Applies to all diesel engines with toothed belt

AG. Volkswagen AG d agen oes ksw not l o V gu y b d Every Everyar120,000 km an ise 210,000 km tee r tho or u ac a ss

2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

2.2.9

Diesel fuel filter Scope of work

Diesel compliant with EN 590

Diesel not compliant with EN 590

Every 90,000 km

Every 30,000 km

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Spark plugs

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2.2.10

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Diesel fuel filter: renewing

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⇒ page 28 . Volkswagen AG gen AG does swa k n l o o t gu Diesel fuel filter: renewing Every 30,000 km y V Every 60,000 km ara db • Applies only to Polo (6R1 & nte ise r eo 6C1) and Touareg tho ra au c s s

Scope of work

Petrol engine compliant with EN 228

E100

Petrol engine not compli‐ ant with EN 228 ⇒ page 33

Spark plugs: Renew • Applies only to W12 and VR6 PFI

Every 60,000 km or 4 years 1)

Every 40,000 km or 4 years 1)

Spark plugs: Renew • Applies only to VR6 FSI and V8 PFI

Every 90,000 km or 6 years 1)

Every 30,000 km / 20,000 km or 2 years 1) and every 15,000 km / 10,000 km or 1 year 1)

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Multi-purpose additive

Prote cted by c o p yri gh t. C op yi

2.2.12

---

AG.

Multi-purpose additive for diesel fuel: adding Multi-purpose additive for petrol fuel: adding

Climate and traffic conditions usu‐ al for passenger vehicles

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Scope of work

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2.2.11

---

in t his d o cu m en

1) Whichever occurs first.

Russia

At every service. At every service.

Brake fluid Scope of work

Climate and traffic conditions usu‐ Only for markets outside Europe al for passenger vehicles and with fixed oil change intervals

Brake and clutch system: change brake fluid • Applies only to vehicles to ►2007

Every 2 years

Brake and clutch system: change brake fluid • Applies to vehicles as of 2008►

16 2. Service work

3 years after initial registration, then every 2 years

Every 2 years

Phaeton 2003 ➤ Maintenance - Edition 03.2021

2.2.13

Automatic gearbox

Scope of work

Climate and traffic condi‐ Countries with hot climate tions usual for passenger ⇒ page 28 vehicles

Automatic gearbox: change ATF.

2.2.14

---

Every 60,000 km

USA Every 80,000 mi

Time and mileage-dependent addition‐ al work for the markets India, China, Russia and USA to model year ►2013

Note ♦ This chapter contains only the time or mileage-dependent

additional work up to model year ►2013 for Chinese, Russi‐ an and USA markets.

♦ For information for other markets, refer to the chapter “Serv‐

ice tables” ⇒ page 6 .

Indian market Applies up to ►2013

Interval

Description of work

Interval service (fixed) ♦ (QG0/QG2/QG3) 2)

Every 15,000 km or 1 year 1)

→ Mainte‐ nance tables

every 30,000 km or 2 years 1) AG. Volkswagen AG d n e g a oes ksw not every service. Multi-purpose additive – for petrol At Vol fuel: adding gu by ara d e nte Dust and pollen filter (cabin filter): renew. Every 15,000 km is r o e o 1) h ut or 1 year ra a c ss Air filter element: renew and clean housing. Every 15,000 km or 1 year 1) Diesel fuel filter: renewing Every 15,000 km Spark plugs: Renew every 30,000 km or 2 years 1)

→ Mainte‐ nance tables

♦ QI4 (appears on service interval display) Inspection service

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1) Whichever occurs first.

2) Oil change service has been omitted in the Indian market.

The interval service is carried out as a substitute. Changing the engine oil is an integral part of the interval service.

Applies up to ►2013

Interval

Prote cted by c o p yri gh t. C op yi

♦ QI4

Every 15,000 km or 1 year 1)

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Interval service (fixed) ♦ (QG0/QG2/QG3) 2)

(appears on service interval display)

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Russian market

⇒ page 91 ⇒ page 79 ⇒ page 165

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– –

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–

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–

⇒ page 105 ⇒ page 78

Description of work → Mainte‐ nance tables

2. Service work

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AG.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Applies up to ►2013 Inspection service

Description of work

every 30,000 km

→ Mainte‐

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– Spark plugs: Renew

⇒ page 79 ⇒ page 91

2) Oil change service has been omitted in the Russian market.

The interval service is carried out as a substitute. Changing the engine oil is an integral part of the interval service.

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Every 60,000 km

⇒ page 125

AG.

Note

Prote cted by c o p yri gh t. C op yi

China market

Description of work

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Sliding sunroof drains: checking – for blockage, cleaning if necessa‐ ry

Interval

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North American market

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1) Whichever occurs first.

⇒ page 165 rrectness o f i t to the co n f orm spec atio h re n wit

– Diesel fuel filter: renewing – Air filter element: check; renew as needed and clean housing.

every 30,000 km or 2 years 1) Every 30,000 km every 30,000 km or 2 years 1)

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– –

Interval

In the Chinese market no engine oils to VW standard 504 00/507 00 may be used because of poor fuel quality. Petrol engines, applies up to ►2013 Oil change service (fixed) ♦ (QG0/QG2/QG3) (appears on service interval display) Oil change service (fixed) ♦ (QG0/QG2/QG3) ♦ QI3 (appears on service interval display) Interval service (fixed) (appears on service interval display) Inspection service (does not appears on service interval display) – Multi-purpose additive for petrol fuel: adding – Dust and pollen filter (cabin filter): renew.

18 2. Service work

Interval

Description of work

Once after 5,000 km

→ Mainte‐ nance tables

At 10,000 km or 1 year 1) then every 10,000 km or 1 year 1)

→ Mainte‐ nance tables

every 20,000 km → Mainte‐ nance tables or 2 years 1) Every 30,000 km → Mainte‐ nance tables or 3 years 1), and then every 30,000 km / 2 years At every service. ⇒ page 105 Every 10,000 km ⇒ page 78 or 1 year 1)

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Petrol engines, applies up to ►2013 – Spark plugs: Renew •

Applies only to 3.0 l V6 FSI, 3.6 l V6 FSI and 4.2 l V8 PFI

– Spark plugs: Renew •

Applies only to 6.0 l W12 PFI

– Air filter element: renew and clean housing. – Camshaft drive toothed belt: renew •

Interval

Description of work

every 20,000 km or 2 years 1)

⇒ page 165

Every 30,000 km or 2 years 1)

⇒ page 165

every 30,000 km or 2 years 1) Every 120,000 km

⇒ page 91 ⇒ page 162

Applies only to 4.2 l V8 PFI

1) Whichever occurs first.

Note

In the China market, it is not permissible to use engine oils with VW standard 504 00/507 00 due to the poor quality of the fuel there. n AG. Volkswagen AG do e wage

s no t gu ara nte Interval eo ra c

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Every 7,500 km or 1 year 1)

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♦ QI2

– Diesel fuel filter: draining – Dust and pollen filter (cabin filter): renew.

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– Air filter element: renew and clean housing. – Diesel fuel filter: renewing 1) Whichever occurs first.

c o p yri gh t. C op yi

Country-specific additional work dependent on time and mileage AG.

Prote cted by

– Change ATF

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Scope of work •

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every 15,000 km → Mainte‐ nance tables or 2 years 1) Every 30,000 km → Mainte‐ nance tables or 3 years 1), and then every 30,000 km / 2 years Every 15,000 km ⇒ page 79 Every 15,000 km ⇒ page 78 or 1 year 1) every 30,000 km ⇒ page 91 or 2 years 1) Every 30,000 km ⇒ page 79

Inspection service (does not appears on service interval display)

2.2.15

→ Mainte‐ nance tables

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(appears on service interval display) Interval service (fixed) (appears on service interval display)

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Oil change service (fixed) ♦ (QG0/QG2/QG3)

Description of work

Interval

Every 30,000 km

Applies only to vehicles with W12 engines only

Idler roller for poly V-belt: renew. • Applies only to Phaeton with V8 petrol engine

Every 120,000 km

2. Service work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Scope of work

Interval

Gearbox mounting: renew • Applies only to Phaeton with towing bracket

Every 150,000 km At 180,000 km/210,000 km, then every 30,000 km

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Prote cted by

c o p yri gh t. C op yi

20 2. Service work

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Diesel particulate filter: Check

Phaeton 2003 ➤ Maintenance - Edition 03.2021

General information

This chapter provides information on the following subjects: Raising vehicle with lifting platform or trolley jack ⇒ page 21 Sticker ⇒ page 23 Entries in service schedule ⇒ page 24 Connecting vehicle diagnosis tester ⇒ page 25 Vehicle identification number ⇒ page 26

. Volkswagen AG gen AG does not gu y b ara d e nte is Severe operating conditions ⇒ page 27 r o eo h ut ra a c Countries withsshot climate ⇒ page 28

Country overview for petrol not compliant with EN 228 ⇒ page 29 Motor code and motor number ⇒ page 30 RME fuel (biodiesel) ⇒ page 31 Countries with high levels of dust ⇒ page 31 Type plate ⇒ page 32 Shortened intervals for spark plug replacement ⇒ page 33 Jacking up mode: Switching self-levelling suspension off and on ⇒ page 36

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Raising vehicle with lifting platform or trolley jack Prote cted by c o py rig ht . C op yi

Note

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3.1

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Country overview for diesel not compliant with EN 590 ⇒ page 28

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wa ks26 Vehicle data sticker ⇒ page Vol

For vehicles with self-levelling suspension, the jacking up mode must be activated when raising the vehicle! AG.

3.1.1

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Activating jacking up mode see ⇒ page 36 .

Safety information

NOTICE Risk of damage to the vehicle due to insufficient clearance between low-lying vehicle components and the lifting platform. – Make sure that the vehicle has sufficient ground clearance.

NOTICE Risk of damage to the lifting platform if its load-carrying ca‐ pacity is exceeded. – Observe the specified load-carrying capacity of the lifting platform.

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021 WARNING Risk of injury if the engine is started with an engaged gear and the drive wheels are in contact with the floor. – Make sure there is sufficient clearance between drive wheels and the floor.

NOTICE Risk of damage to the vehicle when lifted incorrectly. Possible damage to the underbody if the vehicle slides off. – Make sure to only lift the vehicle at the indicated lifting points.

3.1.2

Lifting points for lifting platform and trolley jack

NOTICE Risk of damage to the vehicle due to improper handling of the lifting platform. – Screw support plates of the lifting platform out far enough to ensure sufficient clearance between lifting arm and side member. – Always make sure that the support plates are positioned below the side member reinforcements. Front lifting point AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Position support plate at reinforcement -arrow- of floor pan. Rear lifting point

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AG.

Prote cted by c o py rig ht . C op yi

22 3. General information

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– Remove plastic cap.

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– Remove plastic cap.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Position support plate at reinforcement -arrow- of floor pan. – Put all the plastic caps on again.

3.2

Stickers

In this chapter there are stickers which apply for the German market. The stickers determined for your country can be ob‐ tained from your importer. Attach “Your next service” sticker. ⇒ page 23 Attach “vehicle data sticker” in customer service schedule. ⇒ page 24 Attach “LongLife engine oil” sticker. ⇒ page 24

3.2.1

Attaching “Your next service” sticker

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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Service intervals ⇒ page 6

rrectness o f i t to the co n f orm spec atio h re n wit

– Service sticker “Your next service”: Enter a cross in position for next oil change service or inspection service or legal check such as legislative inspection or gas system check (next service due) and enter date and mileage.

in t his d o cu m en

– Attach sticker to driver side door pillar (B-pillar) -arrow-. ht rig py Co t.

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– Your “next service dates” sticker: Enter a cross in position for next oil change service or inspection service (next serv‐ ice due) and enter date/odometer reading

3. General information

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AG.

Prote cted by c o py rig ht . C op yi

Phaeton 2003 ➤ Maintenance - Edition 03.2021

3.2.2

n AG. Volkswagen AG do es n wage s k l ot g Vo Apply the lower of the two vehicle data stickers -arrow- dinbythe ua ran service schedule. ir se tee o h t or u ac a ss

Attaching “LongLife engine oil” sticker

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–

Attaching “vehicle data sticker” in cus‐ tomer service schedule:

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– For vehicles with LongLife service (PR number QG1), the sticker must be attached as shown below.

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Entries in service schedule

Prote cted by

Therefore it is very important, every time a component is changed, to document this in the service schedule.

•

This also applies to components which were changed before the regular change interval.

24 3. General information

AG.

•

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c o p yri gh t . C op yi

If a component is changed which has a change interval prescri‐ bed by the manufacturer, e.g. the toothed belt, the new change interval begins at the time the component is changed.

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3.3

in t his d o cu m en

– Apply sticker -arrow- as shown on right side of lock carrier (from driver perspective).

Phaeton 2003 ➤ Maintenance - Edition 03.2021

3.4

Connecting vehicle diagnostic tester

Special tools and workshop equipment required ♦ Diagnosis system -VAS 6160 A-

♦ Diagnosis system VCI -VAS 6150 CAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is used s i r Ensure that the selected vehicle diagnostic tester o eo h ut with the respective diagnostic cable. ra only a c s s

Note

♦

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♦ During a road test, always secure testing and measuring

equipment on the back seat.

♦ Only a passenger may operate these devices while the vehi‐

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– Carry out following procedure:

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cle is in motion.

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AG.

Prote cted by c o py rig ht . C op yi

– Connect diagnosis cable connector to diagnostic connection. – Switch on vehicle diagnostic tester. – Switch on ignition. Now follow information given on screen to start desired func‐ tions.

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o th or Location engine ucompartment ac a ss

Vehicle identification number

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The vehicle identification number is located on the extension of longitudinal member -arrow 1- and -arrow 2-. c o p yri gh t . C op yi

Interpretation of vehicle identification number: Prote cted by

Manufacturer Filler charac‐ code ters

3.6

3D Model

Filler charac‐ ters

Model year 2003

AG.

ZZZ

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WVW

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3.5.1

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3.5

Vehicle data sticker

Location: near spare wheel well

The vehicle data sticker is located in rear of vehicle in spare wheel well -AContents of vehicle data sticker The sticker contains the following data of the vehicle

26 3. General information

000 234

Production lo‐ Serial number cation

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

1 - Vehicle identification number (chassis number) 2 - Vehicle type, motor output, gearbox

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

3 - Motor and gearbox codes, paint number, interior equipment 4 - Optional equipment, PR numbers

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AG.

Prote cted by

c o p yri gh t. C op yi

3.7

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The sticker in service schedule includes the same data. The legend can be found below the sticker.

Severe operating conditions

If the vehicle is used under severe operating conditions some work will have to be performed before the next service is due or at shorter service intervals. •

Regular short trips or stop and go operation in urban traffic

•

High percentage of cold starts

•

Vehicle is used in areas with winter temperatures over a long period

•

Regular long periods of idling (e.g. taxis)

•

Vehicle is often driven at full throttle with high payload or whilst towing a trailer

•

Using diesel with elevated sulphur content

•

Regular operation in areas with high levels of dust

•

Countries with generally poor road conditions such as high number of potholes, protrusions, high elevations in the road/ deep “tramlines”.

•

High number of gravel roads with poor surface quality, such as irregularities/bumps, elevations, protruding stones, waves.

•

Subtropical climates (combination of high ambient tempera‐ ture and high air humidity)

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021

3.8

Countries with hot climate

♦ Countries with hot and super hot climates have elevated peak temperatures (50°C) compared with the European average (25°C).

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

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Prote cted by

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Examples in fuel inadequacies that can lead to shortened main‐ tenance / exchange intervals:

rrectness o f i t to the co n f orm spec atio h re n wit

Country overview for diesel not compli‐ ant with EN 590

in t his d o cu m en

3.9

Lebanon Libya Mexico Morocco n AG. Volkswagen AG do es n wage s k l ot g o Niger yV ua b d ran ir se Oman tee o h t or u ac a Puerto Rico ss Palestine Pakistan Saudi Arabia South Sudan Sierra Leone Somalia Syria Chad Tunisia Togo USA United Arab Emirates West Sahara Central African Republic

ility ab y li an pt ce

Abu Dhabi Algeria Egypt Afghanistan Bahrain Burkina Faso China Dubai Djibouti Eritrea Guinea Guinea-Bissau Iran India Iraq Israel Yemen Jordan Kuwait Cameroon Qatar

un le

♦ Locally high ambient temperatures have an influence on the longevity of the engine, gearbox and coolant circuit, such as journeys uphill and at higher speeds as well as start/stop operation.

♦ High sulphur content ♦ Elevated amount of biodiesel ♦ Contaminants in diesel ♦ Elevated amount of water in diesel Abu Dhabi Afghanistan Egypt Algeria Angola

Gambia Georgia Ghana Guatemala Guinea

Malawi Malaysia Mali Morocco Mauritania

Equatorial Guinea Argentina Armenia

Guinea-Bissau Guyana Haiti

Mauritius Macedonia Mexico

28 3. General information

Sierra Leone Zimbabwe Singapore Somalia Sri Lanka and the Mal‐ dives South Africa Sudan South Sudan

Phaeton 2003 ➤ Maintenance - Edition 03.2021

un le

AG.

es, in part or in w l purpos hole ercia , is n m ot com

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Prote cted by c o p yri gh t. C op yi

3.10

Puerto Rico Republic of Congo Rwanda Russia Zambia Saudi Arabia Senegal Seychelles

Vietnam West Sahara Central African Republic Ivory Coast South Africa

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Kuwait Laos Lesotho Lebanon Liberia Libya Macao Madagascar

in t his d o cu m en

Burkina Faso Burundi Cayman Islands China Costa Rica Democratic Republic of the Congo Djibouti Dominican Republic Dubai Ecuador El Salvador Eritrea Fiji Gabon

rrectness o f i t to the co n f orm spec atio h re n wit

Bolivia Botswana Brazil Brunei

Honduras Moldova Surinam India Mongolia Swaziland Indonesia Mozambique Syria Iraq Myanmar Tajikistan Iran Namibia Tanzania k s l w o a V g . e G n nA Jamaica Nepal AG doe Thailand wage s no olks t gu V y Yemen d b New Caledonia Togo ara e nte ris o e Jordan Nicaragua h t or Trinidad and Tobago a au s s Cambodia Dutch Overseas Territo‐ cChad ries Cameroon Niger Tunisia Canada Nigeria Turkey Cape Verde North Korea Turkmenistan Caribbean driving on the Oman Uganda left Kazakhstan Pakistan Ukraine Qatar Panama Uruguay Kenya Papua New Guinea USA Kyrgyz Republic Paraguay Uzbekistan Columbia Peru Venezuela Cuba Philippines United Arab Emirates ility ab y li an pt ce

Azerbaijan Ethiopia Bahamas Bahrain Bangladesh Belize Benin Bermudas Bhutan

Country overview for petrol not compli‐ ant with EN 228

Examples in fuel inadequacies that can lead to shortened main‐ tenance / exchange intervals: ♦ Petrol contaminated with diesel ♦ High sulphur content ♦ Poor boiling point / evaporation ♦ Metallic components / Octane Booster Additive ♦ Contaminants in petrol Abu Dhabi Afghanistan Egypt Algeria

Georgia Ghana Guatemala Guinea

Angola Equatorial Guinea

Guinea-Bissau Haiti

Mongolia Mozambique Myanmar (Burma) Nepal (Indian subconti‐ nent) New Caledonia Nicaragua

Tanzania Thailand Togo Trinidad and Tobago Chad Tunisia 3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Honduras

ility ab y li an pt ce

Dutch Overseas Territo‐ Turkey ries Azerbaijan Indonesia Niger Turkmenistan Ethiopia Iraq Nigeria Uganda Bahamas Iran North Korea Ukraine Bahrain Jamaica Oman Uruguay Bangladesh Yemen Pakistan Uzbekistan Belize Jordan Panama Venezuela Benin (Dahomey) Cameroon Papua New Guinea United Arab Emirates Bermudas Cape Verde Paraguay Vietnam Bhutan Caribbean, left-hand traf‐ Peru West Sahara fic Bolivia Kazakhstan Philippines Central African Republic Brunei Qatar Republic of Congo Macao Burkina Faso (Upper Vol‐ Kenya Rwanda Libya ta) Burundi Kyrgyz Republic Russian Federation Cayman Islands Chile Columbia Zambia Guyana China Cuba Saudi Arabia Cambodia Costa Rica Kuwait Senegal Democratic Republic of Laos Seychelles . Volkswagen AG the Congo gen AG does a w not olks gu Djibouti Lebanon d by V Sierra Leone ara e nte is r o eo Dominican Republic Liberia Singapore h ut ra a c s s Dubai Madagascar Somalia Ecuador Malawi Sri Lanka El Salvador Maldives South Sudan Ivory Coast Mali Zimbabwe Eritrea Morocco Sudan Fiji Mauritania Suriname Gabon Mauritius Syria Gambia Mexico Tajikistan rrectness of i t to the co nform spec at i h re o n wit in t his

Engine code and engine number Note

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AG.

30 3. General information

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Engine code and engine number »Power unit« ⇒ Power unit; Rep. gr. 00; Technical data/engine number»Technical data/en‐ gine number«.

do c um en

Vehicles with four-digit engine codes: Four-digit engine codes are being introduced, starting with letter “C”. The first three digits show the mechanical design of engine and are stamped on the engine as previously. The fourth digit shows the engine output and torque and varies according to engine control unit.

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3.11

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Armenia

Phaeton 2003 ➤ Maintenance - Edition 03.2021

3.12

RME fuel (biodiesel) Note

The following applies only to vehicles through model year 2007 which can use RME fuel. RME fuel may be used only in vehicles which have been ap‐ proved for this purpose by Volkswagen - either in the standard version or in vehicles which have had special equipment (PR No. 2G0) for this purpose. Note ♦ When RME fuel is used and your vehicle is not suitable for

this, the fuel system can be damaged.

♦ When filling the tank with biodiesel, only use RME fuel con‐

forming to EN 14214 (FAME)!

♦ When biodiesel is used which does not conform to the re‐

quired standard, the fuel filter can become blocked. AG. Volkswagen A

n wage olks V by RME fuel must conform to EN 14214 s(FAME). ed ri o th can be identified by the The RME compatibility of the vehicle au ss

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♦ Performance can slightly be lower when using biodiesel. ♦ Fuel consumption can slightly be higher when using biodie‐ sel. ♦ RME can be used in winter at temperatures to approx. -10 ℃ ♦ At ambient temperatures below -10 °C we recommend using winter diesel fuel. Note

♦ When using biodiesel observe the changed intervals for

changing the diesel fuel filter.

♦ If it is planned not to use the vehicle for approx. two weeks, r fo ng

Countries with high levels of dust AG.

♦ High dust content in the air due to road and environmental conditions.

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c o p yri gh t . C op yi

3.13

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it is recommended to fill the tank with conventional diesel beforehand and drive approx. 50 km, to prevent damage to the fuel injection system.

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Characteristics of RME fuel

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PR number 2G0 on the vehicle data sticker ⇒ page 26 .

