SA-97R7

SB-10034370-4351

CSC-10034370-3044
Customer Letter Example (United States)
April 2010
Subject: Service Action 97R7/T2
2009 Model Year Passat, Passat Wagon and CC 3.6L Vehicles
Inspect, and If Necessary, Replace Positive Battery Cable
Dear Volkswagen Owner of VIN
At Volkswagen, we are proud to offer the very best of German engineering, and we work diligently to ensure
that the quality of our vehicles continues to meet our customers’ high expectations. Because we are dedicated
to ensuring your continued satisfaction with your vehicle, we are writing to inform you that an update is available
for your vehicle, and we would like to perform this update for you at no cost.
What is the problem?
The affected vehicles may have a positive battery cable that may corrode and, in rare cases, break. If this
happens, the power supply may be disrupted and the vehicle cannot be started.
What will Volkswagen do?
At no cost to you, we will inspect and, if necessary, replace the positive battery cable in your vehicle.
When will the update be available?
Your authorized Volkswagen dealer has parts available now to inspect and, if necessary, update your vehicle.
This inspection will take about one half-hour, and if repairs are needed they will take about four hours. Both the
inspection and repair (if needed) will be free of charge. Your dealer can also address any other concerns you
may have with your vehicle at this service visit.
This service action will only be available until March 31, 2012, and we encourage you to contact your authorized
Volkswagen dealer and arrange for an appointment at your earliest convenience. Please keep in mind that your
dealer may need additional time for the preparation of the update, as well as to accommodate their daily
workshop schedule. Dealers will not be able to perform this update free of charge after March 31, 2012.
Lease Vehicles
If you are the lessor and registered owner of the vehicle identified in this action, please forward this information
immediately via first-class mail to the lessee within ten (10) days of receipt of this notification.
Service help from us
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable
time, please call or write to:
Volkswagen of America, Inc.
Attn: Customer CARE Center – Hills East (97R7/T2)
3499 West Hamlin Road
Rochester Hills, MI 48309
1-800-893-5298
We regret any inconvenience this matter may cause. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Service & Quality
Customer Letter Example (Canada)
April 2010
Subject: Service Action 97R7/T2
2009 Model Year Passat, Passat Wagon and Passat CC 3.6L Vehicles
Inspect, and If Necessary, Replace Positive Battery Cable
Dear Volkswagen Owner of VIN
At Volkswagen, we are proud to offer the very best of German engineering, and we work diligently to ensure that
the quality of our vehicles continues to meet our customers’ high expectations. Because we are dedicated to
ensuring your continued satisfaction with your vehicle, we are writing to inform you that an update is available for
your vehicle, and we would like to perform this update for you at no cost.
What is the problem?
The affected vehicles may have a positive battery cable that may corrode and, in rare cases, break. If this
happens, the power supply may be disrupted and the vehicle cannot be started.
What will Volkswagen do?
At no cost to you, we will inspect and, if necessary, replace the positive battery cable in your vehicle.
When will the update be available?
Your authorized Volkswagen dealer has parts available now to inspect and, if necessary, update your vehicle.
This inspection will take about one half-hour, and if repairs are needed they will take about four hours. Both the
inspection and repair (if needed) will be free of charge. Your dealer can also address any other concerns you may
have with your vehicle at this service visit.
This service action will only be available until March 31, 2012, and we encourage you to contact your authorized
Volkswagen dealer and arrange for an appointment at your earliest convenience. Please keep in mind that your
dealer may need additional time for the preparation of the update, as well as to accommodate their daily
workshop schedule. Dealers will not be able to perform this update free of charge after March 31, 2012.
Lease Vehicles
If you are the lessor and registered owner of the vehicle identified in this action, please forward this information
immediately via first-class mail to the lessee within ten (10) days of receipt of this notification.
Service help from us
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable
time, please call or write to:
Volkswagen Canada
Attn: Customer CARE Center (97R7/T2)
P.O. Box 842, Stn. A
Windsor, ON N9A 9Z9
1-800-893-5298
We regret any inconvenience this matter may cause. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Service & Quality
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 4 of 31

SB-10034370-5176
Service Action Circular
Code: 97R7
Subject: 2006-2009 Passat and Passat Wagon 3.6L Vehicles and
2009 CC/Passat CC 3.6L Vehicles
Inspect, and If Necessary, Replace Positive Battery Cable
REVISION
Revision Summary:
Expiration date extended to March 31, 2013.
