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CC 2012
Volkswagen CC 2012 Manuals
Manuals and User Guides for Volkswagen CC 2012. We have
3
Volkswagen CC 2012 manuals available for free PDF download: Workshop Manual
Volkswagen CC 2012 Workshop Manual (222 pages)
6-cylinder direct-injection engine (3.6 l engine, 4V)
Brand:
Volkswagen
| Category:
Automobile
| Size: 11.59 MB
Table of Contents
Table of Contents
3
Technical Data
7
Identification
7
Engine Number/Engine Data
7
General Information
9
Numbering of Cylinders
9
Safety Information
10
Safety Precautions During Work on Fuel System
10
Safety Precautions When Using Testers and Measuring Instruments During a Road Test
10
Safety Precautions When Working on the Cooling System
11
Safety Precautions When Working on Ignition System
11
Repair Notes
12
Rules for Cleanliness
12
Foreign Objects in Engine
12
Removing and Installing Engine
13
Removing Engine
13
Separating Engine and Gearbox
21
Securing Engine on Engine and Gearbox Support
23
Installing Engine
25
Assembly Mountings
27
Assembly Overview - Assembly Mountings
27
Removing and Installing Engine Mounting
28
Adjusting Assembly Mountings
30
Checking Adjustment of Assembly Mountings (Engine and Gearbox Mountings)
33
Crankshaft Group
34
Cylinder Block (Pulley End)
34
Assembly Overview - Cylinder Block (Pulley End)
34
Assembly Overview - Poly V-Belt Drive
36
Removing and Installing Poly-V Belt
37
Removing and Installing Tensioner for Poly V-Belt
38
Removing and Installing Vibration Damper
38
Removing and Installing Bracket for Ancillaries
39
Removing and Installing Sealing Flange on Pulley End
40
Cylinder Block, Gearbox End
42
Assembly Overview - Cylinder Block, Gearbox End
42
Removing and Installing Flywheel
42
Renewing Crankshaft Oil Seal (Gearbox End)
43
Crankshaft
46
Assembly Overview - Crankshaft
46
Renewing Needle Bearing in Crankshaft
48
Crankshaft Dimensions
50
Measuring Axial Clearance of Crankshaft
50
Measuring Radial Clearance of Crankshaft
50
Allocation of Main Bearing Shells
51
Removing and Installing Sender Wheel
55
Pistons and Conrods
57
Assembly Overview - Pistons and Conrods
57
Removing and Installing Pistons
58
Checking Pistons and Cylinder Bores
61
Separating New Conrod
62
Cylinder Head, Valve Gear
64
Cylinder Head
64
Assembly Overview - Cylinder Head
64
Removing and Installing Cylinder Head
66
Removing and Installing Cylinder Head Cover
74
Assembly Overview - Vacuum Pump
75
Removing and Installing Vacuum Pump
76
Checking Compression
77
Cover for Timing Chain
81
Assembly Overview - Cover for Timing Chain
81
Removing and Installing Timing Chain Cover
82
Removing and Installing the Camshaft Control Valve Seal
84
Assembly Overview - Valve Timing Housing
85
Chain Drive
87
Assembly Overview - Camshaft Timing Chains
87
Removing and Installing Camshaft Timing Chain
89
Removing and Installing Chain Drive Sprocket for High-Pressure Pump
92
Removing and Installing Timing Chain and Chain Drive for Oil Pump
93
Checking Valve Timing
97
Adjusting Valve Timing
99
Valve Gear
104
Assembly Overview - Valve Gear
104
Measuring Axial Play of Camshaft
106
Removing and Installing Camshaft
107
Removing and Installing Camshaft Adjuster
111
Removing and Installing Camshaft Control Valve
118
Removing and Installing Valve Stem Seals
122
Inlet and Exhaust Valves
125
Checking Valve Guides
125
Reworking Valve Seats
125
Valve Dimensions
127
Lubrication
128
Sump, Oil Pump
128
Assembly Overview - Sump/Oil Pump
128
Removing and Installing Oil Spray Jet
130
Removing and Installing Sump
131
Removing and Installing Oil Pump
133
Engine Oil
137
Oil Filter, Oil Pressure Switch
139
Assembly Overview - Oil Filter Housing, Oil Pressure Switch
139
Checking Oil Pressure and Oil Pressure Switch
141
Cooling
144
Cooling System/Coolant
144
Connection Diagram - Coolant Hoses
144
Checking Cooling System for Leaks
146
Draining and Adding Coolant
148
Coolant Pump, Regulation of Cooling System
153
Assembly Overview - Coolant Pump, Thermostat
153
Removing and Installing Coolant Pump
155
Removing and Installing Thermostat
158
Checking Thermostat
159
Removing and Installing Continued Coolant Circulation Pump V51
159
Radiator, Radiator Fan
160
Assembly Overview - Radiator/Radiator Fan
160
Removing and Installing Radiator
161
Removing and Installing Radiator Cowl with Radiator Fan
163
Removing and Installing Radiator Fan
165
Mixture Preparation - Injection
166
Injection System
166