Prote cted by

♦ Dust is categorised according to particle size or type of dust (organic and inorganic material) such as e.g. pollen, bacte‐ ria, fungal spores or rock dust, mineral fibres. Abu Dhabi Afghanistan Egypt Algeria

Gabon Gambia Georgia Ghana

Macau Madagascar Malawi Maldives

Somalia Sri Lanka Seychelles South Sudan

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021 n AG. Volkswagen AG do es n Mali ot g ua ran Morocco tee or Mauritania ac

ge waGuatemala Angola olks V by Equatorial Guinea Guinea ed ris o h t Argentina au Guinea-Bissau ss Armenia Guyana Azerbaijan Honduras Ethiopia Hong Kong Australia India Bahrain Indonesia Bangladesh Iraq Belize Israel

Sudan Suriname Swaziland Syria Tajikistan Tanzania Thailand Togo Chad Tunisia

Yemen Jordan Cambodia Cameroon Cape Verde Kazakhstan Qatar Kenya Kyrgyz Republic Columbia Cuba

Panama Papua New Guinea Paraguay Peru

United Arab Emirates Vietnam West Sahara Central African Republic

Kuwait Laos Lesotho Lebanon Liberia

Puerto Rico Rwanda Russian Federation Zambia Saudi Arabia

Ivory Coast

Libya

Senegal

Eritrea French Guyana Fiji

Philippines Burundi Bahamas

Sierra Leone Zimbabwe South Africa

Bermudas Cayman Islands Haiti Jamaica Caribbean, left-hand traf‐ fic Dutch Overseas Territo‐ ries Republic of Congo St. Barthélemy St. Martin Trinidad and Tobago

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AG.

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Prote cted by c o py rig ht . C op yi

Identification plate

To reach the type plate the front passenger door must be opened. The type plate is secured above the lower door hinge.

32 3. General information

do c um en

3.14

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

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Benin (Dahomey) Bhutan Bolivia Botswana Brazil Brunei Burkina Faso (Upper Vol‐ ta) Chile China Costa Rica Democratic Republic of the Congo Djibouti Dominican Republic Dubai Ecuador El Salvador

Mauritius Mexico Mongolia Mozambique Myanmar (Burma) Namibia Nepal (Indian subconti‐ nent) Nicaragua Niger Nigeria North Korea Oman Pakistan Palestine

Turkey Turkmenistan Uganda Uruguay Ukraine Uzbekistan Venezuela

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

Note

In some countries a type plate is not required.

3.15

Shortened intervals for spark plug re‐ placement

Shortened spark plug replacement intervals are necessary if fuel not compliant with DIN EN 228 are used. r te o iva r rp fo g n

♦ Petrol contaminated with diesel c o p yri gh t . C op yi

Prote cted by

♦ Contaminants in petrol Country Abu Dhabi Afghanistan Egypt Algeria Angola Equatorial Guinea Armenia Azerbaijan Ethiopia Bahamas Bahrain Bangladesh Belize Benin (Dahomey) Bermudas Bhutan Bolivia Brunei

AG.

♦ Metallic components / Octane Booster Additive

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♦ Poor boiling point / evaporation

30,000 km / 2 years 20,000 km / 2 years

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♦ High sulphur content

do c um en

Examples in fuel inadequacies that can lead to shortened main‐ tenance / exchange intervals:

15,000 km /1 year

10,000 km /1 year

X X X X X X X X X X X X X X X X X X

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Country

30,000 km / 2 years 20,000 km / 2 years

15,000 km /1 year

X X

X X X X X X X

pe rm itte d

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X X

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34 3. General information

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Burkina Faso (Up‐ per Volta) Burundi Chile X China X Costa Rica X Democratic Repub‐ lic of the Congo Djibouti Dominican Republic X Dubai X Ecuador X El Salvador X Ivory Coast Eritrea Fiji X Gabon Gambia Georgia X Ghana Guatemala X Guinea Guinea-Bissau Guyana X Haiti X . Volkswagen AG gen AG does a Honduras ksw X not l o V gu y b ara d Indonesia X nte ise r o eo h t u Iraq X ra a c s s Iran Jamaica X Yemen X Jordan X Cambodia X Cameroon Cape Verde Caribbean, left-hand X traffic Kazakhstan X Qatar X Kenya Kyrgyz Republic Columbia X Cuba X Kuwait X Laos X Lebanon X Liberia

10,000 km /1 year

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Country

30,000 km / 2 years 20,000 km / 2 years

Libya

10,000 km /1 year

Macao Madagascar Malawi Maldives X Mali Morocco X Mauritania Mauritius Mexico X Mongolia X Mozambique Myanmar (Burma) X Nepal (Indian sub‐ X continent) Nicaragua X Netherlands over‐ X seas territories Ar‐ uba, Curacao, SintMaarten (Dutch) Niger AG. Volkswagen AG d agen oes ksw not l o V Nigeria gu by ara d e nte s i r North Korea o eo h ut ra a c Omanss X Pakistan Panama X Papua New Guinea X Paraguay X Peru X Philippines X Republic of Congo Rwanda Russian Federation X Zambia Saudi Arabia X Senegal Seychelles Sierra Leone Singapore X Somalia Sri Lanka X South Sudan Sudan Suriname Syria Tajikistan X Tanzania

X X X X X X

X X X

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X X X X X X

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15,000 km /1 year

X X X X X X 3. General information

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 Country

30,000 km / 2 years 20,000 km / 2 years

Thailand

10,000 km /1 year

Togo Trinidad and Toba‐ go Chad Tunisia Turkey Turkmenistan Uganda Ukraine Uruguay Uzbekistan Venezuela United Arab Emi‐ rates Vietnam West Sahara Central African Re‐ public Zimbabwe

X X X X X X X X X X X X

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Jacking up mode: switching self-level‐ ling suspension off and on

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•

Vehicle stationary.

•

All vehicle doors must be closed.

– Switch on ignition. – Engage parking brake.

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Switch off self-levelling suspension

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Thus the previously adjusted self-levelling is maintained.

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The self-levelling suspension must be switched off in jacking up mode to prevent automatic adjustment when lifting platform or trolley jack is used.

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The self-levelling suspension must be switched off before vehi‐ cle is raised.

36 3. General information

X X

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3.16

15,000 km /1 year

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Press keys -1- and -2- in centre console and hold for 5 sec‐ onds. The “jacking-up mode” is displayed in the dash panel . Volkswagen AG insert. gen AG d a lksw

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Note

For this method the vehicle must be lowered again. AG.

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– The self-levelling suspension is also activated when driving faster than 5 km/h.

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– Press the two buttons -1- and -2- for more than 5 seconds with ignition switched on.

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There are two methods to activates the self-levelling suspension again.

3. General information

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Descriptions of work

This chapter provides information on the following subjects: ♦ Removable towing bracket: checking ⇒ page 40 ♦ Driving light assist: checking function ⇒ page 43 ♦ Automatic gearbox: checking ATF level / changing ATF ⇒ page 44 ♦ Swivel joints and axle mountings: inspecting ⇒ page 45 ♦ Battery: checking battery terminal clamps for secure seating ⇒ page 45 ♦ Battery: checking with battery tester (always refer to work‐ shop manual) ⇒ page 48 . ♦ User profile: allocating to ignition key, entering name of cus‐ tomer ⇒ page 49 ♦ Tyres: checking condition, wear pattern, tread depth and tyre pressure ⇒ page 50 n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran Brake fluid level (dependent upon lining wear): checking ⇒ rised tee o page 62 h t or u ac a s s Brake system and shock absorbers: inspecting for leaks and

♦ Brake fluid: changing ⇒ page 58

♦ The infotainment system ⇒ page 67

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♦

♦ Brakes, front and rear: checking thickness of brake pads and condition of brake discs ⇒ page 65 ♦ Diesel fuel filter: draining ⇒ page 79 ♦ Diesel fuel filter: renewing ⇒ page 79

♦ Diesel particulate filter: reading ash loading level ⇒ page 85 ♦ Window regulators: checking positioning (open and close functions) ⇒ page 70 ♦ Fault memories of all systems: reading with vehicle diagnos‐ tic tester and correcting possible faults according to repair guidelines ⇒ page 71 ♦ Ignition key: checking function ⇒ page 70

♦ Rear lid: lubricating left and right multi-joint hinges ⇒ page 76 ♦ Dust and pollen filter: cleaning housing and renewing filter element ⇒ page 78 ♦ Interior and exterior body: inspecting for corrosion when doors and flaps are open ⇒ page 86 ♦ Poly V-belt: renewing ⇒ page 78 ♦ Poly V-belt: checking condition ⇒ page 78

38 4. Descriptions of work

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♦ Gearbox mounting: renewing ⇒ page 74

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♦ Protective bellows: inspecting ⇒ page 74

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♦ Changed tyre pressure values: storing using infotainment ⇒ page 73

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♦ Bonnet: greasing catch hook ⇒ page 72

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♦ Front passenger airbag: checking activation/deactivation ⇒ page 71

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AG. Volkswagen AG d agen oes Phaeton 2003 ➤ ksw n t l o V Maintenance - oEdition 03.2021 gu y b ara d nte ise r eo tho coolant level Cooling system: checking frost protection and ra au c s ⇒ page 87 s pe rm itte d

♦ Air filter: cleaning housing and renewing filter element ⇒ page 91

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♦ Multi-purpose additive for diesel fuel: adding ⇒ page 103 ♦ Multi-purpose additive for petrol fuels: adding ⇒ page 105 ♦ Engine cover panel -top-: removing and installing ⇒ page 106 ♦ Engine cover panel -bottom- (noise insulation): removing and installing ⇒ page 108 ♦ Oil level: checking ⇒ page 108

♦ Engine oil: draining or extracting; renewing oil filter and re‐ plenishing engine oil ⇒ page 109 ♦ Engine oil: capacities and specifications ⇒ page 120

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♦ Final drive for manual gearbox: checking oil level ⇒ page 124

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♦ Breakdown set: checking ⇒ page 123

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♦ Wheel securing bolts: tightening to specified torque ⇒ page 122

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♦ Road test (performance, handling, noises, air conditioner etc.): carrying out ⇒ page 121

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♦ Engine and components in engine compartment: inspecting for leaks and damage (from above and below) ⇒ page 121

♦ Wiper blades: checking park position, adjusting if necessary ⇒ page 128 ♦ Windscreen wash/wipe system and headlight washer sys‐ tem: checking fluid level and function ⇒ page 130 ♦ Headlight adjustment: checking gas discharge headlights with DLA ⇒ page 147 ♦ Headlight adjustment: checking gas discharge headlights without DLA ⇒ page 135 ♦ Headlight adjustment: checking fog lights ⇒ page 155 ♦ Service interval display: resetting ⇒ page 124 ♦ Service interval display: recoding ⇒ page 124 ♦ Sunroof: checking function, cleaning and lubricating guide rails ⇒ page 125 ♦ Sliding sunroof drains: checking for blockage, cleaning if necessary ⇒ page 125 ♦ Sliding sunroof seal: re-lubricate ⇒ page 128 ♦ Power assisted steering: checking fluid level ⇒ page 133 ♦ Track rod ends: checking clearance, security and boots ⇒ page 157 ♦ Telematics system: activating and deactivating ⇒ page 157 ♦ Transportation level: deactivating ⇒ page 160 ♦ Door arrester: lubricating ⇒ page 161 ♦ Underbody sealant: inspecting for damage to underbody sealant, underbody panels, routing of lines and plugs ⇒ page 162 .

4. Descriptions of work

♦ Transfer box, front and rear final drive, automatic gearbox: checking oil level ⇒ page 44 ♦ Camshaft drive toothed belt: renewing (8-cylinder petrol en‐ gines) ⇒ page 162 ♦ Central display and control unit (CDCU): setting units of measurement, clock and date ⇒ page 162 ♦ Central display and control unit (CDCU): determining lan‐ guage for lettering and language version ⇒ page 164 ♦ Spark plugs: renewing ⇒ page 165

4.1

Removable towing bracket: checking

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Note that checking towing bracket is included in the respective service. However, a repair is charged separately and must be required by the customer.

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Check procedure

– Remove cover -1-.

– Pull off protective cap -1- from ball head mounting -2-.

40 4. Descriptions of work

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This chapter describes how to check and repair a removable towing bracket.

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♦ Idler pulleys for poly V-belt: renewing (8-cylinder petrol en‐ gines) ⇒ page 162

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Insert ball head into mounting. After ball head has been inserted, green mark on hand wheel must be aligned with white mark on ball head. Hand wheel must be entirely in contact. Afterwards, it must be possible to close the towing bracket lock by removing the key. If this is not possible, the following repair procedure must be performed.

Note

If a repair has to be performed, it has only to be in agreement with the customer. A repair must be charged separately. Repair procedure: gen AG does not gu ara nte eo ra c

– If contact surfaces are corroded, eliminate corrosion with a triangular scraper and clean the treated areas with silicone remover. – Apply a thin coat of lubricating paste G 000 650 or G 000 150 on cleaned surfaces.

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– Check contact surfaces -arrows- of ball head for corrosion.

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– Check contact surfaces -arrows- of ball head mounting for corrosion. Volkswa

4. Descriptions of work

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

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42 4. Descriptions of work

AG.

– Insert cover -1-.

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If protective cap is damaged or not available, a new protective cap must be fitted to protect ball head mounting against corro‐ sion. ⇒ ETKA

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– After checking, fit protective cap -1- into ball head mounting -2-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.2

Driving light assist: checking function Note

The driving light assist is also called automatic headlight control (AHC). •

Vehicle must be in natural daylight.

Checking in daylight or brightness – Switch on ignition.

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– Turn light switch -4- to position -2- for driving light assist.

The headlights may not light in brightness. Checking at night or in darkness •

Ignition is switched on.

•

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4. Descriptions of work

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The rain and light sensor -G397- is secured near the interior mirror.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

The rain and light sensor -G397- is located centrally at top of windscreen -arrow-. lkswagenof – Cover the securing area for interior mirror from AG. Vooutside AG do agen es n kswobject -arrow-. l windscreen by hand or with a suitable ot g o V

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Transfer box, front and rear final drive, automatic gearbox: checking oil level

For procedure refer to »Power transmission« ⇒ Power transmis‐ sion; Rep. gr. 39; Checking oil level»Checking gear oil level«. agen lksw Vo by

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Automatic gearbox: checking ATF level and topping up if necessary AG.

4.4

– For procedure refer to »Power transmission« ⇒ Power trans‐ mission; Rep. gr. 37; Checking ATF level and topping up»Checking ATF level and topping up«.

44 4. Descriptions of work

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Gearbox code letters are located on vehicle data plate ⇒ page 26 .

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4.3

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– Turn light switch -4- to position O -1- and switch off ignition.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.5

– –

Swivel joints and suspension link mountings: inspecting

Battery: checking battery terminal clamps for secure seating

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Depending on the vehicle equipment, a battery can be found in the left luggage compartment and additionally a second battery in the right luggage compartment.

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Battery in luggage compartment, left Special tools and workshop equipment required ♦ Torque wrench Note

A securely seated battery terminal clamp ensures trouble free function and long service life of the battery.

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Carry out following procedure:

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– Turn the catches -arrows- to left and remove cover.

4. Descriptions of work

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– Check whether battery terminal clamps are secure on bat‐ tery terminals by moving battery negative cable -1- and bat‐ tery positive cable -2- back and forth.

NOTICE

The battery clamp on the positive terminal is not firmly attach‐ ed. Risk of short circuit or flying sparks. – First, always disconnect the battery earth strap from the battery negative terminal. r fo ng

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– Tighten battery terminal clamp -2- on battery positive termi‐ nal to 6 Nm. – Reconnect battery terminal clamp -1- to battery negative ter‐ minal, and tighten it to 6 Nm. – Tighten bolt -3- for battery attachment to 15 Nm. Note

After the battery has been reconnected: »Vehicle electrics; Electrical system« ⇒ Vehicle electrics; Electrical system; Rep. gr. 27; Procedure after connecting battery»Procedure after con‐ necting battery«. If battery terminal clamp is NOT seated securely on negative terminal: – Tighten battery terminal clamp -1- on battery negative termi‐ nal to 6 Nm.

46 4. Descriptions of work

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– Disconnect battery terminal clamp -1- from battery negative terminal first.

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If the battery terminal clamp is not seated securely on positive terminal:

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

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Maintenance - Edition 03.2021

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– Reinstall engine cover panel.

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Battery in luggage compartment, right

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Carry out following procedure:

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– Unhook the lower cover -arrows-. – Pull cover off in direction of luggage compartment. – Check whether battery terminal clamps are secure on bat‐ tery terminals by moving battery negative cable -1- and bat‐ tery positive cable -2- back and forth.

NOTICE The battery clamp on the positive terminal is not firmly attach‐ ed. Risk of short circuit or flying sparks. – First, always disconnect the battery earth strap from the battery negative terminal. If the battery terminal clamp is not seated securely on positive terminal:

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Disconnect battery terminal clamp -1- from battery negative terminal first.

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nal to 6 Nm.

– Tighten bolt -3- for battery attachment to 15 Nm. Note

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– Reconnect battery terminal clamp -1- to battery negative ter‐ minal, and tighten it to 6 Nm.

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–

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4.7

Battery: checking with battery tester (always refer to workshop manual)

The following are measures to be carried out during a battery inspection within the scope of maintenance. Procedure 1.

Visual check.

Check whether colour indicator is “3-colour” or “2-colour”. Does not apply to AGM batteries.

Battery check using battery tester with printer -VAS 6161-.

48 4. Descriptions of work

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– Reinstall engine cover panel.

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– Tighten battery terminal clamp -1- on battery negative termi‐ nal to 6 Nm.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 4.

Depending on the result of the battery test, “perform cur‐ rent draw test” (charged separately).

⇒ Electrical system, General information; Rep. gr. 27; Checking battery

4.8

User profile: allocating to ignition key, entering name of customer Note

Settings, e.g. for the driver seat, the mirrors, the air conditioning system etc. are stored in a user profile and allocated to a key, so that the settings must not be made again at the start of every journey. Automatic allocation of a user profile – Unlock the vehicle. When a door is unlocked with a key allocated to a profile, the infotainment sets all functions to the stored values. Volkswagen AG AG.the After the ignition is switched infotainment genon, does switches on swa k not l o and the welcome screen is shown whilst the infotainment is V gu y ara db e started. nt ris

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u The infotainment system automatically recognises which keyr acis sa used and sshows which user profile is active.

Then the initial screen is shown. The actual profile is shown by the small key symbol. Selecting user profile manually

Other user profiles can also be called up via the initial screen. Using function button »Guest« the system is started with the standard values adjusted at the factory.

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Enter name for a user profile

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If a user profile is already allocated to the ignition key in use, all stored settings for the user are now activated by the system.

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– Select button SETTINGS in the main menu block -2-. – Select »User profiles«. – Press »Assign key« to assign the vehicle key currently being used to a specific user profile. – Store. – Press »Profile name« to enter a name to the selected profile.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Select lettering and name by turning the rotary/push button in the main menu block -2-. – Confirm selection by pressing the rotary/push button in the main menu block -2-. – Press “Save”.

4.9

Tyres: checking condition, wear pat‐ tern, tread depth, tyre pressure and age

In this chapter you will obtain information on the following sub‐ jects: Checking condition of tyre ⇒ page 50 .

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee Checking tread depth of tyres (including spare wheel)or⇒ page h t or u 51 ac a ss

Checking wear pattern ⇒ page 51 .

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Check tyre inflation pressure using tyre inflator -VAS 5216-, correct if necessary ⇒ page 53 .

4.9.1

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Tyre pressures, Phaeton ⇒ page 56 .

Tyres: checking condition

Tests at delivery inspection

– Check tyre side walls and treads for damage and foreign bodies such as, for example, nails or glass splinters. Tests at service

– Check tyre side walls and treads for damage and foreign bodies such as, for example, nails or glass splinters.

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– Check for appropriate direction of rotation, or make sure that the inner and outer sides have not been interchanged.

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50 4. Descriptions of work

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If damage is determined, always check to see if a new tyre should be fitted.

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Note

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– Check tyres for cupping, one-sided wear, porous side walls, cuts and punctures.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.9.2

Wear pattern: checking

Note

The wear pattern on the front tyres will indicate, for example, if toe and camber settings should be checked: Possible causes of fault: ♦ Feathering on tread indicates incorrect toe setting. ♦ One-sided tread wear is mainly attributed to incorrect cam‐ ber. – When wear of this nature is detected, determine cause by checking alignment (repair measure).

4.9.3

Tread depth: checking (including spare wheel)

– Check tyre tread depth. Minimum tread depth: 1.6 mm Note un le

♦ This figure may vary according to legislation in individual pe rm itte d

countries. Your importer will inform you about this.

♦ The minimum tread depth is reached when the tyres have ♦ If the tread depth is approaching the minimum allowed

depth, inform the customer.

4.9.4

General information

NOTICE

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For safety reasons, only tyres of same type and tread pattern should be fitted on a vehicle! – Observe approved wheel and tyre combinations. ⇒ Wheels and tyres guide; Rep. gr. 44; Wheels, tyres, vehicle geom‐ etry; Wheel and tyre combinations

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worn down level with the 1.6 mm high tread wear indicators -arrows- positioned at intervals around the tyre.

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4. Descriptions of work

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

NOTICE On vehicles with four-wheel drive, tyres of the same type and tread pattern must be used. Damage to centre differential possible. – Observe approved wheel and tyre combinations. ⇒ Wheels and tyres guide; Rep. gr. 44; Wheels, tyres, vehicle geom‐ etry; Wheel and tyre combinations n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r found on Tyre pressures for the relevant model can also be o h t or uor to B-pillar. ac a a sticker. It is attached to the inside of tank flap ss

Note

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♦ The pressures on the sticker apply to cold tyres. Do not pe rm itte d

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♦ Depending on the vehicle, the sticker may also contain in‐

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formation on the comfort tyre pressure. The comfort tyre pressure facilitates improved driving comfort.

♦ Driving with comfort tyre pressure may result in an increased

fuel consumption.For delivery inspections or repairs, the par‐ tial load tyre pressure is to be used.

♦ Adjust the tyre pressure to suit the vehicle load. For delivery

inspections or repairs, the partial load tyre pressure is to be used.

♦ If no inflation pressure is shown for the spare wheel, then

inflate the spare wheel to the highest inflation pressure for the vehicle.

♦ Please note that basic setting should be performed on vehi‐ r te o iva r rp fo ng

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♦ ⇒ Wheel and tyre guide - Standard; Rep. gr. 44; Recommen‐

ded winter tyres (Running gear → Wheel and tyre guide Standard → Rep. Gr. 44 → Recommended winter tyres)

♦ If winter tyres are fitted, a sticker, visible for the customer

and indicating the speed limit, must be applied in the interior of the vehicle.