Problem Description
Vehicles affected by this action may have a positive
battery cable that may corrode and, in rare cases, break.
If this happens, the power supply may be disrupted and
the vehicle cannot be started. This action does not apply
if the 97P4/Y5 RVU has already been done.
Corrective Action
Inspect, and if necessary, replace the positive battery
cable.
VIN Ranges & Production Dates
U.SA.
(Emden)
2006 – 2009 Passat / P assat Wagon
W VW _ _ _3C_6E020265 - W VW _ _ _3C_9E526629
Production Date: 04/20/2005 - 09/26/2008
(Mosel)
2006 – 2008 Passat / P assat Wagon
W VW _ _ _3C_6P005115 - W VW _ _ _3C_8P130434
Production Date: 9/1/2005 - 5/16/2008
CANADA
(Emden)
2006-2009 Passat / Passat CC
W VW _ _ _3C_6E119726 - W VW _ _ _3C_9E519359
Production Date: 11/9/2005 - 9/1/2008
(Mosel)
2006 – 2007 Passat / P assat Wagon
W VW _ _ _3C_6P047215 - W VW _ _ _3C_7P118748
Production Date: 07/27/2005 - 01/16/2007
NOTE:
Check ElsaWeb on the day of repair to verify vehicle
eligibility for this repair. This is the only valid campaign inquiry and
verification source. Some vehicles may be involved in an additional
action(s); any additional work can be done while the vehicle is in for
this action.
Allocation Report of Affected Vehicles
Electronic allocation lists will posted under My Dealership
Reports on the VW Hub on or about April 16, 2010. A list
will not be posted for dealers who have no affected
vehicles.
March 16, 2012
Parts Information and Allocation
Parts were allocated for the previous RVUTB 97P4/Y5
and there will not be an additional allocation. If you
have exhausted your allocated parts but have exceeded
your weekly Upper Order Limit, please submit your
requests
for additional parts via email to [email protected].
If you have questions regarding parts, please contact the
Parts Helpline at 800-767-6552.
Owner Notification Mailing
On or about April 16, 2010 the customer mailing will
take place.
Service Action Expiration Date
This action expires on March 31, 2013. Vehicles
inspected/repaired under this action must have this
service completed before March 31, 2013 to be eligible
for payment. Inspections/repairs performed after
March 31, 2013 will not be eligible for payment.
Dealers should keep this expiration date in mind when
scheduling customers for this action.
Campaign Completion Labeling Guidelines
Vehicles repaired under this action must be identified
with a campaign completion label (part number CAMP
010 000). Labels can be ordered at no cost online via
the
Compliance
Label
Ordering
portal
at
www.vwhub.com.
Claim Entry Procedure
Immediately upon completion of the repair work, enter
the Applicable Criteria ID and Repair Operation from the
following chart. The Applicable Criteria ID is shown in
ElsaWeb. Claims will only be paid for vehicles that
show this campaign open in ElsaWeb on the day of the
repair. To help ensure prompt and proper payment,
attach the screen print to the repair order.
Saga Claim Entry Procedure
Check ElsaWeb to determine whether the “97R7” campaign is open.
Service No. : 97R7
Damage Code : 0099
Parts Manufacturer – Removed part:
Sold vehicle = 7 10
Unsold vehicle = 7 90
Use vendor code AUK
Accounting Instructions
Criterion I.D. 01 - Front Wheel Drive Vehicles
- Check positive battery cable; NO FURTHER WORK REQUIRED
Repair operation: 0183 00 99
30 TU
-- OR -- Check/replace positive battery cable
Repair operation: 9745 55 99
Qty
Part Number
1
1
1K0 253 141J
3C0 971 227C
300 TU
Description
VIN Ranges
Exhaust clamp
Positive battery cable
-----Emden: MY 06 to 3C_8E199973
Mosel: MY 06 to 3C_8P118377
Positive battery cable
from 3C_8E199974
OR
1
3C0 971 227B
OR
from 3C_8P118378
®
Criterion I.D. 02 - 4MOTION Vehicles
- Check positive battery cable; NO FURTHER WORK REQUIRED
Repair operation: 0183 00 99
30 TU
-- OR -- Check/replace positive battery cable
Repair operation: 9745 55 99
Qty
Part Number
1
3C0 971 227C
300 TU
Description
VIN Ranges
Positive battery cable
to 3C_8E199973
OR
Positive battery cable
from 3C_8E199974
to 3C_8P118377
OR
1
3C0 971 227B
OR
from 3C_8P118378
OR from 3C_9E500574
There is NO reimbursement for vehicle wash or vehicle loaner!