Overview of Fitting Locations - Injection System
166
Injectors
168
Assembly Overview - Fuel Rail with Injectors
168
Removing and Installing Injectors
172
Renewing Seals on Injectors
176
Air Filter
180
Assembly Overview - Air Filter Housing
180
Removing and Installing Air Filter Housing
181
Checking Intake Air Preheating
181
Intake Manifold
182
Assembly Overview - Intake Manifold
182
Removing and Installing Lower Part of Intake Manifold with Fuel Rail
184
Removing and Installing Intake Manifold Upper Part
187
Removing and Installing Throttle Valve Module J338
190
Senders and Sensors
192
Checking Fuel Pressure Sender G247
192
Engine Control Unit
195
Removing and Installing Engine (Motor) Control Unit J623
195
Removing and Installing Engine (Motor) Control Unit J623 with Protective Housing
196
High-Pressure Pump
200
Assembly Overview - High-Pressure Pump
200
Removing and Installing High-Pressure Pump
201
Lambda Probe
205
Removing and Installing Lambda Probe G39
205
Removing and Installing Lambda Probe G108
206
Removing and Installing Lambda Probe after Catalytic Converter G130 and Lambda Probe 2 after Catalytic Converter G131
206
Exhaust System
208
Exhaust Pipes and Silencers
208
Assembly Overview - Silencers
208
Separating Exhaust Pipes from Silencers
209
Installation Position of Clamp
211
Emission Control
212
Assembly Overview - Emission Control
212
Removing and Installing Catalytic Converter
213
Exhaust Manifold
216
Assembly Overview - Exhaust Manifold
216
Removing and Installing Exhaust Manifold
217
Ignition System
218
Assembly Overview - Ignition System
218
Removing and Installing Ignition Coils with Output Stage
219
Removing and Installing Engine Speed Sender G28
221
Test Data, Spark Plugs
221
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Volkswagen CC 2012 Workshop Manual (180 pages)
Brand:
Volkswagen
| Category:
Automobile
| Size: 1.72 MB
Table of Contents
Table of Contents
5
Technical Data
7
1 General Notes on Air Conditioning Systems
7
Introduction
7
Additional Information
7
Basics of Air Conditioning
8
Vapour Pressure Table for Refrigerant R134A
9
Refrigerant R134A
10
Characteristics of Refrigerant R134A
11
Refrigerant Machine Oil
13
Comfort
15
How Air Conditioning Works
15
General Safety
16
Safety Precautions for When Working on Vehicles with Air Conditioning and When Handling
19
Refrigerant R134A
19
Basics for Working on Refrigerant Circuit
20
2 General Information on Refrigerant Circuit
23
Refrigerant Circuit Components
23
Design of Refrigerant Circuit
31
Evacuation and Charging Valves for Quick-Release Couplings of Air Conditioner Service Station
31
On Refrigerant Circuit
31
Switch and Sender in Refrigerant Circuit and Related Connections
33
Electrical Components Not Installed in Refrigerant Circuit
36
Pressures and Temperatures in the Refrigerant Circuit
38
Refrigerant Circuit with Expansion Valve
38
Refrigerant Circuit with Restrictor and Reservoir
40
Test and Measurement Work that Can be Performed Using a Pressure Gauge
42
Air Conditioner Service and Recycling Equipment
43
Notes to Repairs on Refrigerant Circuit
44
3 Statutory Texts and Instructions
45
Statutes and Regulations
45
Recycling and Refuse Law
50
Converting R12 Refrigerant Circuits to R134A Refrigerant Circuits and Repairing Them (Retrofitting)
51
Maintaining Records on Refrigerant
51
4 Refrigerant Circuit
52
Important Repair Notes on Air Conditioning
52
Retrofitting Refrigerant Circuit from R12 Refrigerant to R134A Refrigerant
52
5 Working with the Air Conditioner Service Station
53
Important Notes for Working with the Air Conditioner Service Station
54
Connecting Air Conditioner Service Station for Measuring and Checking
54
Draining Refrigerant Circuit Using Air Conditioner Service Station
55
Evacuating Refrigerant Circuit Using Air Conditioner Service Station
56
Charging Refrigerant Circuit Using Air Conditioner Service Station
57
Bringing Air Conditioning System into Service after Charging
58
Charging Container in Air Conditioner Service Station with Refrigerant
59
Draining Air Conditioner Service Station
59
6 Detecting Leaks in Refrigerant Circuit
61
Leak Detection in Refrigerant Circuit Using Compressed Air or Nitrogen
62
Searching for Leaks in Refrigerant Circuits Using Leak Detector V.A.G 1796
64
Detecting Leaks in Refrigerant Circuit Using Leak Detecting System VAS 6196 or Leak Detecting
65
System VAS 6201 or a Later Model
65
7 Clearing Refrigerant Circuit of Contaminants
71