♦ For winter tyres, the tyre pressure does not have be in‐

creased. However, this only applies if the winter tyre used corresponds exactly to the standard summer tyre size and the speed index is no higher than “H”. If this is not the case, please refer to the recommendation of the tyre manufactur‐ er. Note

For technical reasons it is possible that several cross referen‐ ces are not directed to the correct chapter. In this case select the procedure manually in the information.

52 4. Descriptions of work

AG.

♦ Important information on recommended winter tyres can be

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Note

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M+S tyres

in t his d o cu m en

cles with Tyre Pressure Loss Indicator after every pressure change ⇒ page 73 .

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.9.5

Tyre pressures, Phaeton

Special tools and workshop equipment required ♦ Tyre inflater -VAS 5216-

Note ♦ During delivery inspection, check that inflation pressure

sticker is fitted. If the sticker is missing, order a new sticker through ETKA.

♦ The mandatory tyre pressures for the respective model can

be found on a sticker attached to the inside of tank flap or to the B-pillar.

♦ If the inflation pressure sticker is missing, proceed as fol‐

lows:

♦ Locate correct part number for respective vehicle in ETKA. Volkswa

gen AG does not gu b ara d inflation table. nte ise r o eo h t u ra Uniform pressure: if tyre ssizes are not shown for a part num‐ a c s

AG. agen

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ber, then a uniform pressure is valid for all authorised wheel/ tyre combinations. ⇒ Wheels and Tyres Guide - Standard; Rep. gr. 44 pe rm itte d

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Part number -3D0 010 693 CPart number -3D0 010 750 CPart number -3D0 010 780 RPart number -3D0 010 806 C-

Phaeton

Half payload kPa/bar/psi

Full payload kPa/bar/psi Rear

Front

235/55 R17 255/45 R18 235/50 R18 245/45 R19 255/40 R19

250/2.5/36

230/2.3/33

270/2.7/39

260/2.6/38

300/3.0/44 ht rig py Co t.

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Front

Rear 310/3.1/45 340/3.4/49

do c um en

Tyre size

280/2.8/41

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Check tyre pressure using tyre inflator -VAS 5216-, correct if necessary.

4. Descriptions of work

Prote cted by

c o p yri gh t. C op yi

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Part number -3D0 010 693 D-

Phaeton Half payload kPa/bar/psi

Full payload kPa/bar/psi

Tyre size

Front

Rear

Front

Rear

235/55 R17 255/45 R18 235/50 R18 245/45 R19 255/40 R19

250/2.5/36

230/2.3/33

270/2.7/39

310/3.1/45

270/2.7/39

250/2.5/36

290/2.9/42

330/3.3/48

Part number -3D0 010 692 TPart number -3D0 010 750 DPart number -3D0 010 693 GPart number -3D0 010 806 D-

Phaeton

Half payload kPa/bar/psi Rear

235/55 R17 255/45 R18 245/45 R19 235/50 R18 255/40 R19

250/2.5/36

230/2.3/33

pe rm itte d

270/2.7/39

310/3.1/45

290/2.9/42

330/3.3/48

Phaeton

235/50 R18 245/45 R19 255/45 R18

300/3.0/44 280/2.8/41

Rear

Front

Rear

280/2.8/41

320/3.2/46

340/3.4/49

260/2.6/38

300/3.0/44

340/3.4/49

Part number -3D0 010 700 APart number -3D0 010 707-

AG.

Front

Prote cted by c o p yri gh t. C op yi

Tyre size

Full payload kPa/bar/psi

r te o iva r rp fo ng

Half payload kPa/bar/psi

Phaeton Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

245/45 R19

3.0

2.8

3.2

3.4

54 4. Descriptions of work

in t his d o cu m en

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Rear

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Part number -3D0 010 708 NPart number -3D0 010 750 EPart number -3D0 010 693 SPart number -3D0 010 806 EPart number -3D0 010 693 H-

250/2.5/36

Front

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270/2.7/39

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Front

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Tyre size

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

235/50 R18 101Y 255/45 R18 103Y

3.2/45 3.0/44

3.0/44 2.8/41

Part number -3D0 010 360 G-

235/50 R18 101Y 255/45 R18 103Y

Phaeton Half load bar/psi

Full load bar/psi

3.4/49 3.4/49

Front

Rear

Front

Rear

3.3/48 3.1/45

3.1/45 2.9/42

3.4/49 3.3/48

3.4/49 3.4/49

Part number -3D0 010 693 J-

Phaeton Full load bar

Tyre size

Front

Rear

Front

235/55 R17 255/45 R18 245/45 R19 235/50 R18 255/40 R19

2.4

2.2

2.6

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Part number -3D0 010 693 B-

AG.

2.4

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2.6

Rear

2.8

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Half load bar

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Tyre size

3.4/49 3.2/45

Rear

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Front

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Tyre size

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Part number -3D0 010 360 E-

3.0

3.2

Phaeton Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

235/50 R18 245/45 R19 255/45 R18

3.0

2.8

3.2

3.4

2.8

2.6

3.0

3.4

Part number -3D0 010 000-

Phaeton Half payload kPa/bar/psi

Full payload kPa/bar/psi

Tyre size

Front

Rear

Front

Rear

245/45 R19 255/45 R18

250/2.5/36 270/2.7/39

230/2.3/33 250/2.5/36

270/2.7/39 290/2.9/42

310/3.1/45 330/3.3/48

Part number -3D0 010 851 Q-

Phaeton Half load bar

Full load bar

Tyre size

Front

Rear

Front

Rear

235/55 R17 255/45 R18

2.5

2.3

2.7

3.1

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Rear

Front

2.7

2.5

2.9

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

245/45 R19 275/35 R20 235/50 R18 255/40 R19

Front

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Tyre size

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Part number -3D0 010 000 A-

Tyre size All 1)

Phaeton Half load bar Rear

Front

2.5

2.3

2.7

Rear

1) Valid for all authorised wheel/tyre combinations. ⇒ Wheels

r fo ng

and Tyres Guide - Standard; Rep. gr. 44

Phaeton

4.9.6

Prote cted by

2.6 2.8

2.4

AG.

235/55 R17 255/45 R18 235/50 R18 245/45 R19 255/40 R19 275/35 R20

Rear

2.6

Tyre pressure: checking with tyre pres‐ sure monitoring system

With infotainment system ⇒ page 57 With multi-function display in dash panel insert ⇒ page 58 Note

The tyre pressure monitoring system is an additional equip‐ ment. When the tyre pressure monitoring system is being used, infor‐ mation regarding the tyre pressure can be obtained and com‐ pared with the specified values. The tyre pressure monitoring system is used by means of the infotainment system or the multifunction display in the dash panel insert. For additional information see also ⇒ page 67 For required tyre pressures, see page ⇒ page 50

56 4. Descriptions of work

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Front

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Half load bar

Tyre size

3.3

Full load bar

Front

Part number -3D0 010 851 P-

Rear

3.1

Full load bar

Front

Rear

2.8

3.2

3.0

3.4

Phaeton 2003 ➤ Maintenance - Edition 03.2021 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

– Press VEHICLE button -1- for the actual tyre pressures or to switch on the tyre pressure monitoring in the submenu.

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Initial screen of tyre pressure monitoring. System is being initial‐ ised.

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With infotainment system

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Prote cted by

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Note

The function buttons are located at the side of the display next to the relevant text. – Press function button »ON/OFF«, to switch on the tyre pres‐ sure monitoring. – Press function button »Filling info«. Deviations from the specified values can be displayed. Here the specified tyre pressures are displayed at the current tyre temperature in order to let you know what the specified pressure of the warm tyre is. If the values are displayed as »O.K.«, – Press »Back«. If the values are displayed as »not O.K.«, – Correct the tyre pressure, and store the new specified pres‐ sures. For information on how to store the new specified pressures see »New specified pressures«.» « ⇒ page 73 Spare wheel monitoring: – Press »Spare wh. monitor« button to check if the tyre pres‐ sure of the spare wheel differs from the specified value.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 With multifunction display in dash panel insert Note

In the case of this system, the spare wheel (if there is one) must be checked manually. There are wheel electronics in the spare wheel but they cannot supply values until the wheel has been bolted onto the vehicle. The Trigger transmitter necessary for this is not provided for the spare wheel. – In the main menu “Settings”, select the menu item “Tyre pressure”. – In the submenu “Specified pressures”, check whether partial n AG. Volkswagen AG do load or full load has been set. e wage s no t

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– Check the pressure values in the menu “Veh. status”.

♦ Orange: Tyre pressure warning, pressure must be checked ♦ Grey: No wheel electronics detected Note

If there is too much pressure in the tyres, the colour shown remains white as if the pressure were O.K. The specified values must therefore be compared with the saved values in advance. r te o iva r rp fo ng

– When correcting tyre pressures, always inflate with a little more air and then slowly lower the pressure. When doing so, bear in mind the values on the MFI. – If all the values have been corrected and the saved values differ from the prescribed values, then save the new values in the submenu “Change specified pressures”. AG.

Safety notes ⇒ page 58

Procedure, changing brake fluid ⇒ page 59 .

4.10.1

Safety information

CAUTION Risk of skin injuries from acidic brake fluid. Irritation and injury to skin possible. – Avoid contact with eyes.

58 4. Descriptions of work

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Brake fluid: changing

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4.10

in t his d o cu m en

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♦ White: Tyre pressure O.K.

rrectness o f i t to the co n f orm spec atio h re n wit

The wheels of the vehicles can be in three different colours on the MFI.

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gu by ara the – In the “Change specified pressures” submenu, compare ed nte s i r saved specified pressures with the prescribed pressures for o e h ut partial loads aand full load ⇒ page 53 , and correct them if or ac s necessary.

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NOTICE

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Risk of damage to the vehicle from acidic brake fluid. Damage to paintwork and vehicle possible. – Avoid contact of brake fluid with components and paint‐ work, and rinse off any spills with water.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o Phaeton 2003 ➤ eo h t u ra a c Maintenance Edition 03.2021 s s

NOTICE

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4.10.2

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Brake fluid is hygroscopic, i.e. it absorbs moisture from the ambient air. Too much water in the brake fluid can lead to brake system failure. Too high water content also increases the risk of cor‐ rosion within the brake system. – Brake fluid must be stored in air-tight containers.

do c um en

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Risk of damage to the brake system due to improper handling of brake fluid. Mineral oils will damage the plugs and sleeves of the brake system. – Avoid mixing brake fluid with fluids containing mineral oil (such as oils, petrol, cleaning agents etc.).

Procedure, changing brake fluid

Special tools and workshop equipment required ♦ Brake filling and bleeding equipment -VAS 5234-

♦ Brake filling and bleeding equipment -VAS 6860-

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ Tool set for brake bleeding -VAS 6564-

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Carry out following procedure:

60 4. Descriptions of work

AG.

– Release securing bolts -1- and -2- and remove cover up‐ wards.

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– Adjust correct pressure on brake filling and bleeding unit: »Running gear, brake systems« ⇒ Running gear, brake systems; Rep. gr. 47; Bleeding brake system»Bleeding brake system«.

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Observe ⇒ operating instructions for brake filling and bleeding unit.

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♦ Brake pipe bleeding spanner -VAS 5519-

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– Unscrew cap from brake fluid reservoir.

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AG.

Prote cted by c o p yri gh t. C op yi

– Screw adapter onto brake fluid reservoir.

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Ensure that no brake fluid runs through the strainer after com‐ pleting extraction (the brake fluid level in the reservoir must be even with the lower edge of the strainer).

do c um en

Note

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– Extract as much brake fluid as possible using suction hose from brake filling and bleeding unit with strainer installed.

– Connect filling hose from brake filling and bleeding unit to adapter. – Remove caps from bleeder screws of brake calipers. – Push collector bottle bleed hose onto rear bleeder screw 1) , open bleeder screw and let appropriate quantity of brake fluid run out. Close bleeder screw. Torque: »Running gear, brake systems« ⇒ Running gear, brake systems; Rep. gr. 47; Repairing rear brake caliper»Repairing rear brake caliper«. Note

Use suitable bleeder hose. It must seat tightly on bleed screw so that no air can enter the brake system. 1) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive vehicles.

Repeat procedure on other side of vehicle at rear. Note

If brake caliper has 2 valves, connect first the inner and then the outer bleeder valve. – Push collector bottle bleed hose onto front bleeder screw 2) . Open bleeder screw and let appropriate quantity of brake fluid run out (see following table). Close bleeder screw. Torque: »Running gear, brake systems« ⇒ Running gear, brake systems; Rep. gr. 47; Repairing front brake cali‐ per»Repairing front brake caliper«. 2) Start at front right of left-hand drive vehicles and at front left of right-hand drive vehicles.

Repeat procedure on other side of vehicle at front. 4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Table – Sequence and quantity of brake fluid Sequence: wheel brake cylinder, brake caliper

Brake fluid quantity which must flow out of wheel brake cylin‐ ders or brake calipers:

Rear right Rear left Front right Front left

0.25 litre 0.25 litre 0.25 litre 0.25 litre

Total quantity: approx. 1 litre including the amount extracted from the brake fluid reservoir. – Fit caps on bleeder screws of brake calipers. – Switch off brake filling and bleeding equipment. – Take filler hose off adapter. – Unscrew adapter from brake fluid reservoir.

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– Install cover.

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– Screw on cap of brake fluid reservoir.

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– Check brake fluid level -1- and -2- and correct if necessary.

– Check pedal pressure and brake pedal free play. Free play: max. 1/3 of pedal travel.

Brake fluid level (dependent upon brake pad/lining wear): check. r fo ng

Procedure, brake fluid level (dependent upon lining/pad wear): check ⇒ page 63 .

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62 4. Descriptions of work

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Instructions for use and safety ⇒ page 58 .

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4.11

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.11.1

Procedure, brake fluid level (depend‐ ent upon lining/pad wear): checking

– Release securing bolts -1- and -2- and remove cover up‐ wards. Note the following:

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Brake fluid level at delivery inspection:

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

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pe rm itte d

– For the delivery inspection the fluid level must be at MAX. marking -1-.

In order that brake fluid does not overflow the reservoir, MAX marking -1- must not be exceeded. Brake fluid level at inspection service The fluid level must always be judged in conjunction with lin‐ ing/pad wear. When vehicle is in use, fluid level tends to drop slightly due to lining/pad wear and automatic adjustment.

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Recommended brake fluid level, if brake pads are almost at wear limit:

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•

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

“At MIN marking or just above” -2-, “REPLENISHING IS NOT REQUIRED”. •

Recommended brake fluid level when brake pads are new or well within pad wear limit:

“Between MIN and MAX marking”. Note

If the fluid level is below min. marking -2-, the brake system must be checked for leaks before fluid is topped up, “Repair measure”.

4.12

Brake system and shock absorbers: in‐ specting for leaks and damage

Check following components for leaks and damage: ♦ Brake master cylinder ♦ Brake servo (for anti-lock brake system: hydraulic unit) ♦ Brake pressure regulator and ♦ Brake caliper

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♦ Shock absorbers (during inspection only)

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♦ Presence of caps on guide bushes

– Ensure that brake hoses are not twisted.

– Additionally ensure that brake hoses do not touch any vehi‐ cle components when steering is at full lock. – Check brake hoses for abrasion, porosity and brittleness. – Check brake lines for corrosion.

– Check brake connections and fastenings for correct seating, leaks and corrosion. – Check brake lines and brake hoses for correct seating and attachment in retainers. Note

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64 4. Descriptions of work

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Faults found must always be rectified (repair measure).

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♦ Presence of dust caps on brake fluid bleeder screws

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.13

Brakes, front and rear: checking thick‐ ness of brake pads and condition of brake discs

Front disc brake pads: checking thickness ⇒ page 65 Rear disc brake pads: checking thickness ⇒ page 66 Brake discs: checking condition ⇒ page 67 Special tools and workshop equipment required ♦ Pliers -3314-

♦ Torque wrench ♦ Electric hand torch and mirror Note

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara The adapter to loosen and tighten the anti-theft wheel bolts can d nte ise r o be found in the vehicle tool kit. eo h t u ra a c s s pe rm itte d

Front brake pads:

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es, in part or in w l purpos hole ercia , is n m ot com

– For better evaluation of remaining pad thickness, use a test mirror and, if necessary, remove the wheel on the side where the brake pad wear indicator is installed. – If necessary, pull off wheel bolt covers using pliers 3314. – Mark position of wheel relative to brake disc. – Unbolt wheel bolts and remove wheel.

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a - Brake pad thickness without backplate

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– Measure thickness of inner and outer pads.

- Wear dimension: 2 mm

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 The brake pads have reached their wear limit at a pad thick‐ ness of 2 mm (without backplate) and must be renewed (repair measure). Inform customer! Note ♦ When replacing brake pads, always check brake discs as

well for wear!

♦ Checking and if necessary replacing the brake discs is a

repair measure.

– Check brake disc for wear »Running gear, brake sys‐ tem« ⇒ Running gear, brake system; Rep. Gr. 46; Servicing front brakes»Servicing front brakes«. – Install wheel in marked position. – Tighten wheel bolts diagonally and alternately to following specified torque: Specified torque: 120 Nm – Place adapter in vehicle tool kit after completing work. – Fit wheel bolt covers if necessary . Rear brake pads: – Illuminate area behind hole in wheel using an electric hand torch. – Inspect outer pad to determine thickness. – Illuminate inner pad with an electric hand torch and mirror. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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– Inspect inner pad to determine thickness.

a - Inner and outer pad thickness without backplate - Wear dimension: 2 mm

The brake pads have reached their wear limit at a pad thick‐ ness of 2 mm (without backplate) and must be renewed (repair measure). Inform customer! Note

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♦ Checking and if necessary replacing the brake discs is a agen lksw Vo by

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66 4. Descriptions of work

c o p yri gh t. C op yi

repair measure.

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♦ When replacing brake pads, always check brake discs as

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Check brake disc for wear »Running gear, brake sys‐ tem« ⇒ Running gear, brake system; Rep. Gr. 46; Servicing rear brakes»Servicing rear brakes«. Check brake discs Check all brake discs for the following damage pattern: ♦ Cracks ♦ Scoring ♦ Rust (no surface rust) ♦ Burrs on circumference of brake disc Note

Inform customer if brake disc damage is similar to these dam‐ age patterns. Renewing the brake discs is a repair measure.

4.14

The infotainment system

4.14.1

General information on infotainment system

The infotainment system is an electronic system controlling a variety of functions centrally. n AG. Volkswagen A

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♦ Service functions (wiper blades and headlight adjustment) ♦ Navigation (route guidance, route information) ♦ Running gear adjustment (self-levelling and damper control) ♦ etc.

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Control of these functions can be performed via following com‐ ponents:

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♦ Setting variants (voice control, country selection etc.)

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eo tho system (heater controls and air conditioning ♦ Air conditioning ra au c s system, solar sunroof function, auxiliary heater) s

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Infotainment operation via central display and control unit (CDCU) at front in centre console -1AG.

Operation see ⇒ page 68

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note

The functions actually available in the vehicle are dependent on the vehicle equipment.

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Detailed information for the infotainment system can be found in ⇒ Self-study programme No. 274; .

Operation see ⇒ page 69

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Infotainment operation using multifunction steering wheel -arrowInfotainment operation via central display and control unit (CDCU) at rear of vehicle Operation see ⇒ page 70

The respective main menu is shown on display when pressing a button. ♦ The SETTINGS button includes various possibilities to adapt the infotainment system (e.g. key profile, languages, date/ time). ♦ The button RESET resets all functions to standard values adjusted at the factory. ♦ The button ON/DARK switches the infotainment on with igni‐ tion switched off and off with ignition switched on.

68 4. Descriptions of work

AG.

Twelve different functions are controlled with the main menu buttons -2-.

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Main menu block -2- with central rotary/push button

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Central display and control unit (CDCU) operation at front in centre console

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4.14.2

Phaeton 2003 ➤

♦

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The buttons of air conditioning block have fixed functions. In addition to these buttons various adjustments can be done via the function buttons. The buttons are always active. c o p yri gh t . C op yi

The audio block is used to control the radio, TV and music CD functions as well as sound and balance settings.

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Multifunction steering wheel operation AG.

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4.14.3

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The audio block -3-

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The air conditioning block -1-

The 3 buttons for infotainment operation -arrow- are located on inner area of steering wheel, lower right.

Button -1- selects among 7 different displays in the dash panel insert.

Button -2- is a knurled thumb wheel. Values can be selected from a list and confirmed by pressing the thumb wheel. 4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Button -3- shows the previous display or interrupts a procedure.

4.14.4

Central display and control unit oper‐ ation (CDCU) in rear passenger com‐ partment

The buttons of this unit only permit access only to the rear climatic zones.

4.15

Electric windows: checking positioning n AG. Volkswagen AG do es n wage (open and close functions) s k l ot o

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yV db ir se CAUTION ho ut a s After batteries have been disconnected ands reconnected the

Note

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roll-back function of the electric window regulators is disabled. Severe pinching injuries could result! – Reactivate window regulators.

♦ The automatic opening and closing functions of the electric

windows do not work after the batteries have been discon‐ nected and reconnected.

♦ Therefore, with immediate effect, before a new vehicle is

delivered, the window regulators must be reactivated.

♦ Once the windows have been repositioned, the batteries

must not be disconnected again.

Prote cted by

– Lock vehicle again from outside and hold key in lock position for at least 1 second. The one-touch opening and closing function is now ready for use.

4.16

Vehicle keys: checking function

– Separate key ring, so that the function of every key can be checked. – Lock and unlock the vehicle mechanically with keys on driver door. – Insert vehicle keys in ignition lock one after the other and start engine. – If the engine switches off after approx. 3 seconds, the vehi‐ cle key is not adapted to the immobilizer. – Procedure: Guided fault finding (adapting vehicle keys) »General body repairs, exterior« ⇒ General body re‐ pairs, exterior; Rep. gr. 57; Front door, central locking;»Front door, central locking«, adapting ignition keys with remote control.

70 4. Descriptions of work

AG.

– Unlock vehicle again.

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– Insert key into driver door lock and lock the vehicle from outside.

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– Close all doors and windows completely.

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Carry out the following procedure to reactivate the automatic functions of the window regulators:

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Enter number of checked and handed-over ignition keys in diagnosis log.

4.17

Fault memory of all systems: reading with vehicle diagnostic tester, correct‐ ing possible faults according to repair guidelines

– Read event memory ⇒ Vehicle diagnostic tester. – Repair all faults according to repair guidelines. Static faults If one or more static faults are found in the event memory, we recommend seeking agreement from the customer to rectify these faults using Guided Fault Finding. Sporadic faults If only sporadic faults or notes are stored in the event memory and the customer has no complaints regarding the vehicle elec‐ tronic system, erase event memory. Note

The vehicle must always be delivered to the customer with event memory cleared.

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Front passenger airbag: checking acti‐ vation/deactivation un le

4.18

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– Switch off ignition.

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Front passenger airbag deactivated

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– Check “On / Off function” of key switch as follows:

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– Switch off ignition.

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– Check if warning lamp -2- “AIRBAG OFF” in centre console lights up continuously with ignition switched on.

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– Turn ignition key -1- in key-operated switch in centre console to position “perpendicular to direction of travel”.