If customer refused repairs:
Fax repair order to VWoA at (248) 754-5093 and provide VIN, applicable Service Number, Customer
Info, Dealer Number and Date.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2008 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All Rights Reserved.
March 2012
97R7/T2 Page 2 of 31
Customer Letter Example (United States)
April 2010
Subject: Service Action 97R7/T2
2009 Model Year Passat, Passat Wagon and CC 3.6L Vehicles
Inspect, and If Necessary, Replace Positive Battery Cable
Dear Volkswagen Owner of VIN
At Volkswagen, we are proud to offer the very best of German engineering, and we work diligently to ensure
that the quality of our vehicles continues to meet our customers’ high expectations. Because we are dedicated
to ensuring your continued satisfaction with your vehicle, we are writing to inform you that an update is available
for your vehicle, and we would like to perform this update for you at no cost.
What is the problem?
The affected vehicles may have a positive battery cable that may corrode and, in rare cases, break. If this
happens, the power supply may be disrupted and the vehicle cannot be started.
What will Volkswagen do?
At no cost to you, we will inspect and, if necessary, replace the positive battery cable in your vehicle.
When will the update be available?
Your authorized Volkswagen dealer has parts available now to inspect and, if necessary, update your vehicle.
This inspection will take about one half-hour, and if repairs are needed they will take about four hours. Both the
inspection and repair (if needed) will be free of charge. Your dealer can also address any other concerns you
may have with your vehicle at this service visit.
This service action will only be available until March 31, 2012, and we encourage you to contact your authorized
Volkswagen dealer and arrange for an appointment at your earliest convenience. Please keep in mind that your
dealer may need additional time for the preparation of the update, as well as to accommodate their daily
workshop schedule. Dealers will not be able to perform this update free of charge after March 31, 2012.
Lease Vehicles
If you are the lessor and registered owner of the vehicle identified in this action, please forward this information
immediately via first-class mail to the lessee within ten (10) days of receipt of this notification.
Service help from us
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable
time, please call or write to:
Volkswagen of America, Inc.
Attn: Customer CARE Center – Hills East (97R7/T2)
3499 West Hamlin Road
Rochester Hills, MI 48309
1-800-893-5298
We regret any inconvenience this matter may cause. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Service & Quality
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2008 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All Rights Reserved.
March 2012
97R7/T2 Page 3 of 31
Customer Letter Example (Canada)
April 2010
Subject: Service Action 97R7/T2
2009 Model Year Passat, Passat Wagon and Passat CC 3.6L Vehicles
Inspect, and If Necessary, Replace Positive Battery Cable
Dear Volkswagen Owner of VIN
At Volkswagen, we are proud to offer the very best of German engineering, and we work diligently to ensure that
the quality of our vehicles continues to meet our customers’ high expectations. Because we are dedicated to
ensuring your continued satisfaction with your vehicle, we are writing to inform you that an update is available for
your vehicle, and we would like to perform this update for you at no cost.
What is the problem?
The affected vehicles may have a positive battery cable that may corrode and, in rare cases, break. If this
happens, the power supply may be disrupted and the vehicle cannot be started.
What will Volkswagen do?
At no cost to you, we will inspect and, if necessary, replace the positive battery cable in your vehicle.
When will the update be available?
Your authorized Volkswagen dealer has parts available now to inspect and, if necessary, update your vehicle.
This inspection will take about one half-hour, and if repairs are needed they will take about four hours. Both the
inspection and repair (if needed) will be free of charge. Your dealer can also address any other concerns you may
have with your vehicle at this service visit.
This service action will only be available until March 31, 2012, and we encourage you to contact your authorized
Volkswagen dealer and arrange for an appointment at your earliest convenience. Please keep in mind that your
dealer may need additional time for the preparation of the update, as well as to accommodate their daily
workshop schedule. Dealers will not be able to perform this update free of charge after March 31, 2012.
Lease Vehicles
If you are the lessor and registered owner of the vehicle identified in this action, please forward this information
immediately via first-class mail to the lessee within ten (10) days of receipt of this notification.
