Volkswagen Tiguan Service and Repair Manual: General, Technical data
Safety Precautions
Safety Precautions during Road Test with Testing Equipment
If Testing Equipment Must Be Used during a Road Test, Note the Following:
WARNING
Risk of accident due to distractions and testing equipment that is
not secured properly.
The front passenger airbag could pose a risk if it
deploys in a collision
- Operating testing equipment while driving is a distraction.
- Testing equipment that is not secured properly increases the risk of
personal injury.
Always secure testing equipment on the rear seat using a strap and have a second
person in the rear seat operate it.
To Prevent Personal Injury and Damage to
the Electrical/Electronic Components, Note the Following:
- Only connect and disconnect test equipment when the ignition is off.
Caution
Risk of destroying electronic components when disconnecting the
battery.
Follow the steps when disconnecting the battery.
Safety Precautions when Working on Start/Stop System
WARNING
Risk of injury if the engine starts automatically in vehicles with the
Start/Stop System.
- Deactivate the Start-Stop system when working on the vehicle. Turn off
the ignition.
- Only switch the ignition on briefly when necessary.
Identification
Transmission Identification
- Chapter "Transmission Identification, Front Wheel Drive"
- Chapter "Transmission Identification, All Wheel Drive"
Technical Data
Transmission/Engine Allocation
- Chapter "Transmission/Engine Allocation, Golf and Golf Wagon, Manual
Transmission 02Q"
- Chapter "Transmission/Engine Allocation, Golf, Manual Transmission 02Q with
Front Axle Differential Lock"
- Chapter "Transmission/Engine Allocation, CC, Passat, Golf, Manual Transmission
0FB"
- Chapter "Transmission/Engine Allocation, CC, Manual Transmission 02Q"
- Chapter "Transmission/Engine Allocation, Passat, Manual Transmission 02Q"
- Chapter "Transmission/Engine Allocation, Passat, Manual Transmission 0BB"
- Chapter "Transmission/Engine Allocation, Golf All Wheel Drive, Golf Wagon All
Wheel Drive, Manual Transmission 02Q"
- Chapter "Transmission/Engine Allocation, CC All Wheel Drive, Manual
Transmission 02Q"
- Chapter "Transmission/Engine Allocation, Passat All Wheel Drive, Manual
Transmission 02Q"
- Chapter "Transmission/Engine Allocation, Tiguan All Wheel Drive, Manual
Transmission 02Q"
Capacities
Manual Transmission Capacity
Manual transmission
capacity |
Refer to
→ Fluid Capacity Tables; Rep. Gr.03 |
Bevel Box Capacity
Bevel box capacity |
Refer to
→ Fluid Capacity Tables; Rep. Gr.03 |
Gear Ratio Calculation
Example:
|
6th
Gear |
Final Drive |
Drive gear |
ZG1
= 46 |
ZA1
= 24 |
Driven gear |
ZG2
= 33 |
ZA2
= 70 |
i = ZG2 : ZG1.
i
G = gear ratio = ZG
2 :
ZG
1 = 33 : 46 = 0.717
iA=
axle ratio= ZA2 : ZA1=
70 : 24= 2.917
i
total = total ratio= i
G
x i
A = 0.717 x 2.917 = 2.091
1) Z1
= Number of teeth on the drive gear, Z2 = Number of
teeth on the driven gear
Overview - Transmission
Overview - Transmission, Front Wheel Drive
Name
The -arrows- point in the direction of travel.
- Engine
- Clutch
- Manual Transmission
- Input Shaft
- 5th, 6th and Reverse Gear Output Shaft
- 1st through 4th Gear Output Shaft
- Differential
- Front Axle Differential Lock
- With Haldex clutch
- Installed in connection with gasoline engine depending on the
vehicle equipment level.
Ratio
The -arrows- point in the direction of travel.
- 1st Gear
- 2nd Gear
- 3rd Gear
- 4th Gear
- 5th Gear
- 6th Gear
R - Reverse Gear
A - Final Drive
Electrical Components
Component Location Overview - Electrical Components
Component Location Overview - Electrical Components, Manual Transmission
- Transmission Neutral Position Sensor -G701-
- Installed location: in the area of the shift unit under the selector
shaft bracket.
- Removing and installing.
- Back-Up Lamp Switch -F4-
- Installed location: in the area of the shift unit under the selector
shaft bracket.
- Removing and installing.
Component Location Overview - Electrical Components, Clutch Mechanism
Clutch Position Sensor -G476--arrow-,
Scirocco, CC, Golf Cabriolet, Passat, Tiguan
Component location: In the engine compartment under the hose
-1- on the clutch master cylinder
-2- behind the line -3-.
The connector -4- is on the Clutch Position
Sensor -G476-.
Clutch Position Sensor -G476-, Removing and installing.
Clutch Position Sensor -G476--arrow-, Golf
and Golf Wagon
Installed location: in the passenger compartment on the clutch master
cylinder.