Front passenger airbag activated – Switch off ignition. – Turn ignition key -1- in key-operated switch in centre console to position “to direction of travel”.

4. Descriptions of work

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Check if warning lamp -2- “AIRBAG OFF” in centre console does not light up with ignition switched on.

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The front passenger airbag must only be deactivated if in ex‐ ceptional cases a child is transported in a rear-facing child seat on the front passenger seat. Prote cted by

Special tools and workshop equipment required ♦ Universal oil spray G 000 115 A2 Note

Vehicle must be at least at room temperature. Applies only to vehicles ►2010 – Lubricate bonnet arrester with universal oil spray G 000 115 A2 at points marked with -arrows-.

– Operate moving parts several times so that universal oil is able to penetrate. – Remove any excess lubricant using a lint-free cloth. Applies only to vehicles 2011► – Lubricate bonnet arrester with universal oil spray G 000 115 A2 at points marked with -arrows-.

72 4. Descriptions of work

AG.

Bonnet catch hook: grease.

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4.19

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Note

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– Switch off ignition.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Operate moving parts several times so that universal oil is able to penetrate. – Remove any excess lubricant using a lint-free cloth.

4.20

Changed tyre pressure values: storing using infotainment

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The procedure for vehicles with multifunction display in the dash panel insert is described in the chapter entitled “Checking tyre pressure with tyre pressure monitoring system” ⇒ page 56 .

– Press button VEHICLE , -1-.

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Note

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Initial screen of tyre pressure monitoring. System is being initial‐ ised.

The function buttons are located at the side of the display next to the relevant text.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Press function button »ON/OFF«, to switch on the tyre pres‐ sure monitoring. New specified pressures:

– Press function button »New specified pressures«. Using the rotary/push button the current tyre pressures can be determined as new specified pressures in the submenu. – Then press button “Accept”.

4.21

Boots: inspecting . Volkswagen AG

AG – Check outer and inner boots -arrowsfor leaks and damage. agen ksw

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For vehicles with four-wheel drive, also check bellows on rear axle. r fo ng

Gearbox mounting: renewing

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74 4. Descriptions of work

AG.

AL350–5F/AL420-6Q

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Gearbox mounting overview:

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– For procedure refer to »Power transmission« ⇒ Power trans‐ mission; Rep. gr. 37; Removing and installing gearbox»Re‐ moving and installing gearbox«.

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4.22

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– Ensure clamps -1- are fitted on boots.

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AL560-5Q

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Phaeton 2003 ➤

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AL750-6Q

4. Descriptions of work

Phaeton 2003 ➤ . Volkswagen AG Maintenance - Edition 03.2021 gen AG does swa

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♦ The description applies to vehicles up to chassis number

WVWZZZ3DZ58003901.

♦ Lubricant/penetrating oil specification: G 000 115 A2 (200 ml

spray can)

Corrosion protection measures: – Open rear lid.

– Remove left and right lid hinge cover, if fitted.

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Note ♦ Fit supplied spray tube into spray head to enable direct

spraying.

♦ Shake the spray can about 5 times. ♦ The spray can should not be shaken often or violently, oth‐

erwise the oil will foam and this will inhibit its penetrating properties.

– Open and close the rear lid fully a few times. – Reassemble vehicle. – Remove excessive oil from the joints and body. Additional work when hinges are stiff: Note ♦ This additional work is no longer part of the maintenance

and should be treated as a repair measure.

♦ Perform the following procedure to free the hinges again and

protect against corrosion in the future:

– Open rear lid. – Remove left and right lid hinge cover, if fitted.

76 4. Descriptions of work

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– Spray the four hinge joints on both rear lid hinges -arrows-.

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Note

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Rear lid: lubricating left and right multijoint hinges un le

4.23

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

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– Spray the four hinge joints on both rear lid hinges -arrows-.

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wagen repairs, AG. Volksbody AG do – Remove gas-filled strut -2-a⇒ General exterior; n e w ge Rep. gr. 55; Rear lid;y VRemoving gas-filled strut. s not g olks

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Note ♦ Fit supplied spray tube into spray head to enable direct

spraying.

♦ Shake the spray can about 5 times. ♦ The spray can should not be shaken often or violently, oth‐

erwise the oil will foam and this will inhibit its penetrating properties.

The hinges must have a temperature of at least 30°C in the area of the joint, so that the universal oil can penetrate the hinge joints. At cold ambient temperatures before spraying, the hinges must be heated in the area of joint to approx. 30 - 40 °C, using a hot air blower. – Open and close the rear lid fully about 15 times.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note

This hinge treatment must be carried out at least 3 times, so that the hinges move freely in the future and to protect against further corrosion. – Remove excessive oil from the joints and body. – Reassemble vehicle.

4.24

Dust and pollen filter: cleaning housing and renewing filter element

Procedure ⇒ Heating, air conditioning; Rep. gr. 87; Front heater and air conditioning unit; Removing and installing dust and pollen filter.

4.25

Poly V-belt: renewing

4.26

Poly V-belt: checking condition

Carry out following procedure:

♦ Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks-, surface cracks)

NOTICE Visible damage such as sub-surface cracks, layer separation, base disruption, frayed cord strands or flank wear. Failure or malfunction of alternator/engine/belt drive. – Renew poly V-belt.

78 4. Descriptions of work

AG.

♦ Frayed cord strands

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♦ Base disruption

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♦ Layer separation (top layer, cord strands)

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♦ Sub-surface cracks (cracks, core ruptures, cross-sectional breaks)

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– Check poly V-belt -1- for:

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AG. Volkswagen AG d agen oes ksw not l o V Procedure gu by ara d e nte is r o ⇒ Rep. gr. 13; Cylinder block belt pulley end; Removing and eo h ut ra a installing poly V-belt c s s

Phaeton 2003 ➤ Maintenance - Edition 03.2021

NOTICE On petrol or diesel engines, poly V-belts which came into contact with oil, brake fluid, fuel or reducing agent. Failure or malfunction of alternator/engine/belt drive. – Renew poly V-belt. – The replacement of a poly V-belt is a repair measure.

4.27

Diesel fuel filter: draining

Draining water from diesel fuel filter, 6-cylinder diesel engines ⇒ page 79

4.27.1

Draining water from diesel fuel filter, 6-cylinder diesel engines

Special tools and workshop equipment required

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Remove water extraction plug -1-.

– Fit line of diesel extractor -VAS 5226- onto connector.

AG.

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Diesel fuel filter: renewing

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4.28

c o p yri gh t . C op yi

– Tighten water extraction plug to 3 Nm.

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– Renew seal of water extraction plug.

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– Extract about 100 ml diesel fuel using diesel extractor -VAS 5226-.

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♦ Diesel extractor -VAS 5226-

Renewing diesel fuel filter, 6-cylinder diesel engines ⇒ page 80 Renewing diesel fuel filter, 10-cylinder diesel engines ⇒ page 83

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.28.1

Diesel fuel filter, 6-cylinder diesel en‐ . Volkswagen AG gen AG does a w s gines, renewing k not Vol g ss

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For engine codes CARA and CEXA observe that after changing the fuel filter, the fuel system must be bled.

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Special tools and workshop equipment required

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♦ Clean hoses immediately if soiled.

♦ Please observe disposal instructions! Carry out the following procedure: – Remove water extraction plug -1-.

– Fit hose of diesel extractor -VAS 5226- onto connector. – Extract approx. 100 ml diesel fuel using diesel extractor -VAS 5226-. – Renew seal of water extraction plug. – Tighten water extraction plug to 3 Nm. – Loosen all bolts of fuel filter upper part -arrows- approx. 1.5 to 2 turns using cross-over sequence.

80 4. Descriptions of work

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♦ Ensure that no diesel fuel contacts coolant hoses.

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♦ Diesel extractor -VAS 5226-

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Unscrew bolts completely and remove fuel filter upper part.

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– Renew seal -3-.

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– Remove easy change filter -1- and seal -2- from fuel filter lower part -4-.

Note

Please observe disposal instructions! – Insert new easy change filter into fuel filter lower part. – Always moisten new seal -1- slightly with diesel fuel to avoid malfunctions! – Position new seal -1- on fuel filter upper part.

4. Descriptions of work

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– Tighten fuel filter upper part to fuel filter lower part.

– Tighten bolts according to sequence shown in illustration.

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– Tighten bolts to 5 Nm torque. agen lksw Vo by

The tightening sequence ensures that the fuel filter upper part is kept straight and the seal is not damaged. AG.

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Bleeding fuel system for engine codes: CARA and CEXA •

There must be sufficient fuel in the tank.

– Activate fuel pump ⇒ Vehicle diagnostic tester. – After the fuel system has been bled, start engine. – Allow engine to run for several minutes at mid revs, then switch engine off again. – Read event memory and erase if necessary. – Carry out a leakage test of the fuel system. Note

If there is still air in the fuel system, the engine can change to emergency running mode during road test. In this case, switch the engine off and erase the fault memory. Then continue with a road test.

82 4. Descriptions of work

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– Position fuel filter upper part with seal on fuel filter lower part.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a s s Special tools and workshop equipment required

Diesel fuel filter, 10-cylinder diesel en‐ gines, renewing

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4.28.2

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♦ Diesel extractor -VAS 5226-

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Removing diesel fuel filter:

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– Unclip cover -arrows- from fastenings and pull off upwards. – Remove plug from side connection of fuel filter housing. – Extract diesel fuel from side connection of fuel filter housing using diesel extractor -VAS 5226-. Remove connection for fuel hoses:

– Remove bolts -arrows- and remove connection with lines from filter housing. Removing fuel filter cover:

4. Descriptions of work

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Remove cover bolts -arrowsfor fuel filter housing and re‐ move cover.

rrectness of i t to the co nform spec at i h re o n wit in t his

– Install fuel filter cap -1-.

84 4. Descriptions of work

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– Insert new filters -3- and renew seal -2-.

AG.

Installing:

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Please observe disposal instructions!

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Note

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– Pull filter elements -3- off cover -1-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Tighten fuel filter cover bolts -arrows- to 8 Nm. – Install connection for fuel hoses.

Note

Renew seal between fuel filter cover and connection for fuel hoses. –

Diesel particulate filter: reading ash loading level

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4.29 es, in part or in w l purpos hole ercia , is n m ot com

4.30

Diesel particulate filter: renewing

Installation position of diesel particulate filter, see vehicle under‐ side. – Removing and installing diesel particulate filter. ⇒ Rep. gr. 26 Note

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Every time the diesel particulate filter is changed, the ash mass comparison adaption must be set to »0«, ⇒ Vehicle diagnostic tester

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– Check ash loading ⇒ Vehicle diagnostic tester.

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–

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4. Descriptions of work

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.31

Interior and exterior body: inspecting for corrosion with doors and flaps open

Test locations ♦ Sliding roof frame ♦ Inner and outer door frame ♦ Area around trim strips ♦ Windscreen roof edge ♦ Outer and inner A-pillar ♦ Bonnet ♦ Wheel arches

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86 4. Descriptions of work

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♦ Inner and outer tailgate

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.32

Cooling system: checking frost protec‐ tion and coolant level Note

♦ The water used for mixing has a major influence on the

effectiveness of the coolant. Because the water quality dif‐ fers from country to country and even from region to region, the quality of the water to be used in the cooling system has been specified by Volkswagen. Distilled water fulfils all requirements. Therefore,Gonly ever use distilled water when . Volkswagen AG gen A up or renewing doecoolant. a mixing coolant for topping w sn lks ot g u

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ara ⇒ Elec‐ db ♦ Use only coolant additives which conform with the n ise

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tee r tronic parts catalogue (ETKA). Other coolant additives ho or may ut a a reduce ss corrosion protection substantially. The resulting cdam‐ age could lead to loss of coolant and subsequent severe damage to the motor.

corrosion damage as well as scaling. Furthermore, the boil‐ ing point is raised. For these reasons, the cooling system must be filled all year round with a coolant additive.

♦ Because of its high boiling point, the coolant improves en‐

gine reliability under heavy loads, particularly in countries with tropical climates.

♦ The refractometer -T10007A- or refractometer -T10007B-

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must be used to determine the current anti-freeze value.

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♦ Mixed in the proper proportions, coolant inhibits frost and

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♦ Scale -1- of the refractometer is calibrated for the coolant

additives G12++ and G12evo.

♦ Scale -2- of the refractometer is calibrated for the coolant

additive G13.

♦ If it is not possible to ensure that the same type of coolant

additive is filled: always determine anti-freeze protection us‐ ing the scale for G13.

♦ Frost protection must be guaranteed down to -25°C as a

minimum and, in countries with arctic conditions, down to approx. -36°C. Increasing the frost protection is permissible only if climatic conditions require stronger frost protection. It may, however, be increased only to a maximum of -48°C. Otherwise, the cooling effect will be impaired. 4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

♦

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t Do not reduce the coolant concentration by adding water u ra a c even in the warm season or in hot countries.ssFrost protection pe rm itte d

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must be guaranteed down to at least -25°C.

♦ The temperature reading on the refractometer corresponds

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♦ Never reuse old coolant.

es, in part or in w l purpos hole ercia , is n m ot com

to the »ice flocculation point«. Flakes of ice may start form‐ ing in the coolant at this temperature.

♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.

4.32.1

Frost protection: checking and replen‐ ishing coolant additive, if necessary

Read precise value for the following tests at light-dark border. Using a pipette, place a drop of water on the glass to improve the readability of the light-dark border. The light-dark border can be clearly recognised on the “WATERLINE”.

Prote cted by

Scale -1- of the refractometer is calibrated for the coolant addi‐ tives G12++ and G12evo.

The scale -2- is only calibrated for coolant additive G13. – If frost protection is too low, drain some coolant and add coolant additive.

88 4. Descriptions of work

AG.

c o p yri gh t. C op yi

– Check concentration of coolant additive using refractometer (refer to operating instructions).

do c um en

Note

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♦ Refractometer -T10007B-

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♦ Refractometer -T10007A-

r te o iva r rp fo g n

Special tools and workshop equipment required

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ If the currently used coolant additive cannot be determined

AG. Volkswagen AG d precisely, use the scale -2- for coolant additive G13. agen o

es n ot g ua ran tee or ac

w olks yV b ed ris ho t au Check coolant additive concentration ss after road test again.

♦ Please observe disposal instructions! un le

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4.32.2

Coolant level: checking, replenishing coolant if necessary pe rm itte d

–

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

Special tools and workshop equipment required

in t his d o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

♦ Adapter -V.A.G 1274/9-

r te o iva r rp fo ng

♦ Coolant system charge unit -VAS 6096-

c o p yri gh t . C op yi

– Check coolant level in expansion tank with engine cold.

4. Descriptions of work

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Note

Small quantities of coolant can be replenished. For larger quan‐ tities use the cooling system charge unit -VAS 6096-. Note operating instructions for the cooling system charge unit -VAS 6096-. Note

If fluid loss is greater than can be expected through normal use, determine source and rectify (repair measure).

90 4. Descriptions of work

Prote cted by

– If coolant is too low, add required amount according to mix‐ ing ratio.

AG.

When the inspection service and the delivery inspection are carried out, the coolant level should be between max. and min. markings.

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c o p yri gh t . C op yi

Note

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Min. and max. markings are visible in filling area.

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r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Unscrew cap -1- from expansion tank.

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.32.3

Mixing ratio

Frost protection to

Coolant additive portion

Distilled water

-25°C -36 °C

approx. 40% approx. 50 %

approx. 60 % approx. 50 %

4.33

Air filter: cleaning housing and renew‐ ing filter element Note

♦ Vehicles with 6-cylinder engines are fitted with one air filter. ♦ Vehicles with V8, V10 and W12 engines have two air filters

in the engine compartment.

Removing and installing air filter element for 10-cylinder diesel engines ⇒ page 91 . Removing and installing air filter element for 6, 8 and 12-cylin‐ der petrol engines ⇒ page 98 . Removing and installing air filter element for 6-cylinder diesel engines ⇒ page 95 .

4.33.1

Air filter element for 10-cylinder diesel engines: removing and installing

Special tools and workshop equipment required . Volkswage n AG wage

Note

Removing and installing the right air filter element is described below. The left air filter element is removed and installed in the same manner.

ht rig py Co t.

r fo ng

Remove engine cover panel ⇒ page 106 .

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

b ed ris o h t au

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ks ♦ Pliers for spring-type yclips Vol -VAS 6499-

4. Descriptions of work

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AG.

Prote cted by c o p yri gh t. C op yi

Phaeton 2003 ➤ Maintenance - Edition 03.2021

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

–

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–

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Disconnect intake pipe -1- from intakeseconnecting pipe of d nte i r o intake manifold flap -2-. eo h ut ra a c s s Note as follows:

– Release connector by pulling the retaining clip -arrows-. – Pull off hose or pipe without auxiliary items.

r fo ng

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Prote cted by c o py rig ht . C op yi

92 4. Descriptions of work

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– Place the hose or pipe -1- to side.

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– When installing ensure the retaining lugs -A- engage secure‐ ly.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

–

pe rm itte d

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Note

♦ Self-tapping bolts are used in production to fasten the upper

♦ For this reason it is only permitted to use a power screwdriv‐

er, if the following prerequisites are fulfilled:

♦ The speed of the power screwdriver must be 200 rpm maxi‐

mum.

♦ It must be possible to set a maximum specified torque of

3 Nm.

– Pull off connector -1-.

ht rig py Co t.

r te o iva r rp fo ng

– Loosen clip -2- using spring-type clip pliers -VAS 6499- and remove intake hose.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

rrectness o f i t to the co n f orm spec atio h re n wit

part of air filter to the lower part of air filter as well as to the intake connection. If these bolts are loosened or tightened with a cordless screwdriver, it is possible that the thread in the upper part of air filter will be damaged.

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Remove bolts of air filter d upper part -arrows-. e nte is r o eo h ut ra a c s s

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Prote cted by c o py rig ht . C op yi

– Remove air filter element -1-. – Blow out air filter housing with compressed air if necessary. Note

Note installation position of air filter element!

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Install new filter element -1-. Ensure it is seated correctly.

seated.

♦ Do not pinch cables or lines. – Connect connector -1-. – Connect hose onto air mass meter and secure clip -2- using spring-type clip pliers -VAS 6499-. – Insert intake pipe in intake connecting pipe of intake mani‐ fold flap, when doing this ensure for correct seating of retain‐ ing lugs -A- or securing clip -arrow-.

– Install engine cover panel.

94 4. Descriptions of work

AG.

♦ Ensure that sealing surfaces of air filter housing are properly

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Prote cted by c o py rig ht . C op yi

Note

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r fo ng

– Fit upper part of air filter, and tighten bolts of upper part of air filter to 2 Nm -arrows-.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Installing

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.33.2

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Air filter element for 6-cylinder diesel engines: removing and installing un le

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Special tools and workshop equipment required

ht rig py Co t.

r fo ng

Remove engine compartment cover. ⇒ page 106

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Removing

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Pliers for spring-type clips -VAS 6499-

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AG.

Prote cted by c o py rig ht . C op yi

– Unscrew bolt -arrow B- from filler neck of windscreen washer container. – Remove filler neck of windscreen washer container -1- in direction of arrow. – Pull off connector -2-. – Loosen clip -3- using spring-type clip pliers -VAS 6499- and remove intake hose. Note

For a better overview the securing bolts of the air filter upper part -arrows A- are shown in the following illustration when the air filter is removed.

4. Descriptions of work

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ility ab y li an pt ce

un le

Phaeton 2003 ➤ Maintenance - Edition 03.2021

♦ Self-tapping bolts are used in production to fasten the upper

♦ For this reason it is only permitted to use a power screwdriv‐

er, if the following prerequisites are fulfilled:

♦ The speed of the power screwdriver must be 200 rpm maxi‐

mum.

3 Nm.

– Unscrew bolts -arrows- from air filter housing.

AG.

Prote cted by

Note

Note installation position of air filter element! – Blow out air filter housing with compressed air if necessary.

96 4. Descriptions of work

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c o p yri gh t . C op yi

– Take out used filter element -1-.

ht rig py Co t.

– Lift filter housing upper part and remove upwards.

do c um en

r te o iva r rp fo g n

♦ It must be possible to set a maximum specified torque of

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Installing

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Fit upper part of air filter, and tighten bolts of upper part of air filter to 2 Nm -arrows-. Note

♦ Ensure that sealing surfaces of air filter housing are properly

r fo ng

♦ Do not pinch cables or lines.

ht rig py Co t.

seated.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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– Install new filter element -1-. Ensure it is seated correctly.

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AG.

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– Connect hose onto air mass meter and secure clip -3- using spring-type clip pliers -VAS 6499-. – Connect connector -2-. – Install filler neck -1- for windscreen washer container. – Install engine cover panel.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.33.3

Air filter element for 6, 8 and 12-cyl‐ inder petrol engines: removing and in‐ stalling

Special tools and workshop equipment required n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Removing Note

rrectness o f i t to the co n f orm spec atio h re n wit

Type 1

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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♦ Pliers for spring-type clips -VAS 6499-

♦ Self-tapping bolts are used in production to fasten the upper r te o iva r rp fo ng

er, if the following prerequisites are fulfilled:

Prote cted by

♦ It must be possible to set a maximum specified torque of

3 Nm.

– Loosen both clips -1- and -2- and pull off intake hose.

98 4. Descriptions of work

AG.

mum.

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c o p yri gh t . C op yi

♦ The speed of the power screwdriver must be 200 rpm maxi‐

ht rig py Co t.

♦ For this reason it is only permitted to use a power screwdriv‐

in t his d o cu m en

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Pull connector -7- off air filter housing. – Loosen heat protection at press buttons -4- and -5-. – Remove bolts -1-, -2-, -3- and -6- from air filter housing. – Raise filter housing upper part and remove upwards. – Take out used filter element. Note AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec at i h re o n wit in t his

– Blow out air filter housing -1- with compressed air if neces‐ sary.

ht rig py Co t.

r fo ng

Installing

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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Note installation position of air filter element!

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AG.

Prote cted by c o p yri gh t. C op yi

– Insert new air filter element -1-.

4. Descriptions of work

Phaeton 2003 ➤ Maintenance - Edition 03.2021

ility ab y li an pt ce

– Install intake hose.

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–

pe rm itte d

–

n AG. Volkswagen AG do es n wage s k l ot g o Reinstall filter housing upper part with bolts -1-, -2-, -3- and yV ua b d ran -6-. e tee ris o h t or u Press heat protection onto press buttons -4and -5-. ac a ss

Removing

rrectness o f i t to the co n f orm spec atio h re n wit

Type 2

es, in part or in w l purpos hole ercia , is n m ot com

– Reconnect connector -7-.

Remove engine cover panel, if necessary. ⇒ page 106 – Detach coolant hose from clips.

AG.

– Disconnect lines to air filter housing -arrow- as follows:

– On the rear line, press locking ring -1- off flange of line -3using screwdriver -C-.

100 4. Descriptions of work

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Prote cted by c o py rig ht . C op yi

– Remove throttle valve module bolts -2-.