Service help from us
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable
time, please call or write to:
Volkswagen Canada
Attn: Customer CARE Center (97R7/T2)
P.O. Box 842, Stn. A
Windsor, ON N9A 9Z9
1-800-893-5298
We regret any inconvenience this matter may cause. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Service & Quality
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 4 of 31
Campaign Work Procedure
97R7 Service Action
If there are questions regarding the work procedure, contact the Campaign Helpline at 1-800-741-2919.
Required Tools
•
V.A.G 1383A Engine/Gearbox Jack with Universal
Support Plate V.A.G 1359/2 (or equivalent)
•
V.A.G 1331 Torque Wrench 5-50Nm (or
equivalent)
•
NRI81034A Under Hoist Stand/Screw Jack (or
equivalent). Available through Equipment
Solutions
•
V.A.G 1921 Hose Clamp Pliers
•
VAS 6254 Chain Pipe Cutter (or equivalent)
•
V.A.G 1523A Body Repair Saw (or equivalent)
•
T10038 Tensioning Straps (or equivalent)
•
T10096 Locating Pins
•
80-200 Pry Lever (or equivalent)
•
T10236 Release Tool (or equivalent)
•
VAS 5051B
•
VAS 5052/A
l
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 5 of 31
Required Parts:
Part Description
Part Number
Quantity
Exhaust clamp (for Front-wheel drive only)
1
Positive battery cable:
Emden: MY 06 to 3C_8E199973
Mosel: MY 06 to 3C_8P118377
1
OR
Positive battery cable:
Emden: from 3C_8E199974
Mosel: from 3C_8P118378
Emden: from 3C_9E500574
Campaign completion label
Tip: If Campaign Completion label is
present, no further work is required
Section A – Check Part Number
Note: Because of the difference in the clip
positioning points, different positive
battery cables are needed for the
vehicles
It is important to check the part number
of the existing cable to determine which
replacement cable is needed
•
Unclip battery service cover on side trim
⇐ Check part number on the sticker -arrow•
If part number is 3C0 971 227, then part number
3C0 971 227C must be installed
•
If part number is 3C0 971 227A, then part number
3C0 971 227B must be installed
•
If correct part number is currently installed,
positive battery cable is not one that needs to be
replaced, WORK IS COMPLETE; otherwise,
continue to Section B
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 6 of 31
Section B – Front Wheel Drive
and 4MOTION® Vehicles
Note: Positive battery cable is routed from
trunk to engine compartment
On vehicles with front-wheel drive, the
central and rear muffler and the heat
shield must also be removed
WARNING!
 Keep open flames and sparks away and
DO NOT smoke near batteries!
 Avoid sparks when working with cables
and electrical units
 Always reinstall battery positive (B+) or
negative (-) terminal covers if removed
during servicing
 Danger of injury! Always observe
warning notes and safety precautions!
⇐ Remove two bolts -1- from bottom rear of side
trim and remove anchor point -2⇐ Remove bolts -3⇐ Remove the four press buttons -arrows- using
Release Tool – T10236, and remove trim from
mounts in vehicle
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 7 of 31
(Wagon):
⇐ Remove two bolts -1⇐ Remove lock carrier cover -2- upward and out of
lock carrier
Tip: It is not necessary to completely remove
interior trim
⇐ On left side of vehicle, remove two bolts -1- and
remove tie down -2⇐ Remove two bolts -3- and tie down -4⇐ Remove bolt -5- and coat hook bracket -6⇐ Unscrew clamping pin -7- using a screwdriver with
hex socket head (3mm) and remove expanding rivet
-8⇐ Pull trim -9- inward out of retainers and slide out of
way enough to gain access to positive battery cable
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 8 of 31
Tip: Before disconnecting battery,
disable the alarm
WARNING!