Clutch Position Sensor -G476-, Removing and installing.
Repair Information
General Repair Information
The highest level of care and
cleanliness along with tools that function properly are required to ensure a
proper and successful transmission repair. The usual basic safety precautions
apply when making vehicle repairs.
Some general repair information for
individual repair procedures, that appear many times throughout the manual, is
summarize here. They apply to this repair manual.
Special ToolsRefer to Workshop Equipment and Special Tools for a
complete list of special tools used in the repair manual.
Transmission
- Make sure that the alignment bushings between the engine and
transmission are positioned correctly when installing the manual
transmission.
- Clean the contact surfaces when installing brackets as well as parts
that have been waxed. Contact surfaces must be free of wax and grease.
- Allocate the bolts and other components. Refer to the Parts Catalog.
- Fill the transmission fluid when repairing the manual transmission.
Seals and Gaskets
- After removing gaskets, examine the contact surface on housing/shaft for
burrs resulting from removal or for other damage.
- Thoroughly clean the separating surfaces and apply Sealant.
- Allocation. Refer to the Parts Catalog.
- Fill the space between the sealing lips halfway with Grease-arrow-
before installing the radial shaft seal.
- Grease allocation. Refer to the Parts Catalog.
- The open side of the gaskets point toward the fluid to be sealed in.
- Lightly lubricate the O-rings before inserting to prevent the rings from
being crushed during assembly.
Sealant
- Clean the housing separating surfaces thoroughly before applying the
Sealant.
- Apply Sealant evenly and not too thick.
- Allocation. Refer to the Parts Catalog.
- Sealant must not go into the bleed holes.
Retainers
- Replace the circlips.
- Do not stretch the circlips.
- The circlips must rest at the bottom of the groove.
- Replace the adapter sleeves. Installed position: slot is lengthwise to
line of force.
Bolts and Nuts
- Always loosen or tighten bolts and nuts on covers and housings
diagonally.
- Especially delicate parts, such as clutch pressure plates, must not be
distorted. Loosen and tighten bolts and nuts in stages in a diagonal
sequence.
- The tightening specifications given apply to unoiled bolts and nuts.
- Replace self-locking bolts and nuts after removing them.
- Make sure the contact surfaces and visible surfaces on the nuts and
bolts are waxed after assembling.
- Use a thread cutter to clean all threaded holes containing self-locking
bolts to remove any locking compound residue. Otherwise the bolts could
shear the next time they are removed.
- Please make sure that the thread pitch is correct so that the proper
thread cutter is used during cleaning, and the thread does not get damaged.
Bearings
- Insert the bearings with transmission fluid.
- Install the new tapered roller bearings. It is not necessary to oil
them.
- Install needle bearings with the lettered side (thicker metal) facing
the fitting tool.
- Replace all the tapered roller bearings that are on the same shaft, and
use tapered roller bearings from the same manufacturer.
- Do not interchange inner and outer bearing races with those from other
bearings of the same size, bearings are paired.
Shims
- Measure the shims at several locations with a micrometer caliper. It is
possible to measure the necessary shim thickness by the different
tolerances.
- Check for burrs or damage.
- Only install perfect shims.
Synchronizer Rings
- Do not interchange them. When reusing synchronizer rings, always install
on the same gear wheel.
- Check for wear and replace if necessary.
- Check the grooves -arrow 1- on the
synchronizer ring -A- and the inner race for
flat areas (grooves are worn).
- The coating on the synchronizer rings must not be damaged.
- If an intermediate ring -B- is installed,
check this intermediate ring on the outer friction surface
-arrow 2- and inner friction surface
-arrow 3- for "grooves",
"wear grooves" and "blue
coloring (from overheating)".
- Check taper of drive gear for "grooves" and
"scoring".
- Coat the synchronizing with transmission fluid and then install.
Toothed Gears, Synchronizer Hubs
- Clean before installing. Warm using the Inductive Heater -VAS6414- to a
maximum 100 ºC (212 ºF).
- Pay attention to the installed location.
Selector Gears
- After assembling, check the selector gears for minimum axial clearance
and ease of movement.
Clutch Mechanism
Disconnect the battery. Refer to → Electrical Equipment.
If the battery is to be reconnected: Refer to → Electrical Equipment.
Clutch
- Do not tilt the clutch pressure plate. Loosen and tighten it diagonally
and in small steps.
- To reduce odor caused by a burnt clutch, thoroughly clean the clutch
housing and the flywheel running surface with a clean cloth.
See More:
Volkswagen Tiguan Service and Repair Manual > Rear doors: Rear Door
Tools
Special tools and workshop equipment required
Wrench - Door Adjusting -3320-
Door Adjusting Wrench - Joint -3320/1-
Wrench - Door Adjusting - Box Wrench -3320/2-
Wrench - Door Adjusting - Box Wrench -3320/3-
Torque Wrench 1331 5-50Nm -VAG1331-
Cylinder Head Bolt Socket -3410-
Gauge - G ...