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– Pull connector -3- off throttle valve module.

in t his d o cu m en

r te o iva r rp fo ng

– Open clips -1-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Press securing sleeve -2- in direction of arrow and pull line -A- off line -B- at the same time.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec at i h re o n wit in t his

– Pull out air filter housing part upwards. Note

Note installation position of air filter element!

ht rig py Co t.

r fo ng

– Remove air filter element -A-.

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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– On front line, press securing ring -B- together and pull line -A- off air filter housing.

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AG.

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– If necessary, blow out air filter housing with compressed air and install new air filter element. Installing – Install air filter element.

4. Descriptions of work

101

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ Ensure that sealing surfaces of air filter housing are properly

seated.

♦ Do not pinch cables or lines. – Secure air filter housing with spring clips -1-.

– Bolt on throttle valve module -2- and tighten to 3 Nm. – Reconnect connector -3-.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

pe rm itte d

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– Push line -arrow- together again.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Then press locking ring -1- onto flange of line -3- until it can be heard to engage.

– Clip coolant hose into clips.

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AG.

Prote cted by c o p yri gh t. C op yi

102 4. Descriptions of work

ht rig py Co t.

– Install engine cover panel.

do c um en

r te o iva r rp fo g n

– Reconnect line -A- until it engages.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.34

Multi-purpose additive for diesel fuel: adding

4.34.1

Specification for using multi-purpose additive for diesel fuel

Note ♦ In the market mentioned below there is a particularly high

risk of deposits forming on the injectors and inlet valves owing to the quality of the fuel.

♦ To counteract the formation of deposits, a multi-purpose ad‐

ditive for diesel fuel must be added.

♦ Only additives compliant with VW 505 26 (multi-purpose ad‐

ditive G 001 790 M3) may be used.

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♦

n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b After adding the additive, it is extremely important toedfully ran s i tee rof the refuel the vehicle to achieve optimal effectiveness o h t or u additive. ac a ss

Country

rrectness of i t to the co nform spec at i h re o n wit in t his

4.34.2

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

– During each change oil service, fill entire bottle of multi-pur‐ pose additive for diesel fuel into regular fuel tank. Russia

Recommendation for using multi-pur‐ pose additive for diesel fuel

Note

♦ In the following markets with a high risk of coke and deposit

c o p yri gh t . C op yi

♦ After adding the additive, it is extremely important to fully AG.

Prote cted by

♦ The multi-purpose additive can also be used in all other

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refuel the vehicle to achieve optimal effectiveness of the additive.

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ditive G 001 790 M3) may be used.

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♦ Only additives compliant with VW 505 26 (multi-purpose ad‐

do c um en

formation, the addition of a multi-purpose additive is recom‐ mended owing to the lower concentration of additives in the diesel fuel.

markets that are not listed in the table.

– During each change oil service, fill entire bottle of multi-pur‐ pose additive for diesel fuel into regular fuel tank. Country Afghanistan Egypt Albania Equatorial Guinea Argentina Azerbaijan

Liberia Mali Morocco Mauritania Macedonia Moldova 4. Descriptions of work

103

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Country

pe rm itte d

r te o iva r rp fo ng

es, in part or in w l purpos hole ercia , is n m ot com

rrectness o f i t to the co n f orm spec atio h re n wit

in t his d o cu m en

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Prote cted by

c o p yri gh t . C op yi

104 4. Descriptions of work

ht rig py Co t.

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Belize Myanmar Benin Dutch Overseas Territories Bhutan Nigeria Brazil Pakistan Brunei Panama Burkina Faso Paraguay China Saudi Arabia Democratic Republic of the Congo Senegal Dominican Republic Sierra Leone El Salvador Zimbabwe Ivory Coast Sri Lanka and the Maldives Fiji South Africa Gambia Sudan Georgia South Sudan Ghana Surinam Guatemala Syria Guinea Thailand Guinea-Bissau Togo olkswagen AG V . G A n does and Tobago Guyana Trinidad age ksw not Vol gu y b ara Haiti Chad d e nte ris o eo h t Honduras Turkmenistan u ra c sa s Indonesia Ukraine India USA Iraq Belarus Jamaica Venezuela Jordan Central African Republic Cayman Islands Zimbabwe Cambodia Cameroon Canada Cape Verde Caribbean, left-hand traffic Columbia Laos Lebanon

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.35

Multi-purpose additive for petrol fuel: adding

4.35.1

Specification for using multi-purpose additive for petrol fuel

Note ♦ In the market mentioned below there is a particularly high

risk of deposits forming on the injectors and inlet valves owing to the quality of the fuel.

♦ To counteract the formation of deposits, a multi-purpose ad‐

ditive for petrol fuel must be added.

♦ Only additives compliant with VW 507 53 B (multi-purpose

additive G 001 780 M3) may be used.

♦ Observe the dosing instructions on the additive container. ♦ After adding the additive, it is extremely important to fully

refuel the vehicle to achieve optimal effectiveness of the additive.

– Fill multi-purpose additive for petrol fuels into regular fuel tank during each oil change service. Country

un le

pe rm itte d

♦ In the following markets with a high risk of coke and deposit

formation, the addition of a multi-purpose additive is recom‐ mended owing to the elevated olefin content and aromatics in the petrol.

♦ Only additives compliant with VW 507 53 B (multi-purpose

additive G 001 780 M3) may be used.

♦ Observe the dosing instructions on the additive container. ♦ After adding the additive, it is extremely important to fully

refuel the vehicle to achieve optimal effectiveness of the additive. r te o iva r rp fo ng

♦ The multi-purpose additive can also be used in all other

markets that are not listed in the table.

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AG.

Prote cted by c o py rig ht . C op yi

Algeria Bahrain Bolivia Brazil

Country

ht rig py Co t.

– Fill multi-purpose additive for petrol fuels into regular fuel tank during each oil change service.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

rrectness o f i t to the co n f orm spec atio h re n wit

Note

Recommendation for using multi-pur‐ pose additive for petrol fuel

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4.35.2

Volkswagen AG AG.Russia does agen ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

4. Descriptions of work

105

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

AG.

Prote cted by

Side engine cover panel Remove right engine cover panel as follows: – Lever off cover -2-.

106 4. Descriptions of work

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c o p yri gh t. C op yi

Engine cover panel -top-: removing and installing

ht rig py Co t.

4.36

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

China Ghana Indonesia Iraq Iran Japan Yemen Jordan Cambodia Qatar Columbia Kuwait Lebanon Malaysia Mauritius Niger Nigeria Oman Pakistan Peru Philippines Saudi Arabia Senegal Singapore Surinam Syria Chad Uzbekistan United Arab Emirates Vietnam

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Country

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

pe rm itte d

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

– Pull engine cover panel out of fastenings -arrows-, and re‐ move it upwards. Centre engine cover panel for 6-cylinder petrol engine

in t his d o cu m en

ht rig py Co t.

r te o iva r rp fo ng

– Unclip engine compartment covers -1- and -2- and remove upwards.

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AG.

Prote cted by

c o p yri gh t . C op yi

10-cylinder diesel engine Removing: – Disengage engine cover panel at the securing points -arrows- and remove upwards. – Remove bolts of side engine compartment covers. – Remove side engine compartment covers. 4. Descriptions of work

107

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Installing: – Fit engine cover panel at securing points -arrows-, and press it on until it engages. – Retighten side engine compartment covers.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Removing:

– Disengage engine cover panel at points shown -arrows- and lift. Note

Keep engine cover panel straight when pulling off. Installing:

– Position engine cover panel over front retainers then press on until the cover engages. r fo ng

Engine cover -bottom- (noise insula‐ tion): removing and installing

»General body repairs, exterior« ⇒ General body repairs, exteri‐ or; Rep. gr. 50; Noise insulation»Noise insulation« Note

For technical reasons it is possible that several cross referen‐ ces are not directed to the correct chapter. In this case select the procedure manually in the information.

4.38

Engine oil level: checking

Note the following: – After shutting off engine, wait at least 3 minutes so that the oil can flow back into the sump. – Pull out dipstick, wipe with a clean cloth and push dipstick in again to limit stop. – Pull dipstick out again and read oil level.

108 4. Descriptions of work

AG.

The procedure of removing the engine cover panel -bottom(noise insulation) can be found in Workshop Manual under:

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Procedure

ht rig py Co t.

4.37

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

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6-cylinder diesel engine (TDI common rail)

Phaeton 2003 ➤ Maintenance - Edition 03.2021 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t always be in area A for the delivery inspection. Oil level must u r a This way,ssyou will achieve the greatest possible customer ac

Note

♦

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c o p yri gh t. C op yi

A - Do not top up oil.

rrectness of i t to the co nform spec at i h re o n wit in t his

experimentally and is sufficient for the technical functionality of the engine in all operating conditions. During all other service events, the oil level must be checked and corrected as necessary if the customer requests this. This enables an additional topping-up to the specified oil quantity to the upper limit of the dip stick. Due to tolerances, the oil temper‐ ature and the drip time, various quantities may be required for topping up.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

♦ The oil-change quantity in the service table was determined

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satisfaction.

B - Oil can be replenished up to area -A-. C - Oil must be replenished. The oil level must then be at least in the upper half of the measuring area -B-. – If oil level is above -A- marking, drain or extract excess oil in order to avoid damage to catalytic converter. – If the oil level is below marking -C- replenish a sufficient amount of oil (at least 0.5 l) ⇒ page 6 .

4.39

Draining or extracting engine oil, re‐ newing oil filter and replenishing en‐ gine oil

Draining or extracting engine oil 3), ⇒ page 110 . Renew oil filter ⇒ page 111 . Replenishing engine oil ⇒ page 120 . 3) For the V8 engine and the W12 engine it is not permitted to extract engine oil.

4. Descriptions of work

109

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.39.1

Engine oil: draining or extracting

Note ♦ For engines with upright oil filter module, the oil filter should

be renewed before changing the engine oil ⇒ page 119 ⇒ page 117 . When removing the filter element a valve is opened, the oil in the filter housing automatically flows into crankcase.

♦ For the V8 engine and the W12 engine it is not permitted to

extract engine oil.

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drain plug must always be renewed.

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– Clean M24 oil drain plug and fit new seal. The M14 oil drain plug with integrated seal must always be renewed. ⇒ Elec‐ tronic Parts Catalogue ETKA

AG.

Please observe disposal instructions!

– Screw in oil drain plug together with seal hand-tight and then tighten to specified torque. – Fill engine oil. Engine oil capacity: ♦ ⇒ Maintenance tables ♦ Engine oil: capacities and specifications ⇒ page 120 Specified torques for oil drain plug: ♦ M14: 30 Nm ♦ M24: 50 Nm

110 4. Descriptions of work

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Note

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– Let engine oil drain.

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– Remove oil drain plug.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

NOTICE Excessive torque can cause leaks in the area of the oil drain plug or even damage. – Tighten oil drain plug to specified torque.

4.39.2

Oil filter: renewing

Renewing oil filter on 6-cylinder petrol engine ⇒ page 111 . Renewing oil filter on 12-cylinder petrol engine ⇒ page 112 . Renewing oil filter on 8-cylinder petrol engine ⇒ page 114 . Renewing oil filter on 10-cylinder diesel engine ⇒ page 117 . Renewing oil filter on 6-cylinder diesel engine ⇒ page 119 .

4.39.3

Oil filter on 6-cylinder petrol engine: re‐ newing

Special tools and workshop equipment required ♦ Torque wrench Note

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♦ Oil new O-rings before installing.

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♦ Please observe disposal instructions!

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Carry out following procedure:

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♦ Prevent engine oil from dripping onto subframe.

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– Loosen threaded cover -2- on hexagon -1- or along perime‐ ter and remove.

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– Remove oil drain plug -1- of threaded cover and drain oil.

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4. Descriptions of work

111

AG.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Clean sealing surfaces on threaded cap and oil filter hous‐ ing. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Install threaded cap -2- with new O-ring and tighten to 25 Nm. – Fit oil drain plug in threaded cap with new seal and tighten to 10 Nm. r te o iva r rp fo ng

Oil filter on 12-cylinder petrol engine: renewing

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♦ Torque wrench

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112 4. Descriptions of work

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4.39.4

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– Renew filter element -4-.

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Installing

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Removing

♦ Please observe disposal instructions!

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Prevent engine oil from dripping onto components in engine compartment.

AG.

– Loosen threaded cover -3- on hexagon -2- or along perime‐ ter and remove.

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– Remove oil drain plug -1- of threaded cover and drain oil.

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♦ Oil new O-rings before installing.

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Note

– Clean sealing surfaces on threaded cap and oil filter hous‐ ing. Installing

– Renew filter element -5-. – Install threaded cap -3- with new O-ring -4- and tighten to 25 Nm. 4. Descriptions of work

113

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Fit oil drain plug -1- with new seal -2- and tighten to 10 Nm.

4.39.5

Oil filter on 8-cylinder petrol engine: re‐ newing

Special tools and workshop equipment required ♦ Pliers for spring-type clips -VAS 6499-

♦ Reversible ratchet -VAS 5300/68♦ Extension -VAS 5300/70-

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Note

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Removing

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♦ Torque wrench

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♦ Universal joint -VAS 5300/71-

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♦ Please observe disposal instructions! ♦ Oil new O-rings before installing.

♦ Prevent engine oil from dripping onto components in engine

compartment.

– Remove engine cover panels. Note

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114 4. Descriptions of work

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– Remove bolts -1- of air duct -2-.

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Before changing the oil filter, the complete air filter housing must be removed due to the narrow installation conditions.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Pull off connector -1-. – Loosen clip -2- using spring-type clip pliers -VAS 6499- and remove intake hose. – Remove the 4 bolts from air filter upper part -arrows-.

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– Remove the two bolts -1- and place cable guide with con‐ nectors downwards.

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– Remove air filter element -A-.

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Note installation position!

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– Pull off ignition coil connectors with output stages -2-.

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– Remove air filter upper part upwards.

4. Descriptions of work

115

AG.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Remove bolt from air filter lower part mounting -1-.

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– Pull air filter lower part out of lower mounting -2-.

– Guide the air filter lower part -1- out in direction of ignition coils with final output stages.

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116 4. Descriptions of work

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The standing oil filter is visible between longitudinal member and engine block -arrow-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Loosen and remove threaded cap -1- from upright oil fil‐ ter on hexagon -arrow-, using e.g. reversible ratchet -VAS 5300/68-, extension -VAS 5300/70-, universal joint -VAS 5300/71- and a 24 mm socket bit.

– Renew filter element -1-. – Clean sealing surfaces on threaded cap and oil filter hous‐ ing. – Install threaded cap -3- with new O-ring -2- and tighten to 25 Nm. The remaining assembly steps are basically a reverse of the dismantling procedure.

4.39.6

Oil filter on 10-cylinder diesel engine: renewing

Special tools and workshop equipment required

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♦ Oil filter tool -T10192-

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Installing

4. Descriptions of work

117

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

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Note

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Removing

♦ Please observe disposal instructions! ♦ Oil new O-rings before installing.

– Cover engine, e.g. with oil spill cloth.

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– Install threaded cap -1- with new O-rings -2- and -4- and tighten to 25 Nm.

118 4. Descriptions of work

AG.

– Renew filter element -3-.

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– Clean sealing surfaces on threaded cap and oil filter hous‐ ing.

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– Remove upper part of filter from filter housing using tool -T10192-.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.39.7

Oil filter on 6-cylinder diesel engine: re‐ newing

Remove engine cover. ⇒ page 106 Special tools and workshop equipment required ♦ Socket insert -SW 32-.

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Note

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Removing

♦ Please observe disposal instructions! ♦ Oil new O-rings before installing.

– Cover area around oil filter sealing cap -arrow- with, e.g. oil spill cloth.

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– Release sealing cap -arrow- using a 32 mm socket.

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– Remove sealing cap together with oil filter element. – Separate oil filter element -3- from sealing cap -1-. – Clean sealing surfaces on threaded cap and oil filter hous‐ ing.

4. Descriptions of work

119

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Installing – Renew oil filter element -3-. – Install sealing cap -1- with new O-rings -2- and -4- and tight‐ en to 35 Nm. The remaining assembly steps are basically a reverse of the dismantling procedure.

4.39.8

Engine oil: replenishing

Engine oil: capacities and specifications ⇒ page 120 Oil level: checking ⇒ page 108

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3.2 l 177kW 6.0 l 309kW 6.0 l 309kW 4.2 l 246kW 4.2 l 246kW 3.2 l 177kW 3.2 l 177kW 6.0 l 331kW 6.0 l 331kW 6.0 l 331kW 3.6 l 206kW 3.6 l 206kW 3.0 l 184kW

6.0 11.8 11.8 7.5 7.5 6.0 6.0 12.5 12.5 12.5 6.2 6.2 6.2

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AYT BAN BAP BGH BGJ BKL BRK BRN BRP BTT CHNA CMVA CPFA

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120 4. Descriptions of work

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VW engine oil standards With flexible service With fixed service 504 00 / 503 00 504 00 / 503 01 504 00 / 503 01 504 00 / 503 00 504 00 / 503 00 504 00 / 503 00 504 00 / 503 00 504 00 / 503 01 504 00 / 503 01 504 00 / 503 01 504 00 504 00 ---

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Capacity / output

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Engine code

Phaeton Oil quantity with fil‐ ter (I)

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502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 / 501 01 502 00 502 00 502 00

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Diesel engines Engine code Capacity / output AJS BMK CARA CEXA 1) CEXA 2) CEXB

Phaeton Oil quantity with fil‐ ter (I)

5.0 l 230kW 3.0 l 165kW 3.0 l 171kW 3.0 l 176kW

10.0

VW engine oil standards With flexible service With fixed service

8.3 8.3 8.3

506 01 507 00 507 00 507 00

3.0 l 176kW

8.3

507 00

505 01

3.0 l 180kW

8.3

507 00

1) With diesel particulate filter Vehicles with diesel particulate

filter (fitted at the factory) can be identified by PR No. 7GG, 7MB, 7MG, 7GA, 7MQ, 7MJ on the vehicle data sticker.

2) Without diesel particulate filter

4.41

Engine and components in engine compartment: inspecting for leaks and damage (from above and below)

Inspect as follows: – Check engine and components in engine compartment for AG. Volkswagen AG d agen oes leaks and damage. n lksw

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♦ Fuel system

♦ Lubrication system

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♦ Air conditioning system ♦ Intake system ♦ And brake system Check for leaks, abrasion, porousness, cracks, correct seating and attachment in retainers. Note

♦ Arrange for defects to be rectified as repair measures. ♦ If fluid loss is greater than can be expected through normal

use, determine source and rectify (repair measure).

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Road test: performing (driving behav‐ iour, noises, air conditioner etc.) c o p yri gh t . C op yi

Which of the following can be checked depends on vehicle equipment and local conditions (urban/country).

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Check the following during a road test:

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4.42

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♦ Cooling and heating system

♦ Engine: output, misfiring, idling speed, acceleration ♦ Clutch: pulling away, pedal pressure, odours ♦ Gear selection: ease of operation, stick position

4. Descriptions of work

121

Phaeton 2003 ➤ Maintenance - Edition 03.2021 ♦ Automatic gearbox: Selector lever position, shift lock/ignition key removal lock, shift behaviour, dash panel insert display ♦ Foot brake and handbrake: function, free travel and effec‐ tiveness, pulling to one side, juddering, squeal ♦ ABS function: pulsing must be felt at the brake pedal during ABS-regulated braking ♦ Steering: function, steering free clearance, steering wheel centred when vehicle is travelling straight ahead ♦ Tilting roof: function ♦ Radio/radio navigation system: function, reception, GALA, interference noise ♦ Multi-function indicator (MFI): functions ♦ Air conditioning system: check function (At low temperatures the function of air conditioner must be checked in a work‐ shop). ♦ Vehicle: pulls to one side when travelling straight ahead (lev‐ el road). ♦ Imbalance: wheels, drive shafts, propshaft ♦ Noise/vibration: wheel bearing, exhaust system ♦ Engine: hot starting behaviour

4.43

Wheel securing bolts: tightening to n AG. Volkswagen AG do specifiedlkstorque es n wage o yV

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♦ Adapter set for tamper-proof wheel bolts -T10313-

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The adapter to loosen and tighten the anti-theft wheel bolts can be found in the vehicle tool kit.

122 4. Descriptions of work

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♦ Torque wrench au ss ♦ Adapter set for tamper-proof wheel bolts -T10101 A-

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note

♦

AG. Volkswagen AG d agen oes ksw not l o V gu by a d e nte alter‐ Ensureothat wheel bolts are tightened diagonallyraand ris eo h nately ut to the following torque setting: ra a c s s

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♦ If the adapter to loosen or tighten the anti-theft wheel bolts

Specified torque: 120 Nm

4.44

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

is not available in the vehicle, use the corresponding adapter set for tamper-proof wheel bolts.

Tyre repair set: checking if bottle is damaged or used; checking shelf life of tyre sealant Note

♦ The tyre repair set is located in the spare wheel well.

♦ The tyre repair set contains a filler bottle with tyre sealant.

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Expiry date: checking

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– Check the expiry date. The expiry date is printed on a sticker on the tyre repair set -arrow-. – Enter the expiry date in maintenance table.

– Renew tyre sealant if the expiry date -arrow- has been reached. (The tyre sealant must not be more than 4 years old). – After replacing tyre sealant: attach new sticker -1- to tyre repair set. 4. Descriptions of work

123

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ If the tyre sealant has been used, the container must be

renewed.

♦ Please observe disposal instructions!

4.45

Manual gearbox/final drive: checking oil level

Procedure »Power transmission« ⇒ Power transmission; Rep. gr. 34; Removing and installing gearbox»Removing and instal‐ ling gearbox«

4.46

Service interval display: resetting with diagnosis tester

The service interval display (SID) must be reset during: ♦ every delivery inspection (see note) ♦ every oil change service, interval service and inspection service ♦ each oil change (flexible/fixed) is carried out! Note

It is also possible to reset the service interval display manually. However, bear in mind that if the SID is reset manually, the G. Volkswagen A AG do agen vehicle will be coded to fixed intervals. This also modifies es n ksw the l ot g o adaptation channel for oil quality. yV ua db un le

Service interval display: recoding with diagnosis tester ODIS Service

Connect vehicle diagnostic tester. Switch on ignition. Carry out identification of vehicle. Enter task data, or select “Without task”. Select “Control units”. Select “Dash panel insert”. Select “Guided Functions”. Select “Change flexible/fixed intervals”. Carry out adaptation according to the information of “Guided functions”. r fo ng

– – – – – – – – –

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Recoding from flexible to fixed intervals

Changing values for maximum distance to be driven (km) until next oil change service (fixed) during delivery inspection Prote cted by

124 4. Descriptions of work

AG.

– Connect vehicle diagnostic tester.

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ODIS Service

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4.47

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– Select the respective service which is to be reset.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 ODIS Service

4.48

Sunroof: checking function, cleaning and greasing guide rails

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– Check function of sunroof.