Blowing through Refrigerant Circuit with Compressed Air and Nitrogen
71
Purging (Cleaning) Refrigerant Circuit with Refrigerant R134A
73
8 Complaints
128
Possible Complaints about Refrigerant Circuit
128
Smells from Heater and Air Conditioner Unit
129
9 Connecting Air Conditioner Service Station
132
For Vehicles that Have Connections on both Low-Pressure and High-Pressure Sides of
132
Refrigerant Circuit
132
10 Checking Pressures on Vehicles
133
Checking Pressures in Refrigerant Circuit (Using Air Conditioner Service Station)
133
Checking Systems with a Restrictor and Collector
136
Compressor
138
Checking Systems with an Expansion Valve and Reservoir (with Internally Regulated Air Conditioner Compressor)
141
Checking Systems with an Expansion Valve and Reservoir
147
Compressor)
147
Checking Systems with a Restrictor and Reservoir and Air Conditioner Compressor Regulating Valve N280 (with Externally Regulated Air Conditioner Compressor)
149
Checking Systems with an Expansion Valve, Receiver and Air Conditioner Compressor
154
Regulating Valve N280 (with Externally Regulated Air Conditioner Compressor)
154
With Expansion Valve, Receiver and Electrical Air Conditioner Compressor
164
11 Renewing Components
165
In the Event of Leaking or Damaged Components (Apart from the Air Conditioner Compressor, Receiver or Reservoir)
166
Renewing Air Conditioner Compressor
167
Renewing Receiver or Reservoir, and Restrictor
169
12 Testing Equipment and Tools
171
List of Test Equipment, Tools and Materials
171
Volkswagen CC 2012 Workshop Manual (120 pages)
Brand:
Volkswagen
| Category:
Automobile
| Size: 4.84 MB
Table of Contents
Table of Contents
3
Technical Data
5
Safety Information
5
Safety Regulations for Working on Fuel Supply
5
Safety Precautions When Using Testers and Measuring Instruments During a Road Test
5
Safety Precautions When Working on Vehicles with a Start/Stop System
6
Identification
7
Engine Number/Engine Data
7
General Information
8
Rules for Cleanliness When Working on Auxiliary/Supplementary Heater and Fuel System
8
Repair Notes
9
Routing and Attaching Lines
9
General Repair Instructions
9
Assembly Overview - Fuel Tank, Vehicles with Front-Wheel Drive
10
Fuel Supply System
10
Assembly Overview - Fuel Tank, Vehicles with Four-Wheel Drive
14
Emptying Fuel Tank
18
Emptying Fuel Tank When Fuel Pump Is Intact
18
Continued for All Vehicles
20
Vehicles with Auxiliary Heater
20
Special Tools and Workshop Required
26
Emptying Fuel Tank at Fuel Delivery Unit Flange
27
Removing and Installing Fuel Tank
30
Continuation for All Other Engine Codes
33
Vehicles with Engine Code BWS or CCZB
39
Vehicles with Engine Code CNNA
39
Assembly Overview - Fuel Delivery Unit/Fuel Gauge Sender
45
Fuel Delivery Unit, Fuel Gauge Sender
45
Installation Position of Fuel Delivery Unit
46
Removing and Installing Fuel Delivery Unit, Fuel Gauge Sender
47
If a New Fuel Delivery Unit Is Installed
54
Installing Fuel Line
54
Assignment of Plug-In Connectors
55
Colour Assignment
55
Plug-In Connectors
55
Separating Plug-In Connectors
55
Fuel Filter
59
Activated Charcoal Filter with Fuel Tank Leak Detection
60
Assembly Overview - Activated Charcoal Filter System
60
Removing and Installing Activated Charcoal Filter
61
Checking Fuel System for Leaks
62
Schematic Overview of Activated Charcoal Filter System
67
Activated Charcoal Filter Without Fuel Tank Leak Detection
70
Assembly Overview - Activated Charcoal Filter System
70
Removing and Installing Activated Charcoal Filter
70
Checking Fuel Tank Breather
71
Accelerator Pedal
74
Assembly Overview - Accelerator Module
74
Removing and Installing Accelerator Pedal Module - GX2-
74
Checking Fuel System Pressurisation Pump G6
77
Checking Function and Voltage Supply
77
Fuel Pump
77
Test Sequence
78
Vehicle Diagnostic Tester
78
Checking Fuel Pressure
80
If no Fault Is Found
85
If Reading Matches Specification
85
If Specification Is Not Obtained
85
Checking Holding Pressure
88
Checking Residual Pressure at Flange for Delivery Unit
90
If no Fault Can be Determined
90
If Pressure Drops Again (Leak on Fuel Tank Side)
90
Removing and Installing Suction-Jet Pump
110
Function of Suction-Jet Pump
112
If Engine Starts OK Now
112
Removing Suction-Jet Pump
112
Installing Suction-Jet Pump
113
Removing and Installing Fuel Gauge Sender G
115
Senders and Sensors
115
Removing and Installing Fuel Gauge Sender 2 G169
116
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