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Carry out following procedure:

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– Switch on ignition. – Carry out identification of vehicle. – Enter task data, or select “Without task”. – Select “Control units”. – Select “Dash panel insert”. – Select “Guided Functions”. – Select “Oil change service (fixed)”. – Follow instructions in “Guided functions” mode. – Reset “-1- Oil change service (fixed)”. – Follow instructions in “Guided functions” mode. agbe en Adriven The current values for maximum distance (km) until next oil change service are shown in the AG. Volkswto G do agen es n ksw tester. l display of the vehicle diagnostic ot g o yV ua db ran e – Select “No”. oris tee h t u maximum distance to be driven until next oil ochange ra – Select values afor service, according to specifications c s valid in your country. – Carry out adaptation according to the information of “Guided functions”.

– Clean guide rails arrows and grease with lubricating paste G 060 751 A2. AG.

4.49

Sliding sunroof drains: checking for blockage, cleaning if necessary

Special tools and workshop equipment required

4. Descriptions of work

125

Phaeton 2003 ➤ Maintenance - Edition 03.2021

rrectness of i t to the co nform spec at i h re o n wit in t his

– Open sliding sunroof.

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Carry out following procedure:

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♦ Cleaning and fitting tool -VAS 6620-

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Note

Removal and installation of plenum chamber is performed as a separate charge. – If fitted, remove cover -1- by loosening fasteners -A and B-.

126 4. Descriptions of work

AG.

– Removing plenum chamber cover ⇒ General body repairs, exterior; Rep. gr. 50; Plenum chamber cover.

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If this is the case, the test is completed. If only a small quantity of water or no water at all flows out of the wheel housings, perform the following procedure:

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– Pour tap water into sliding sunroof drains and check if al‐ most the same quantity of water flows out of the wheel hous‐ ings.

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– Check sliding sunroof drain holes -arrowsfor dirt and clean if necessary.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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– To press out dirt, guide cleaning and fitting tool -VAS 6620onto drain valves by pushing and pulling it slowly.

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– Drains -arrows- are located on the left and right side, inside the plenum chamber.

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– Check plenum chamber drains -arrowsfor dirt and clean if necessary.

4. Descriptions of work

127

Phaeton 2003 ➤ Maintenance - Edition 03.2021

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Sliding sunroof seal: lubricate. es, in part or in w l purpos hole ercia , is n m ot com

4.50

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Install in reverse order.

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–

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo To check, pour tap water again through the sliding sunroof h ut ra a drain holes. c s s

Note

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Only use special grease -G 060 172 A3- or the later type of spe‐ cial grease -G 052 141 A2- to regrease the sunroof seal. Apply only a very thin coat of grease onto seal. 1 gram is sufficient for the complete seal.

Clean residue of old grease from seal before applying fresh grease. – Open the glass or solar panel and grease the front edge of seal first. r te o iva r rp fo g n

Wiper blades: checking park position, adjusting if necessary

– Perform check as follows:

128 4. Descriptions of work

AG.

The correct park position can be checked only if the wiper arms are moved first to service position »Maintenance & Serv‐ ice« and »Wiper change« using infotainment system.

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Note

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4.51

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– Now tilt the glass or solar panel to grease the side and rear edges.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Switch on ignition and the infotainment. – Switch off windscreen wiper. – Press button »Settings« in the main menu block -2- in info‐ tainment and call-up the submenu »Others«, »Maintenance & Service« and »Wiper change«. The wiper arms are moved up automatically. – Press button »Wiper change« in infotainment again.

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– Check park position.

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Windscreen of LHD vehicles:

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara The wiper arms return to the lower of the two original positions. d nte ise r o eo h – Now check and adjust wiper blade park position.aut ra c s s

The distance -a- between wiper blade and lower edge of wind‐ screen must be 5 mm. r fo ng

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Specified torque for wiper arm: 18 Nm

4. Descriptions of work

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– If necessary, adjust park position by loosening cone and moving wiper arm.

129

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Windscreen of RHD vehicles:

– Check park position. The distance -a- between wiper blade and lower edge of wind‐ screen must be 20 mm. – If necessary, adjust park position by loosening cone and moving wiper arm. Specified torque for wiper arm: 18 Nm

4.52

Window wash/wipe system and head‐ light washer system: checking function and settings

4.52.1

Anti-freeze: checking protection of flu‐ id, topping up fluid if necessary . Volkswag n AG wage

Special tools and workshop equipment required y Volks

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Note

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♦ Refractometer -T10007B-

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♦ Refractometer -T10007A-

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In countries and regions where no frost occurs due to the local climatic conditions, the anti-freeze protection does not need to be checked. Read precise value for the following tests at light/dark boun‐ dary. Using a pipette, place a drop of water on the glass to improve the readability of the light/dark boundary. The light-dark border can be clearly recognised on the “WATERLINE”. – Check concentration of anti-freeze additive using refractom‐ eter.

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130 4. Descriptions of work

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The scale -4- of the refractometer is applicable for the antifreeze protection of the window wash/wipe system.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Mixing ratio Anti-freeze protection to

pe rm itte d

Depending on season, a winter product with anti-freeze protec‐ tion or a summer product with increased cleaning capabilities should be used. Ready-to-use window cleaner (Ready Mix) does not need to be mixed with water.

♦ Genuine washer fluid ⇒ ETKA prevents the spray jets, wash‐ r te o iva r rp fo ng

er fluid reservoirs and connecting hoses from freezing.

♦ In vehicles with fan jets, the reservoir must be filled with

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

Use genuine washer fluid ⇒ ETKA throughout all year to fill window wash/wipe system.

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Genuine washer fluid, as this fluid has a low viscosity at tem‐ peratures below freezing. Otherwise the complicated spray jet system can become blocked by the crystallised washer fluid, which affects the spray pattern of the spray jet. Genu‐ ine washer fluid ensures that the fan jets remain fully func‐ tional at low temperatures.

3 parts 2 part 1 part

rrectness o f i t to the co n f orm spec atio h re n wit

– Top up fluid in window wash/wipe system (only if customer requests to do so).

Note

Water

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-17/-18°C -22/-23 °C -37/-38 °C

Genuine washer fluid

⇒ ETKA n AG. Volkswagen AG do es n wage s k l ot g o 1 part yV ua b d ran ir se tee 1 part o h t or u ac a 1 part ss

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♦ Genuine washer fluid ⇒ ETKA can also be used in the sum‐

mer. The powerful cleanser easily removes wax and oil resi‐ due from the glass.

♦ Frost protection must be guaranteed to approx. -25°C (ap‐

prox. -35°C in countries with an arctic climate) in the wind‐ screen wash/wipe system.

4. Descriptions of work

131

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.52.2

Window wash/wipe system and head‐ light washer system: checking jet set‐ ting and adjusting jets if necessary

Note ♦ If the spray field is uneven due to soiling in the spray jet,

remove spray jet »Vehicle electrics; Electrical system« ⇒ Ve‐ hicle electrics; Electrical system; Rep. gr. 92; Windscreen washer system»Windscreen washer system«, and rinse it with water opposite to direction of spray. AG. Volkswagen o yV the spraying direction is permitted. db ise r Never use solid objects to clean tho the washer jets! au s s

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♦

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Washer jet adjustment for window wash/wipe system:

– If both spray fields are not at same height, adjust spray direction upwards or downwards as follows:

AG.

Note

Only control function of spray jets but do not adjust them. The jet adjustment dimensions are for the left-hand headlight (right-hand headlight mirror image)

132 4. Descriptions of work

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Spray jet function of headlight washer system:

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– Adjust spray jet at adjuster -1- by hand upwards or down‐ wards.

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r te o iva r rp fo g n

The spray jets are preset. However, small differences in height may be corrected.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Switch on dipped beam headlight. – Operate windscreen washing system. The headlights are washed if the windscreen wiper lever is held in »wipe position« for at least 1.5 seconds. The washer jet must spray to centre of headlights, see -B- and -C-.

If spray pattern deviates from specifications, carry out repair n AG. Volkswagen AG do es n wage measures. o olks

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Cold fluid:

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4.53

Carry out following procedure:

– Remove reservoir cap with built-in dipstick -arrow-. Prote cted by c o p yri gh t. C op yi

– Screw filler cap on hand tight and unscrew again.

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Note

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– Wipe dipstick with a clean cloth.

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es, in part or in w l purpos hole ercia , is n m ot com

– Do not start engine but bring front wheels to straight-ahead position.

The cap must be fully screwed on in order to obtain an accurate fluid level reading. – Check fluid level: fluid level should be in area of MIN mark‐ ing (up to 2 mm above or below marking).

4. Descriptions of work

133

Phaeton 2003 ➤ Maintenance - Edition 03.2021

pe rm itte d

ted.

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♦ If fluid level is above specified range, fluid must be extrac‐

♦ If fluid level is below above-mentioned area, hydraulic sys‐

“G 002 000” fluid.

– Screw cap on hand tight. Fluid at operating temperature (above approx. 50 °C)

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Carry out following procedure:

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– Do not start engine but bring front wheels to straight-ahead position. – Remove reservoir cap with built-in dipstick -arrow-. – Wipe dipstick with a clean cloth. – Screw filler cap on hand tight and unscrew again.

134 4. Descriptions of work

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

♦ If the hydraulic system is not leaking, top up with

rrectness o f i t to the co n f orm spec atio h re n wit

tem must be checked for leaks (repair measure). It is not sufficient just to top up with fluid.

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Note

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

ility ab y li an pt ce

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

The cap must be fully screwed on in order to obtain an accurate fluid level reading. – Check fluid level: The fluid level must be between MIN. and MAX. marking. Note

r fo ng

♦ If fluid level is below MIN. marking, hydraulic system must

AG.

be checked for leaks (repair measure). It is not sufficient just to top up with fluid. If the hydraulic system is not leaking, top up with “G 002 000” fluid.

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♦ If fluid level is above MAX. marking, fluid must be extracted.

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marking.

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♦ During the delivery inspection, the oil level must be at MAX.

– Screw cap on hand tight.

4.54

Headlight adjustment: checking gas discharge headlights without DLA Note

♦ Additional weights are no longer used. ♦ Instead, a different inclination setting on the headlight adjust‐

ment unit is used.

♦ If the maintenance tables are used, the settings are dis‐

played in the vehicle-specific maintenance list as of model year 2014.

♦ In the US, Canadian and Mexican markets SAE-compliant

headlights are used.

♦ As of model year 2014 the headlight adjustment is subject to

a separate charge.

Test and adjustment prerequisites ⇒ page 136 Check headlight adjustment (ECE). ⇒ page 136 Check headlight adjustment (SAE). ⇒ page 137

4. Descriptions of work

135

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Gas discharge headlights without “Dynamic Light Assist” dy‐ namic main beam regulation: adjusting for vehicles up to week 47/08 ⇒ page 139 Gas discharge headlights without “Dynamic Light Assist” dy‐ namic main beam regulation: adjusting for vehicles from week 48/08 ⇒ page 145 .

4.54.1

Test and adjustment conditions

•

Tyre pressure OK

•

Headlight lenses must not be damaged or dirty. y Volksw

•

Reflectors and lights OK

•

s The initialisation of the headlight range scontrol must have 1) been completed.

•

The vehicle must be rolled forward and backward several metres or front and rear springs must be bounced fully sev‐ eral times so that springs settle.

•

Vehicle and headlight adjuster must be on a level surface.

•

Vehicle and headlight adjustment unit must be aligned.

•

Inclination must be set.

•

Event memory must be cleared.

•

If the headlight adjustment unit has an adjustment mode, select it.

•

Refer to the ⇒ operating instructions for headlight adjust‐ ment units.

AG. Volkswagen AG d agen oes

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1) During the initialisation, the step motors for the headlight

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Headlight adjustment (ECE): adjusting

♦ Headlight adjustment unit -VAS 621 005♦ Vehicle diagnostic tester

The inclination on the headlight adjustment unit is set according to the fuel level in the fuel tank. Inclination setting for ECE-compliant gas discharge headlights, LED headlights and DLA headlights Fill level of fuel gauge

Inclination

0 to 1/2 1/2 to 1

1.0% 1.0%

Light pattern for dimmed beam, version 1: Check the following: – Whether, with the dipped beam switched on, the horizontal bright/dark boundary contacts the dividing line -1- of the test area and

136 4. Descriptions of work

AG.

♦ Headlight adjustment unit -VAS 621 001-

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Special tools and workshop equipment required

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4.54.2

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range control are reset to dipped beam position. The initialisa‐ tion of the headlight range control is performed during vehicle start or after an "on" signal is applied to terminal 15.

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Note

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Check whether the breaking point -2- between the horizontal part of the light/dark border on the left and the rising part on the right lies on the vertical line of the central point -3-. The bright core of the light beam must be to the right of the vertical line.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

♦ To simplify the determination of the breaking point -2-, cover

and uncover left (from driver perspective) half of the head‐ light a few times. Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

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– With the dipped beam switched on, the lowest part of the horizontal light-dark border must touch the dividing line -1- of the test area

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Check the following:

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Light pattern for dimmed beam, version 2:

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– The breaking point -2- between the horizontal part of the light-dark border on the left and the slope on the right should be on the vertical line passing through the centre mark. Note

To simplify the determination of the breaking point -2-, cover and uncover left (from driver perspective) half of the headlight a few times. Then check dipped beam again.

4.54.3

Headlight adjustment (SAE): checking

Special tools and workshop equipment required 4. Descriptions of work

137

Phaeton 2003 ➤ Maintenance - Edition 03.2021 ♦ Headlight adjustment unit -VAS 621 001♦ Headlight adjustment unit -VAS 621 005♦ Vehicle diagnostic tester Note ♦ The VOL/VOR marking is visible on the outside the head‐

light.

♦ The lateral adjustment mechanism is sealed on SAE-compli‐

ant headlights.

The inclination on the headlight adjustment unit is set according to the fuel level in the fuel tank. Inclination setting for SAE-compliant VOL gas discharge head‐ lights, LED headlights and DLA headlights Fill level of fuel gauge

Inclination

0 to 1/2 1/2 to 1

0.7 % 0.7 %

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pe rm itte d

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VOL: Visual Optical Aim Left -1-

– Check whether the left horizontal light-dark border touches the separating line -1- in the test area of the headlight ad‐ justment unit. Inclination setting for SAE-compliant VOR gas discharge head‐ lights, LED headlights and DLA headlights

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138 4. Descriptions of work

r te o iva r rp fo g n

c o p yri gh t. C op yi

VOR: Visual Optical Aim Right -2-

0.0 % 0.0 %

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0 to 1/2 1/2 to 1

Inclination

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Fill level of fuel gauge

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Check whether the right horizontal light-dark border touches the separating line -2- in the test area of the headlight ad‐ justment unit.

4.54.4

Gas discharge headlights without “Dy‐ namic Light Assist” dynamic main beam regulation: adjusting for vehicles up to week 47/08

Because the automatic headlight range control does not have AG. Volkswagen AG d a manual adjustment, the basic setting procedure must be per‐ agen oes ksw not l o V formed to adjust the headlights. gu y b a d ise

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r The adjusting mechanism in the headlight housingthowill be dam‐ u a aged if the automatic range control basic settings are not per‐ s s formed.

rrectness of i t to the co nform spec at i h re o n wit in t his

After the headlights have been adjusted, the event memory must be read. Therefore, the procedure described here must be strictly followed. Basic setting using diagnostic tester Note

Before performing headlight basic setting, put self-levelling sys‐ tem in basic position. Carry out following procedure:

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Connecting vehicle diagnostic tester ⇒ page 25 .

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– Press button for “Vehicle self-diagnosis” -arrow- on display. Indicated on display:

4. Descriptions of work

139

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Phaeton 2003 ➤ nte is r o eo h Maintenance - Edition 03.2021 ut ra a c s s

Note

Perform basic setting individually on left and right-hand side.

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The control unit identification and coding are displayed -arrow-. Indicated on display:

– Select “04 - Initiate basic setting” -arrow-. Indicated on display:

140 4. Descriptions of work

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Indicated on display:

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– Select “Range control” - “29” = left headlight or “39” = right headlight.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

–

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–

AG. Volkswagen AG d agen oes ksw not l o gu (001 selects y V number block of display -arrowEnter 001d bon ara nte isegroup number 001”). r “display o eo h t u ra a c s Confirm entry with Q button on display's number block. s

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After “wait” appears on display, the following message appears:

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Note

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– Now adjust headlights

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The necessary adjustments for the individual headlights can only be performed when using the infotainment system and service function “Headlight settings” is active. agen lksw Vo by

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Indicated on display:

Information for the infotainment system see ⇒ page 67 . Releasing headlights – Carry out following procedure: – Switch on ignition. First the initial screen displays “Welcome”. – Press function button -1- “Settings”.

4. Descriptions of work

141

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Select submenu “Other”. – Press button on right next to “Maintenance / Service” – Press button on left next to “Headlights”. Thus the headlight spray jets are extended and remain extended until the igni‐ tion is switched off. The headlight setting can now be performed properly. After work is completed, the headlights are locked mechanically by pressing the button again.

rrectness of i t to the co nform spec at i h re o n wit in t his

2 - Height adjustment

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

1 - Lateral adjustment

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Adjusting left headlight

Both adjustment screws on right-hand headlight are a mirror image. – Turn lateral adjustment bolt -1- and height adjustment bolt -2- until the correct setting is achieved.

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c o p yri gh t. C op yi

142 4. Descriptions of work

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Adjusting right headlight

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Location of adjustment screw on left-hand headlight is a mirror image. Note ♦ The main beam is only height-adjustable. The lateral adjust‐

ment is preset and must not be changed.

♦ If the vehicle is equipped with separate dipped and main

beam, adjust main beam additionally. When adjusting main beam ensure that the adjustment unit is set to 0%.

– Adjust the height of the headlight with a screwdriver -1-. – After adjusting headlights, press the button -arrow- on the display. Indicated on display:

– Enter 002 on number block of display -arrow- (002 selects “display group number 002”). n AG. Volkswagen AG do – Confirm entry with Q button on display's number block. e wage

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Indicated on display:

The reference position of the headlight will now be “learnt” by the control unit.

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Indicated on display:

r te o iva r rp fo ng

– Press the -arrow- button on display.

4. Descriptions of work

143

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

– Press the -arrow- button on display.

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Any system faults that are stored will be displayed one after the other. If faults are stored, repairs are necessary. The fault log must accompany vehicle to repair. – Press the -arrow- button on display. Indicated on display:

144 4. Descriptions of work

AG.

Indicated on display:

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– Select “02 - Read event memory” -arrow-.

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Indicated on display:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Select “GoTo” -arrow-.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Press the “End” button -arrow-. – Switch off ignition and separate diagnosis connections.

4.54.5

Gas discharge headlights without “Dy‐ namic Light Assist” dynamic main beam regulation: adjusting for vehicles from week 48/08

Note

do c um en

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r te o iva r rp fo g n

As of model year 2014 the headlight adjustment is subject to a separate charge.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Press “End” button in End menu.

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Indicated on display:

4. Descriptions of work

145

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Phaeton 2003 ➤ Maintenance - Edition 03.2021

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

LED module on left for daylight running lights and side light -L176-; the side light is dimmed.

Bulb for left curve light -L148-

Left gas discharge lamp -L13- or right gas discharge lamp -L14-

Side marker: as trim

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Front left turn signal bulb -M5- or front right turn signal bulb -M7-

Prote cted by

The covering flaps on left and right open and the lifting cylinders are extended, making the covering flaps and adjusting bolts accessible. Press the covering flaps forwards until they engage in their end position.

The lifting cylinders are retracted. The adjusting bolts are now easy to reach. – Now, adjust headlights as follows: Adjusting left headlight – Turn the adjusting bolts with a hexagon wrench.

146 4. Descriptions of work

AG.

– Carrying out basic setting of headlight range control ⇒ Vehi‐ cle diagnostic tester

agen lksw Vo by

c o p yri gh t . C op yi

– Put the running gear in workshop mode ⇒ page 36 .

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r lamp and dynamic Overview: Headlight with gas discharge o h t or u Light Assist” (including high beam regulation without “Dynamic ac a s s masked permanent high beam MDF)

Phaeton 2003 ➤ Maintenance - Edition 03.2021

Height adjustment

Lateral adjustment

– Turn height adjustment screw -2- until setting is correct. Note

In some markets, the adjustment bolt for lateral adjustment is -1- encapsulated. Lateral adjustment is not permissible here. – Turn adjusting bolt for lateral adjustment -1until setting is AG. Volkswagen AG d agen correct. oes n lksw o yV

b – Repeat the adjusting procedure on the other side of the ed ris o vehicle. h t u

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Headlight adjustment: checking gas discharge headlights with DLA

rrectness o f i t to the co n f orm spec atio h re n wit

Note

♦ Additional weights are no longer used. ♦ Instead, a different inclination setting on the headlight adjust‐

ment unit is used.

♦ If the maintenance tables are used, the settings are dis‐

played in the vehicle-specific maintenance list as of model year 2014.

♦ In the US, Canadian and Mexican markets SAE-compliant r te o iva r rp fo ng

headlights are used.

♦ As of model year 2014 the headlight adjustment is subject to

a separate charge.

Check headlight adjustment (SAE). ⇒ page 149

agen lksw Vo by

c o p yri gh t . C op yi

Check headlight adjustment (ECE). ⇒ page 148

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Conditions for checking and adjusting: ⇒ page 147

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4.55

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Close the covering flapss by hand.

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AG.

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Gas discharge headlights with “Dynamic Light Assist” dynamic main beam regulation: adjusting ⇒ page 153

4.55.1

Conditions for testing and adjustment:

•

Tyre pressure OK

•

Headlight lenses must not be damaged or dirty. 4. Descriptions of work

147

Phaeton 2003 ➤ Maintenance - Edition 03.2021 •

Reflectors and lights OK

•

The initialisation of the headlight range control must have been completed. 1)

•

The vehicle must be rolled forward and backward several metres or front and rear springs must be bounced fully sev‐ eral times so that springs settle.

•

Vehicle and headlight adjuster must be on a level surface.

•

Vehicle and headlight adjustment unit must be aligned.

•

Inclination must be set.

•

Event memory must be cleared.

•

If the headlight adjustment unit has an adjustment mode, select it.

•

Refer to the ⇒ operating instructions for headlight adjust‐ ment units.

1) During the initialisation, the step motors for the headlight

range control are reset to dipped beam position. The initialisa‐ tion of the headlight range control is performed during vehicle start or after an "on" signal is applied to terminal 15.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o Special tools and workshop equipment required uth or ac a s s ♦ Headlight adjustment unit -VAS 621 001-

Headlight adjustment (ECE): adjusting

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es, in part or in w l purpos hole ercia , is n m ot com

♦ Vehicle diagnostic tester

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♦ Headlight adjustment unit -VAS 621 005-

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4.55.2

The inclination on the headlight adjustment unit is set according to the fuel level in the fuel tank. Inclination setting for ECE-compliant gas discharge headlights, LED headlights and DLA headlights

Test pattern with dynamic main beam

c o p yri gh t . C op yi

♦ For dynamic main beam test pattern, headlights need to be Prote cted by

tester. After resetting, DLA main beam distribution is actu‐ ated automatically.

♦ Pay special attention to correct alignment of the adjustment

sighting device on the headlight adjuster. Only when this has been done can you adjust the headlights to ensure that they do not dazzle other road users.

♦ In vehicles with DLA the dipped headlight setting can be

checked as an alternative. ⇒ page 149

♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation.

148 4. Descriptions of work

AG.

♦ The basic settings can only be reset using vehicle diagnostic

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reset to basic settings using vehicle diagnostic tester.

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Note

1.0% 1.0%

r te o iva r rp fo g n

0 to 1/2 1/2 to 1

Inclination

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Fill level of fuel gauge

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Check the following: – Whether the horizontal light-dark border touches the sepa‐ rating line -1- in the test area when the main beam is on.

– Whether the breaking point -2- between horizontal part of the light-dark border on the right and the rising part on the left lies on the vertical line of the central point -3-. The bright core of the light beam must be to the left of the vertical line. Note

Volkswagen AG

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Headlight adjustment, on the other hand, can only be carried out using the test pattern with dynamic main beam. The control‐ ler only uses the DLA main beam distribution test program.

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Headlight adjustment (SAE): checking

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4.55.3

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– The breaking point -2- between the horizontal part of the light-dark border on the left and the slope on the right should be on the vertical line passing through the centre mark.

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– With the dipped beam switched on, the lowest part of the horizontal light-dark border must touch the dividing line -1- of the test area

Special tools and workshop equipment required

4. Descriptions of work

149

light.

♦ The lateral adjustment mechanism is sealed on SAE-compli‐

ant headlights.

Inclination

0 to 1/2 1/2 to 1

0.7 % 0.7 %

Test pattern with dynamic main beam Note ♦ For dynamic main beam test pattern, headlights need to be

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte The basic settings can only be reset using vehicle odiagnostic ris eo h ut is actu‐ tester. After resetting, DLA main beam distribution ra a c s s

reset to basic settings using vehicle diagnostic tester.

♦

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ated automatically.

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♦ Pay special attention to correct alignment of the adjustment

rrectness of i t to the co nform spec at i h re o n wit in t his

sighting device on the headlight adjuster. Only when this has been done can you adjust the headlights to ensure that they do not dazzle other road users.

♦ In vehicles with DLA the dipped headlight setting can be

checked as an alternative. ⇒ page 151

♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation. Check the following:

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150 4. Descriptions of work

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– Whether the horizontal light-dark border touches the sepa‐ rating line -1- in the test area when the main beam is on.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Whether the breaking point -2- between horizontal part of the light-dark border on the right and the rising part on the left lies on the vertical line of the central point -3-. The bright core of the light beam must be to the left of the vertical line. Note

The setup pattern applies only to the left headlight. The setup pattern for the right headlight is a mirror image. Test pattern with dipped headlights Testing may also be carried out with dipped headlights switched on. Nevertheless, said dynamic main beam test pattern is pre‐ ferred. For checking dipped headlight it is not necessary to use the vehicle diagnostic tester. Headlight adjustment, on the other hand, can only be carried out using the test pattern with dynamic main beam. The control‐ ler only uses the DLA main beam distribution test program.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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– With the dipped beam switched on, the lowest part of the horizontal light-dark border must touch the dividing line -1- of the test area

– The breaking point -2- between the horizontal part of the light-dark border on the left and the slope on the right should be on the vertical line passing through the centre mark. Inclination setting for SAE-compliant VOR gas discharge head‐ lights, LED headlights and DLA headlights

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0.0 % 0.0 %

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0 to 1/2 1/2 to 1

Inclination

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Fill level of fuel gauge

4. Descriptions of work

151

Phaeton 2003 ➤ AG. Volkswagen AG d agen oes Maintenance - Edition 03.2021 ksw not l o V

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♦ For dynamic main beam test pattern, headlights need to be

reset to basic settings using vehicle diagnostic tester.

♦ The basic settings can only be reset using vehicle diagnostic

tester. After resetting, DLA main beam distribution is actu‐ ated automatically.

♦ Pay special attention to correct alignment of the adjustment

sighting device on the headlight adjuster. Only when this has been done can you adjust the headlights to ensure that they do not dazzle other road users.

♦ In vehicles with DLA the dipped headlight setting can be

checked as an alternative. ⇒ page 152

♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation. Check the following:

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152 4. Descriptions of work

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– Whether the horizontal light-dark border touches the sepa‐ rating line -1- in the test area when the main beam is on.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Note

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by ed ris beam Test pattern with dynamic main o th au ss

Phaeton 2003 ➤ Maintenance - Edition 03.2021

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–

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be on the vertical line passing through the centre mark.

Note

As of model year 2014 the headlight adjustment is subject to a separate charge. Identification:

rrectness o f i t to the co n f orm spec atio h re n wit

Gas discharge headlights with “Dy‐ namic Light Assist” dynamic main beam regulation: adjusting

r te o iva r rp fo ng

There is no external difference between headlights with “Dy‐ namic Light Assist” and headlights without DLA The production control number 8G3 means that the vehicle is equipped with DLA.

in t his d o cu m en

Overview: Headlight with gas discharge lamp and dynamic high beam regulation “Dynamic Light Assist” (including masked per‐ manent high beam MDF) ht rig py Co t.

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4.55.4

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Front left turn signal bulb -M5- or front right turn signal bulb -M7-

LED module on left for daylight running lights and side light -L176-; the side light is dimmed.

Bulb for left curve light -L148-

Left gas discharge lamp -L13- or right gas discharge lamp -L14-

Side marker: as trim

– Put the running gear in jacking-up mode ⇒ page 36 .

4. Descriptions of work

153

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Carrying out basic setting of headlight range control ⇒ Vehi‐ cle diagnostic tester The covering flaps on left and right open and the lifting cylinders are extended, making the covering flaps and adjusting bolts accessible. Press the covering flaps forwards until they engage in their end position.

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Adjusting left headlight

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– Turn the adjusting bolts with a hexagon wrench.

Lateral adjustment

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Height adjustment

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In some markets, the adjustment bolt for lateral adjustment is -1- encapsulated. Lateral adjustment is not permissible here.

AG.

– Turn adjusting bolt for lateral adjustment -1- until setting is correct. – Repeat the adjusting procedure on the other side of the vehicle. Close the covering flaps by hand.

154 4. Descriptions of work

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Note

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– Turn height adjustment screw -2- until setting is correct.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.56

Headlight adjustment: checking fog lights Note

♦ Additional weights are no longer used. ♦ Instead, a different inclination setting on the headlight adjust‐

ment unit is used.

♦ If the maintenance tables are used, the settings are dis‐

played in the vehicle-specific maintenance list as of model year 2014.

♦ As of model year 2014 the headlight adjustment is subject to

a separate charge.

Test and adjustment conditions ⇒ page 155 Check headlight adjustment ⇒ page 155 . Adjusting fog lights and other additional lights ⇒ page 156 .

4.56.1

Test and adjustment conditions

•

Tyre pressure OK

•

Lenses must not be damaged or dirty.

• •

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eral times so that springs settle.

Vehicle and headlight adjuster must be on a level surface.

•

Vehicle and headlight adjuster must be aligned.

•

Inclination must be set.

•

Refer to the ⇒ operating instructions for headlight adjust‐ ment units.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

4.56.2

es, in part or in w l purpos hole ercia , is n m ot com

•

Headlight adjustment: checking

Special tools and workshop equipment required ♦ Headlight adjustment unit -VAS 621 001♦ Headlight adjustment unit -VAS 621 005-

Inclination setting for fog lights

2.1 % 2.0 %

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0 to 1/2 1/2 to 1

Inclination ht rig py Co t.

Fill level of fuel gauge

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The inclination on the headlight adjustment unit is set according to the fuel level in the fuel tank.

4. Descriptions of work

155

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Fog lights:

– Check whether the upper light-dark border touches the set‐ ting line and runs horizontally over the entire width of the test agen AG. Volkswagen AG doe w s no olks screen. tg yV

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Other additional lights:

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Fog lights and other auxiliary lights: ad‐ justing

Note

As of model year 2014 the headlight adjustment is subject to a separate charge. Adjusting right fog light

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156 4. Descriptions of work

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– To reduce the beam range turn adjustment screw -arrow- to the right. There is no provision for lateral adjustment.

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– Unclip the cover in the bottom part of the bumper, working from the middle of the vehicle.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

4.56.3

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and set according to valid guidelines.

or ac

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Location of adjustment screw on left-hand headlight is natemirror ise r o eo h image. aut ra c s s

– Correct with the adjusting bolt -1- until the setting is correct.

Carry out following procedure:

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Track rod ends: checking clearance, firm seating and boots

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4.57

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Adjusting LED fog lights

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– Check play by moving track rods and wheels with the vehicle raised (wheels hanging free). Clearance: zero clearance – Check attachment. – Check link joint boots -1- and -2- and track rod joint boots -3are seated correctly and not damaged.

4.58

Telematics system: activating and de‐ activating

“The emergency call module is designed for the American and Canadian markets.” 4. Descriptions of work

157

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ At delivery the control unit is in transportation mode, the

self-diagnosis is switched off.

♦ This mode must be deactivated for all tests. ♦ Before the vehicle is delivered the transportation mode

must be activated again to prevent log-in into the mobile telephone network and especially to prevent the battery dis‐ charging. Note

♦ Before the Telematics system is used by the customer for

the first time, it is enabled by the Volkswagen dealership.

♦ The system is enabled. ⇒ Operating manual for telematics

system

♦ When the telematics services are enabled, the vehicle spe‐

cific data, e.g. model, chassis number etc. are written into the non-volatile memory ofenthe control unit. Volkswagen AG AG. Telematics wag olks yV b ed ris ho t au

4.58.1

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Telematics control unit: checking

Selecting operating mode – Press the »Guided fault finding« button on display.

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Note

Telematics control unit - fitting location:

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4.58.2

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– Now perform work instructions ⇒ Vehicle diagnostic tester.

If the vehicle battery must be disconnected for service work, first deactivate the telematics system using vehicle diagnostic tester. This prevents the telematics control unit from being acti‐ vated automatically. – The upper luggage compartment trim can only be folded down, when the nine Torx bolts (T20) -arrows- are removed first.

158 4. Descriptions of work

rrectness of i t to the co nform spec at i h re o n wit in t his

Indicated on display:

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Connect vehicle diagnostic tester: ⇒ page 25 ss

Phaeton 2003 ➤ Maintenance - Edition 03.2021

The Telematics control unit, which is now visible

– Can be removed by disconnecting the multi-pin connector (42-pin) -1- and two aerial connectors -2- including three n AG. Volkswagen AG do bolts -3-. e wage

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Buttons (roof module)

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♦ “Dot” -1- accept a telephone call, hang up, end a telephone connection and activate voice command.

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♦ “Status - LED” -3- RED = system fault, GREEN = OK, FLASHING = dialling or active connection.

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♦ “Emergency call or airbag crash signal” -4- emergency call connection to service centre, vehicle data transfer (GPS etc.).

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♦ “Operator” -2- dial the telephone number of the service cen‐ tre, automatic transfer of (GPS position, etc.) and data, acti‐ vate radio mute, activate hands-free mode, voice connection to operator, to obtain information.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

4.58.3

4. Descriptions of work

159

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ Displays “Status - LED” -3- RED = system faults: ♦ Perform work instructions ⇒ Vehicle diagnostic tester.

4.59

Transportation level: deactivating Note

♦ The transportation level is activated when “Fault Running

gear Workshop” is displayed in the dash panel insert.

♦ The transportation level can also be deactivated when ex‐

ceeding 80 km/h during a road test.

– Connect vehicle diagnostic tester ⇒ page 25 . – Switch on ignition. Note

Transportation level can be deactivated via ⇒ Guided fault find‐ ing. AG. Volkswagen AG d agen oes

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–

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db ise rgroup Select "Running gear" (repair 01; 40 to 49). o h ut a Select „Adaptive suspension“. ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

– Select "01 - Systems capable of self-diagnosis". – Select "Adaptive suspension functions". Ending output

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– Select "Activate/deactivate transportation level".

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160 4. Descriptions of work

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Indicated on display:

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– Press »GoTo« button on display -arrow-.

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Indicated on display:

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Press the »End« button on display -arrow-. – Press »End« button in End menu. – Switch off ignition.

4.60

Door arrester: grease.

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Perform the following procedure:

– Lubricate door arrester at positions -1-, -2-, -3- and -4- with universal oil spray -G 000 115 A2-. Ensure universal oil penetrates by moving door several times over all detents.

in t his d o cu m en

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– Wipe off excess universal oil with a cloth.

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– Then, lubricate door arrester rollers with lubricating paste -G 000 150- at positions marked with an -arrow-.

4. Descriptions of work

161

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.61

Underbody sealant: inspecting for damage to underbody sealant, under‐ body panels, routing of lines and plugs

During inspection, also check floor pan, wheel housings and sills. . Volkswagen AG

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Note

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

4.63

Camshaft drive toothed belt: renewing (8-cylinder petrol engines)

– Carry out procedure: »Power unit« ⇒ Power unit; Rep. gr. 15; Removing, installing and tensioning toothed belt»Re‐ moving, installing and tensioning toothed belt«.

4.64

Central display and control unit (CDCU): setting units of measurement, clock and date

Carry out adjustment as follows:

162 4. Descriptions of work

AG.

– Adhere to specified torques: »Power unit« ⇒ Power unit; Rep. gr. 13; Removing and installing poly V-belt»Removing and installing poly V-belt«.

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– Renew the two idler pulleys -item 2- and -item 5-.

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Idler pulleys for poly V-belt: renewing (8-cylinder petrol engines)

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4.62

es, in part or in w l purpos hole ercia , is n m ot com

Faults found must always be rectified (repair measure). This inhibits corrosion and rusting through.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Press main menu button ON/DARK -item 1- with infotainment system switched off.

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The system is switched on.

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– Select button SETTINGS in the main menu block -2-. – Select »Other functions« in the submenu.

rrectness of i t to the co nform spec at i h re o n wit in t his

– Select »Units of measurement« in the submenu. – Select the required units of measurement, e.g. (kilometres, litres, temperature in degrees centigrade), in the main menu block by turning the rotary/push button. – Confirm selection by pressing the rotary/push button. – Select »Time« in the submenu.

– Select required time by pressing the rotary/push button in the main menu block. Note

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– Select »Accept« in the submenu.

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– Select required data, e.g. (day, month, year), in the main menu block by pressing the rotary/push button.

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– Select »Date« in the submenu.

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– Select »Accept« in the submenu.

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The time is set for the infotainment and for the analogue clock.

4. Descriptions of work

163

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.65

Central display and control unit (CDCU): determining language for let‐ tering and language version Note

This adaptation is required only for vehicles for some export markets. Adapting language version using diagnostic tester – Carry out language version adaptation using diagnostic test‐ er in operating mode »Guided fault finding«. Note

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pe rm itte d

Adapting language version with infotainment

– Select the required language by turning the rotary/push but‐ ton.

164 4. Descriptions of work

AG.

Here the language for »Lettering and language version« can be determined.

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– Select »Language« in the submenu.

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– Select button SETTINGS in the main menu block -2-.

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The system is switched on.

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– Press main menu button ON/DARK -item 1- with infotainment system switched off.

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Confirm selection by pressing the rotary/push button. A "tick" appears before the selection.

4.66

Spark plugs: Renew

Spark plugs, renewing on 6-cylinder engine ⇒ page 166 . Spark plugs, renewing on 8-cylinder engine ⇒ page 170 . Spark plugs, renewing on 12-cylinder engine ⇒ page 173 . Special tools and workshop equipment required ♦ Spark plug socket -3122B-

♦ Torque wrench

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♦ Puller -T10095/a- for 6-cylinder petrol engine

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♦ Oil seal extractor -T10118- for 6-cylinder petrol engine

4. Descriptions of work

165

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 n AG. Volkswagen AG do e wage

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AG.

4.66.1

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♦ Exhaust emissions test binder

Renewing spark plugs, 6-cylinder en‐ gine

Removing: – Unclip engine cover panels -1- and -2- and remove upwards.

166 4. Descriptions of work

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♦ Spring type clip pliers -VAS 6499- for 8-cylinder engine

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♦

s no t gu ara nte eo ra c

ks Vol by d Puller -T40039- for 8-cylinder engine e ris ho t au ss

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Release connector lock: – Apply assembly tool -T10118- to connector lock -arrow- and carefully pull upwards until connector lock releases.

–

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is coils with output r Pull off connectors -1 to 6- for ignition o eo h ut ra stages upwards. a c s s

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– Before pulling off, note positions of ignition coils with output stages relative to connectors.

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The flat side of the connector must align with the flat side of ignition coil with final output stage -arrows-.

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– Slide puller T10095/a from the flat side of the connector in direction of arrow onto ignition coil with output stage. – Pull out ignition coil with output stage upwards vertically.

4. Descriptions of work

167

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Unscrew spark plugs using spark plug socket -3122B-. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se te o h t Spark plug designation and specified torque ⇒ Rep. gr. 28;e or u ac a s Test data, sspark plugs

Note

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♦

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♦ Please observe disposal instructions!

♦ When installing new spark plugs, regrease ignition coils with

output stage using silicone paste ⇒ ETKA.

♦ The applicable silicone paste is stated in the ETKA along

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with the corresponding ignition coil and/or spark plug.

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– Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage -arrow-.

168 4. Descriptions of work

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Note

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Installing:

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Screw in new spark plugs using spark plug socket and ex‐ tension -3122B-. Carry out following procedure:

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– Carefully set ignition coils with final output stages onto spark plugs by hand.

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The flat sides of connectors must align -arrows-.

– Reconnect connectors -1 to 6-. – Install engine cover panels -1- and -2-.

4. Descriptions of work

169

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.66.2

Spark plugs, renewing on 8-cylinder engine

♦ To pull off spark plugs, fit puller -T40039- on top, thick rib

-arrow- of ignition coils with final output stages.

♦ If the lower ribs are used, they could be damaged.

r fo ng

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170 4. Descriptions of work

AG.

Before pulling off connectors, note positions of ignition coils with output stages relative to connectors and mark if necessary.

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Note

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– Unscrew bolts -1-.

ht rig py Co t.

– Remove engine cover panels.

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Note

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Removing:

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Press connectors -2- in direction of ignition coils with final output stages. – Then press connector lock by hand and pull connectors off.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Carry out following procedure:

pe rm itte d

– Pull out ignition coils with output stages in direction of arrow using puller -T40039-.

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es, in part or in w l purpos hole ercia , is n m ot com

ht rig py Co t.

c o p yri gh t. C op yi

Note

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Carry out following procedure:

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– Unscrew spark plugs using spark plug socket -3122B-.

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♦ Spark plug designation and specified torque ⇒ Rep. gr. 28; AG.

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Test data, spark plugs

♦ Please observe disposal instructions! Installing: Note

♦ When installing new spark plugs, regrease ignition coils with

output stage using silicone paste ⇒ ETKA.

♦ The applicable silicone paste is stated in the ETKA along

with the corresponding ignition coil and/or spark plug.

4. Descriptions of work

171

Phaeton 2003 ➤ Maintenance - Edition 03.2021

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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– Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage -arrow-.

– Screw in new spark plugs using spark plug socket and ex‐ tension -3122 B-. – Push on ignition coils with output stages turning slightly. They must be felt to engage.

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172 4. Descriptions of work

AG.

– Install engine cover panels.

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c o p yri gh t. C op yi

– Retighten cable guide with bolts -1-.

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– Push on connectors -2- again so that they engage.

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Note installation position, see item -3- in illustration.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

4.66.3

Spark plugs, renewing on 12-cylinder engine

Renewing spark plugs (vehicles with engine codes BAN and BAP) ⇒ page 173 Renewing spark plugs (vehicles with engine codes BRN, BRP and BTT) ⇒ page 177 Renewing spark plugs (vehicles with engine codes BAN and BAP) Removing: – Remove engine cover panels.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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– Loosen clips -1- and -2- using spring-type clip pliers -VAS 6499- and pull off intake hose.

ht rig py Co t.

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c o p yri gh t . C op yi

– Pull off hose -1-.

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r te o iva r rp fo g n

– Pull off connector -1-.

4. Descriptions of work

173

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Carefully pull out ignition coils -2-.

174 4. Descriptions of work

AG.

– Note installation position of ignition coils with final output stages.

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Prote cted by c o py rig ht . C op yi

– Disconnect connectors -1- at ignition coils with final output stages -2-.

ht rig py Co t.

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– Unscrew bolts -arrows-, and remove upper part of intake manifold -1-.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Unscrew spark plugs using spark plug socket -3122 B-. Note ♦ Spark plug designation and specified torque ⇒ Rep. gr. 28;

Test data, spark plugs

♦ Please observe disposal instructions! Carry out following procedure: Installing: Note ♦ When installing new spark plugs, regrease ignition coils with

output stage using silicone paste ⇒ ETKA.

♦ The applicable silicone paste is stated in the ETKA along AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

ility ab y li an pt ce

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with the corresponding ignition coil and/or spark plug.

ht rig py Co t.

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do c um en

– Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage -arrow-.

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AG.

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– Screw in new spark plugs using spark plug socket and ex‐ tension -3122 B-.

4. Descriptions of work

175

Phaeton 2003 ➤ Maintenance - Edition 03.2021 – Push on ignition coils with output stages turning slightly. They must be felt to engage.

Note installation position, see -items 1 + 2-.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

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– Push on connectors -1- again so that they engage.

pe rm itte d

Note

es, in part or in w l purpos hole ercia , is n m ot com

– Reinstall upper part of intake manifold -1-.

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AG.

176 4. Descriptions of work

ht rig py Co t.

– Push on connector -1-.

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r te o iva r rp fo g n

– Screw in bolts -arrows-, and tighten them to 7 Nm +180°.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Renew gasket between lower part of intake manifold and upper part of intake manifold.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Connect hose -1-.

ility ab y li an pt ce

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–

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h Secure ut intake hose with clips -1- and -2- using spring-type ra a c s clip spliers -VAS 6499-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Install engine cover panels.

Removing:

ht rig py Co t.

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– Remove engine cover panel.

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Renewing spark plugs (vehicles with engine codes BRN, BRP and BTT)

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– Release hose clamp -1- and pull off connecting pipe -2- from union. agen lksw Vo by

– Release connecting hose -3- by compressing circlip -4- and pull hose off. AG.

– Loosen vacuum line -5- and pull off. – Loosen hose clamp and pull connecting hose off -6-.

4. Descriptions of work

177

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Pull connector -1- off throttle valve module 2 -J544-. – Release connecting hose -3- by compressing circlip -2- and pull hose off. – Also perform the first two procedures on the left throttle valve module -J338-.

AG.

178 4. Descriptions of work

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– Disconnect connectors -1- at ignition coils with final output stages -2-.

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– Unscrew bolts -arrows-, and remove upper part of intake manifold -1-.

in t his d o cu m en

r te o iva r rp fo ng

– Release vacuum line -5- by compressing circlip -4- and pull line

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AG. Volkswagen AG d agen oes Phaeton 2003 ➤ ksw not l o gu yV b ara d Maintenance Edition 03.2021 e nte ris eo ho t ra au c ss

– Note installation position of ignition coils with final output stages.

in t his d o cu m en

ht rig py Co t.

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– Carefully pull out ignition coils -2-.

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AG.

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– Unscrew spark plugs using spark plug socket -3122 B-. Note ♦ Spark plug designation and specified torque ⇒ Rep. gr. 28;

Test data, spark plugs

♦ Please observe disposal instructions! Carry out following procedure: Installing: Note ♦ When installing new spark plugs, regrease ignition coils with

output stage using silicone paste ⇒ ETKA.

♦ The applicable silicone paste is stated in the ETKA along

with the corresponding ignition coil and/or spark plug.

4. Descriptions of work

179

Phaeton 2003 ➤ Maintenance - Edition 03.2021

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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– Apply a thin bead of silicone paste on the circumference of the sealing hose of the ignition coil with output stage -arrow-.

– Screw in new spark plugs using spark plug socket and ex‐ tension -3122 B-.

AG.

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Renew gasket between lower part of intake manifold and upper part of intake manifold.

180 4. Descriptions of work

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c o p yri gh t . C op yi

Note

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Note installation position, see -items 1 + 2-.

in t his d o cu m en

r te o iva r rp fo ng

– Push on ignition coils with output stages turning slightly. They must be felt to engage.

Phaeton 2003 ➤ Maintenance - Edition 03.2021

– Install upper part of intake manifold -1-, and tighten bolts -arrows- to 7 Nm +180°.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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– Further assembly is performed in the reverse order of re‐ moval.

4. Descriptions of work

181

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AG.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021

Exhaust emissions test

This chapter provides information on the following subjects: Exhaust emissions test for petrol engines ⇒ page 189 Exhaust emissions test for diesel engines ⇒ page 182 . Note ♦ Please observe the country specific legal regulations. ♦ The exhaust emissions test described below has been cre‐

ated according to the legal regulations valid in Germany.

Emissions test intervals: Vehicles with regulated catalytic converter or vehicles with die‐ sel engine: ♦ 3 years after initial registration and then every 2 years. ♦ Vehicles for commercial passenger transport, e.g. taxis: ev‐ ery 12 months

5.1

Exhaust emissions test for odiesel en‐ AG. V lkswagen AG d n e g a oes gines ksw not Vol y db

e ♦ Exhaust emissions test for ris diesel engines with diesel tester ho t V.A.G 1743 ⇒ page 182 au

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Exhaust emissions test for diesel en‐ gines using diesel tester V.A.G 1743

Special tools and workshop equipment required

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AG.

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182 5. Exhaust emissions test

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♦ Diesel tester -V.A.G 1743-

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5.1.1

rrectness o f i t to the co n f orm spec atio h re n wit

Information on whether vehicles are fitted with “Onboard diag‐ nosis” or not can be found in the engine list. ⇒ page 1

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♦ Exhaust emissions test for diesel engines with OBD ⇒ page 187

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♦ or

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♦ Engine speed adapter -VAS 6296-

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♦ Engine speed adapter -VAS 5087 A-

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♦ Data reader -V.A.G 1798♦ or ♦ Data reader -V.A.G 1799♦ ⇒ Data sheets for exhaust emissions test Note ♦ All test conditions and data required for exhaust emissions

test: ⇒ Data sheets for exhaust emissions test

♦ If possible, the test should be completed outdoors following

a road test. If this is not possible for various reasons (weath‐ er, excessive noise in residential areas), then the test can be carried out in a workshop.

♦ To reduce noise levels, the bonnet should be closed on first

catch during tests.

Carrying out visual check of components that affect pollution – Performing visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage

5. Exhaust emissions test

183

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note

Faults found are to be rectified. Test conditions •

Engine temperature at least 80 °C

•

No fault in event memory

AG. Volkswagen AG d agen o

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Note

♦ The engine speed adapter -VAS 5087 A- or the engine

speed adapter -VAS 6296- can be used instead of the TDC sender, for engines where the hole of the TDC sender can‐ not be reached or cannot be reached easily or is large.

ht rig py Co t.

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♦ It is not possible to use the diesel tester pick-up clamp (for AG.

cylinder 1).

– Connect engine speed adapter -VAS 5087 A- with ignition switched off as follows:

184 5. Exhaust emissions test

rrectness o f i t to the co n f orm spec atio h re n wit

Description, measuring process, function, setting up and opera‐ tion see ⇒ V.A.G 1743 operating instructions

in t his d o cu m en

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es n Connecting test units y Volksw ot g ua b d ran e tee ris -V.A.G 1743- according to operating in‐ Connect diesel tester o h t or structions. ac au

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ Follow operating instructions for engine speed adapter -VAS

5087 A-!

n AG. Volkswagen AG do es n wage ot g ua b d ran tions! e tee ris o h t or u ac a ss Connect adapter cable -VAS 5087/3- from output connector

olks ♦ Strictly follow the safety precautions y Vin the operating instruc‐

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of engine speed adapter -VAS 5087 A- to pick-up clamp input of diesel tester -V.A.G 1743-. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

–

rrectness of i t to the co nform spec at i h re o n wit in t his

– Turn switch for number of cylinders to respective number of cylinders. – Connect a cable from adapter -VAS 5087/1- to engine speed adapter -VAS 5087 A- (socket VAS 5087/1).

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♦ Black clamp on negative.

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♦ Red clamp on positive

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– Using the other wires from adapter -VAS 5087/1- make a connection to the vehicle battery, by connecting:

Note ♦ When using the engine speed adapter -VAS 5087 A- press

button “Start”. The red signal lamp must flash for approx. 10 seconds. Then the green signal lamp must light up.

♦ The engine speed must now be displayed on diesel tester

-V.A.G 1743-.

♦ If the engine speed is displayed incorrectly or not at all

⇒ Operating instructions for VAS 5087

Perform exhaust emissions test according to instructions on diesel tester -V.A.G 1743- display. If this message appears on the display:

n 1/min Mode k 1/m T °C XXX XXXX B X.XX XX

Unit ready to carry out measurements. Checking idling speed: Idling speed not within specified range:

5. Exhaust emissions test

185

Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note

The idling speed and maximum speed can be checked but not adjusted. – If the values are not within specified range, a repair measure must be made. Perform acceleration test: – Press “button for acceleration test”. First, a fresh air comparison is performed. If this message appears on the display:

n 1/min tB s k 1/m Gas T °C M XXX XXXX -.- X.XX 0 XX -

Current values for temperature and speed are displayed. The arrow pointing upwards indicates that the unit is waiting for the throttle burst. – Depress accelerator pedal fully and hold for specified time. – Check maximum engine speed (not adjustable). Note olkswagen AG G. V If the governed speed (maximum speed) is exceeded, off gen Alift does wa s k not l accelerator pedal immediately and perform repair measures. Vo g

ua ran tee

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–

by ed ris o If the values are not within specified th range, a repair measure au must be made. ss

If this message appears on the display:

n 1/min tB s k 1/m Gas T °C M XXX XXXX -.- -.- 1 XX -

The display remains “frozen” during the evaluation phase (ap‐ prox. 15 seconds). After the evaluation phase, the display changes to:

n 1/min tB s k 1/m Gas T °C M XXX XXXX X.XX X.XX 1 XX -

The arrow pointing upwards indicates that the unit is waiting for the next throttle burst. Repeat test 4 times.

The following is indicated on display after each throttle burst:

n 1/min tB s k 1/m Gas T °C M XXX XXXX X.XX X.XX X XX -

Prote cted by

The display remains until a further throttle burst is performed or another measurement is called up.

186 5. Exhaust emissions test

AG.

After 5 seconds, this display changes to:

n 1/min tB s k 1/m Gas T °C M XXX XXXX X.XX X.XX X XX -

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The following is indicated on display after each throttle burst:

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In this way, the unit measures and registers at least four throttle bursts. After the fourth and for each further throttle burst an average of the last three measurements is performed.

After 10 seconds, this display changes to:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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If the unit detects a valid throttle burst (the speed increases continually during measuring period tx), the following is indica‐ ted on display:

tB s k 1/m band width M Average X.XX X.XX X.XX tB s k 1/m band width M Average X.XX X.XX XX -

Phaeton 2003 ➤ Maintenance - Edition 03.2021 If the opacity figures are equal to or less than the prescribed figures, cease measurements. But if the determined opacity figures are over the prescribed figures, locate fault during a repair measure ⇒ Fault finding, engine.

5.1.2

Exhaust emissions test for diesel en‐ gines with OBD

Special tools and workshop equipment required ♦ Exhaust gas testing station L -VAS 7320 ANote ♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.

♦ The OBD monitors all components and part systems influ‐

encing the exhaust emissions quality.

♦ It is possible to carry out an exhaust emissions test only

when all units of the emissions testing station are connected properly and joined to each other according to the operating instructions. G. Volkswagen AG d oes not gu ara nte eo ra c

♦ All work to be performed is displayed by the emissions test‐lkswagen A

ing station.

Conditions for testing

•

For bar code reading of specified data for EET, the EET data sheet must be printed out.

•

Automatic gearbox: selector lever in position “P” or “N”.

•

Manual gearbox: gear lever in neutral

•

Parking brake applied

•

12V battery fully charged (if battery charge is too low, raise idling speed if necessary).

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

♦ Vehicle identification number ♦ Fuel type ♦ Mileage

The following vehicle data can be found in the vehicle registra‐ tion certificate part 1:

AG.

♦ Key numbers

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♦ Registration number

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– Enter the following data:

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Vehicle data input

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– Perform exhaust emissions test according to instructions on display.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

•

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♦ Registration number: “e.g. WOB-HH 1234” ♦ Emission key No. “field 14.1 (code for field 14)” ♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)” ♦ Vehicle identification number “field E” 5. Exhaust emissions test

187

Phaeton 2003 ➤ Maintenance - Edition 03.2021 ♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” ♦ Nominal speed “field P4” Specified data input for EET There are different ways to enter the specified data: ♦ 1. By manual input ♦ 2. By bar code input from EET data sheet ♦ 3. Through ELSA web service Note ♦ If there is no ESP to deactivate the engine speed limiter, the

. Volkswagen AG rev limit can be measured using the engine speed alimited gen AG by does ksw must not l the control unit. To do this, all the EET specifications o V gu y ara be entered manually. db e n s

i or

tee or ac

th ♦ To use the ELSA web service, the exhaust gas testing sta‐ au pe rm itte d

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tion L which is used for the exhaustssemissions test must be integrated in the workshop network.

♦ The ELSA web service automatically transmits the data for

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

the specific vehicle via the network to the respective mask (exception: nominal speed can only be entered manually).

Manual specified data input for EET: Note

♦ See ⇒ Data sheets for exhaust emissions test of the respec‐

tive engine for the requisite test conditions and data for the emissions test.

♦ The nominal speed is located in field P4 of the registration

certificate part 1 or field 7 of the vehicle document and must always be entered manually. r te o iva r rp fo ng

value 2500 ± 200 rpm in the box for rev limit and 2500 in the box for engine speed for conditioning.

Speed for conditioning

Number of throttle bursts for conditioning

Engine oil temperature (min. value)

Select engine oil temperature measurement procedure

Idling speed

Governed speed

Nominal speed (registration certification part 1, vehicle document)

Governed speed measuring period (1 second)

Type plate value ⇒ page 189

10 - Select probe type (No. of probe)

188 5. Exhaust emissions test

AG.

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– Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows:

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– Perform manual data input according to instructions on dis‐ play.

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♦ If the engine speed limiter cannot be deactivated, enter the

Phaeton 2003 ➤ Maintenance - Edition 03.2021 11 - Select measuring mode 12 - Measured period portion Note

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ility ab y li an pt ce

♦ When performing the exhaust emissions test, the respective es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

engineer must always use the vehicle-specific exhaust emis‐ sions limit value indicated on the type plate.

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ If no value is indicated on the type plate, the opacity figure

specified by the manufacturer and indicated in ELSA must be used.

♦ If no value is indicated on the type plate and no opacity

figure has been specified by the manufacturer, the statutory opacity figures (2.5 m -1 or 1.5 m -1, depending on date of initial registration) must be used.

♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1

applies.

Specified data input for EET as bar code:

– If specified data for EET are available as bar code, read bar code of EET data sheet with bar code reader. r fo ng

AG.

– Inspect all exhaust emissions relevant components.

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Inspection

ht rig py Co t.

If the opacity figure on the EET data sheet is different from the value indicated on the type plate, enter the type plate value manually.

do c um en

The nominal speed can only be entered manually.

– Check if exhaust system is fitted and complete and check for leaks and damage. Procedure – Follow instructions from exhaust gas testing station. Evaluation Note

If the exhaust emissions test was performed at governed speed, the log note “governed speed <90 % of the nominal speed (idle speed control)” is entered in the log.

5.2

Exhaust emissions test for petrol en‐ gines

Special tools and workshop equipment required ♦ Exhaust gas testing station L -VAS 7320 A-

5. Exhaust emissions test

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♦ The following description refers to vehicles fitted with “On‐

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board diagnosis” OBD.

♦ The OBD monitors all components and part systems influ‐

encing the exhaust emissions quality.

♦ It is possible to carry out an exhaust emissions test only

when all units of the emissions testing station are connected properly and joined to each other according to the operating instructions.

♦ All work to be performed is displayed by the emissions test‐

ing station.

Conditions for testing

For bar code reading the EET data sheet must be printed out.

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Automatic gearbox: selector lever in position “P” or “N”.

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Manual gearbox: gear lever in neutral

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Parking brake applied

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12V battery fully charged (if battery charge is too low, raise idling speed if necessary).

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Vehicle data input – Enter the following data: ♦ Registration number ♦ Key numbers ♦ Vehicle identification number ♦ Fuel type ♦ Mileage The following vehicle data can be found in the vehicle registra‐ tion certificate part 1: ♦ Registration number: “e.g. WOB-HH 1234” ♦ Emission key number “Field 14.1 (code for field 14)” ♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)” ♦ Vehicle identification number “field E” ♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for field D.2)” Specified data input for EET There are different ways to enter the specified data: ♦ 1. By manual input ♦ 2. By bar code input from EET data sheet ♦ 3. Through ELSA web service

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– Perform exhaust emissions test according to instructions on display.

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All test conditions and data required for exhaust emissions test are found on EET data sheet for the respective engine.

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 Note ♦ To use the ELSA web service, the exhaust gas testing sta‐

tion L which is used for the exhaust emissions test must be integrated in the workshop network.

♦ The ELSA web service automatically transmits the data for

the specific vehicle via the network to the respective mask.

Manual specified data input for EET: Note

All test conditions and data required for exhaust emissions test can be found in the ⇒ Data sheets for exhaust emissions test for respective engine. – Perform manual data input according to instructions on dis‐ play. – Enter displayed values on EET data sheet in column “Test values for exhaust emissions test” on display as follows: 1-

Test speed (idling speed)

Warm-up phase for catalytic converter

Engine temperature

Increased idling speed

CO content at increased idling speed

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does not gu ara d e nte is r o eo Select regulating probe type; either “Step-type probe” or h ut ra a “Broad-band probe”. c s s Vol Idling speed by

Lambda probe value

– If specified data for EET are available as bar code, read bar code of EET data sheet with bar code reader. All data required are shown on display. Inspection – Inspect all exhaust emissions relevant components.

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– Check if exhaust system is fitted and complete and check for leaks and damage. Procedure

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– Follow instructions from exhaust gas testing station.

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Specified data input for EET as bar code:

5. Exhaust emissions test

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ABS

TCS ATF EET AUS 32

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Common rail “CR” Diesel exhaust fluid DIN DLA

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ATF level BEV CNG CO

Deutsches Institut für Normung e.V. (German Standards Authority) Dynamic Light Assist: a system with variable road illumination allows the vehicle to be driven permanently with main beam without dazzling oncoming traffic. DPF Diesel particulate filter DS Direct shift DSP Digital service plan DSG Dual clutch gearbox ATA Anti-theft alarm ECE Economic Commission for Europe eHybrid (plug-in High-performance plug-in hybrid vehicles made by Volkswagen. Even longer distances hybrid) can be covered fully electrically (commuters). eTSI (mild hybrid) Electrified power units made by Volkswagen. Savings in fuel consumption plus higher comfort. ETKA Electronic parts catalogue Part no. Abbreviation for part number EN European standard EOBD European On-Board Diagnosis ESP Electronic stabilisation program. Prevents potential vehicle skidding by targeted inter‐ vention in the brake and motor management systems. FAME Fatty acid methyl ester

192 6. Glossary

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AdBlue®

Anti-locking brake system. The ABS is a regulating system in the brake system, that prevents locking when braking. This helps to maintain directional stability and steerabil‐ ity. Term to be used in place of “Haldex” with immediate effect. Legal implications make this step necessary. The term may nevertheless appear in older documents but need not be replaced. Traction control system The TCS prevents the wheels from slipping when the vehicle is driven off. Automatic Transmission Fluid. Gear oil for automatic gearbox. Exhaust emissions test Abbreviation for “Aqueous Urea Solution” with 32.5% urea content, see also (AdBlue®) ⇒ page 192 Is an invented name. This fluid is also referred to as “NOx reducing agent AUS 32”, “AUS 32” or “Diesel Exhaust Fluid” (in the US). AdBlue® is a colourless reducing agent that is used for exhaust post-treatment in order to reduce nitrous oxides and particulates. AdBlue® is a registered trademark of the VDA (Verband der Automobilindustrie German association of the automotive industry) in the USA, Germany, the European Union and other countries. The AdBlue urea solution is not mixed with diesel fuel, but is carried in a separate tank in the vehicle. Filling level of ATF in gearbox Battery Electric Vehicle. Electric vehicle Compressed Natural Gas. Compressed natural gas Carbon monoxide. Produced when fuels containing carbon are not combusted com‐ pletely This term refers to a common high-pressure injection line, the “rail”, which supplies all cylinders of the relevant cylinder bank with fuel. Designation used in the US for the NOx reducing agent AUS 32, or the AdBlue®.

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Explanation

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Term

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 Term

Explanation GJ

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All-season tyre All-season tyres (also called all-weather tyres) can be used in the summer and also the winter. GTE The sports derivative as an independent vehicle concept. HEV Hybrid Electric Vehicle. Hybrid vehicle Hybrid (full hybrid) Introduction to the hybrid technology by Volkswagen. Convenient electric cruising over short distances and at inner-city speeds. MM Maintenance manual LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐ pending on individual driving style and conditions under which the vehicle is used. For the LongLife service a special engine oil is required. LED Light-emitting diode LED LPG Liquefied petroleum gas. Liquefied petroleum gas or LPG MHEV (mild hy‐ Mild Hybrid Electric Vehicle brid) MIL Malfunction indicator light. American designation for exhaust emissions warning lamp K83 MPI Multi-point injection M+S Winter tyre (M+S tyre). Winter tyres are designed for low temperatures and wintry road conditions. NAR North American region NSC National Sales Company NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBl‐ agent AUS 32 ue®) ⇒ page 192 NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBl‐ agent AUS 32 ue®) ⇒ page 192 OBD On-board diagnosis. The OBD monitors all components influencing the exhaust emis‐ sions quality. n AG. Volkswagen AG do es n OBD-II American onboard diagnosis olkswage ot g V ua by A vehicle with hybrid drive whose d rabattery PHEV Plug-in hybrid electric vehicle. can also be e nte s i r o e recharged externally using mains electricity. h t or ac au ss PR No. Abbreviation of production control number. It identifies among other things optional equipment, country-specific deviations PM Particulate matter. Soot particle value for diesel engine emissions PMS Particulate reduction system QG0 Vehicles are “not” factory-fitted with components for LongLife service. For mainte‐ nance, the intervals based on time and distance (non-flexible intervals) apply. QG1 Vehicles are factory-fitted with active LongLife service. This means vehicles have a flexible service interval display and are fitted with the following components: ♦ Flexible service interval display in dash panel insert ♦ Engine oil level sensor ♦ Brake pad wear indicator

The LongLife service is not factory-activated. This means vehicles have a fixed service interval display (time and mileage dependent service intervals): These vehicles are fitted with the following components: ♦ Non-flexible service interval display in dash panel insert ♦ Engine oil level sensor r fo ng

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QG2

6. Glossary

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Phaeton 2003 ➤ Maintenance - Edition 03.2021 Term

Explanation QG3

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194 6. Glossary

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® Registered trademark Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐ formed by the electronic motor management. RON Research Octane Number. Measurement unit of the knock resistance of petrol SPF Particulate filteragen AG. Volkswagen AG do es n ksw t gu Vol TPMS, TPLI Tyre Pressure Monitoring System, TyreoPressure Loss Indicator by ara d e nte s i r SAE Society of Automotive Engineers. Association which creates proposals/guidelines for eo tho au implementing legal requirements (e.g. standards).r ac s s SCR With the SCR process (selective catalytic reduction) the noxious nitrogen oxides emis‐ sions are reduced to a great extent and are converted to steam and nitrogen by the urea solution. A special urea solution (AdBlue®) is injected into the exhaust system upstream of a special catalytic converter. PFI Intake manifold injection system (indirect injection system) SULEV Super Ultra Low Emission Vehicle TSI TSI turbocharger. Charging with turbocharger only. TSI twincharger. Charging with turbocharger and compressor TGI Charging with turbocharger and natural gas injection system TDI Turbo diesel engine - direct injection ULEV Ultra low emission vehicle VDA German association of the automotive industry VW Volkswagen ESI Extended servicing interval ZEV Zero Emission Vehicle ASSY Assembly

Phaeton 2003 ➤ Maintenance - Edition 03.2021

7 Date

---Change history--Chapter

Scope of modification

Chapter updated.

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23/02/2 Exhaust emissions test ⇒ page 182 018

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7. ---Change history---

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05.06.2 Jacking up mode: Switching self-levelling sus‐ 020 pension off and on ⇒ page 36

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26/03/2 Service tables ⇒ page 6 Chapter updated. 021 Road test (performance, handling, noises, air Chapter updated conditioner etc.): carrying out ⇒ page 121 Multi-purpose additive for diesel fuel: adding ⇒ Chapter updated. AG. Volkswagen AG d agen oes page 103 ksw not l o gu yV b ara d Multi-purpose additive for petrol fuels: adding ⇒ isChapter updated. e nte r o eo page 105 h ut ra a c s s Cooling system: checking frost protection and Chapter updated coolant level ⇒ page 87 Windscreen wash/wipe system and headlight Chapter updated washer system: checking fluid level and func‐ tion ⇒ page 130 Battery: checking with battery tester (always re‐ Chapter updated fer to workshop manual) ⇒ page 48 . Poly V-belt: checking condition ⇒ page 78 Chapter updated

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