Negative battery cable must be
disconnected first to prevent triggering
Pyrotechnic Battery Isolator
Triggering the Pyrotechnic Battery
Isolator is not covered under this action
•
Switch off ignition and all electric consumers and
remove ignition key
⇐ Unscrew battery terminal of ground cable -1- on the
negative battery terminal
⇐ Open cap of the fuse box and remove retaining nut
-circle- for the positive battery cable
⇐ Disconnect Mass Air Flow Sensor -1⇐ Loosen clamp -2- using tool V.A.G 1921 hose
clamp pliers or equivalent
⇐ Remove screws -3- and remove air filter housing
and air intake ductwork from vehicle
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 9 of 31
⇐ Remove air filter box carrier -arrow- by removing
screws -1⇐ Disconnect harness from carrier -A-
•
Pull back rubber boot from starter motor and
disconnect cable and connector
•
Remove rubber boot from wiring loom
•
Unclip positive battery cable on the side member
⇐ Open cap of jump start junction block and remove
retaining nut for the positive cable -arrow-
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 10 of 31
•
Raise vehicle on hoist to a comfortable level
•
Loosen and fold back wheel well liner to expose the
positive battery cable
•
Loosen grommet for positive battery cable and pull
cable out of trunk area
⇐ Remove sound dampening trim (pictured) on driver
side to expose positive battery cable
⇐ Remove noise insulation cover -1- by removing
screws -2- and -3- (if equipped)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 11 of 31
• Install special tool T10038 (or equivalent) on driver
side rear and passenger side rear to secure vehicle
on hoist
WARNING!
Failure to properly support vehicle when the
rear axle is disconnected may cause an
imbalance in vehicle weight and cause
vehicle to fall off of hoist!
Tip: Placing under hoist stands (or
equivalent) on the front end of
vehicle, as pictured, can also be
used as a substitute to support the
vehicle and prevent an imbalance in
vehicle weight when rear axle is
disconnected
• If vehicle is front wheel drive, proceed to
Section C
• If vehicle is 4MOTION® , proceed to Section D
Section C – Front Wheel Drive Vehicles
Tip: For removal/installation and
individual replacement of central
and rear muffler, a cutting line is
identified on connection pipe
between center and rear muffler
⇐ Cutting line is marked by an indentation on the
pipe. Mark cutting line with chalk -arrow-
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 12 of 31
WARNING!
Wear goggles and protective clothes to
avoid injuries from metal debris
• Cut off exhaust pipe at a right angle on the cutting
line using pipe cutter VAS 6254 or saw V.A.G 1523 A
(or equivalent)
Tip: Do not use torch or similar
equipment to cut exhaust pipe
⇐ Remove rear exhaust -7- by removing bolts
-5- for exhaust hanger -8- and disconnect from
retaining loop -3-
Tip: Lubricate retaining loops -3- prior
to removal in order to prevent
damage
Damage to retaining loops is not
covered by this action
⇐ Remove center exhaust -6- by loosening clamp
-2- and bolts-5- for exhaust hanger and disconnect
from retaining loop -3Tip: Remove rear cross member to aid
in removal of center exhaust
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 13 of 31
•
Support rear axle with an engine/transmission jack
V.A.G 1383 A with universal support plate V.A.G
1359/2 below subframe and secure with strap
Note: Only one side of vehicle is shown, for
illustrative purposes only
⇐ One at a time, remove bolts from positions -1- and
-2- on rear subframe and install locating pins
T10096 and torque pins to 20 Nm
⇐ Perform same on opposite side
Tip: DO NOT DISCARD bolts, as they
will be reused
Note: Locating pins T10096 may only be
tightened to a maximum of 20 Nm;
otherwise, damage will occur to
threads of locating pins
Note: Locating pin T10096 properly
installed with taper side down
prevents misalignment of subframe
to body
•
Position of subframe is now secured
•
Lower subframe slightly to allow enough working
room for heat shield removal
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 14 of 31
⇐ Detach bolt -1- from the securing strap and remove
retaining clips -arrows•
Carefully pull heat shield for the center muffler
forward and remove it
Note: Do not damage or distort heat shield
for center muffler
•
Remove positive battery cable
Tip: For easier installation, tie together
the front part of the cable (before the
Y-piece) with a zip tie and remove
rubber grommet
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 15 of 31
•
Carefully route the new positive battery cable via the
rear axle
WARNING!
Make sure the fiberglass-reinforced area
-arrow- does not get damaged
•
Push cable through opening in the trunk and position
it on the side member
•
Reinstall wheel well liner
•
Clip cable in the rear axle area and route it
according to its original course
Tip: Use tool number 80-200 pry lever (or
equivalent) to clip battery cable clips
properly in place
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 16 of 31
• Carefully reinstall center muffler heat shield
⇐ Reinstall bolt -1- for the securing strap and retaining
clips -arrows-
Note: Contrary to the specifications in the repair
manual, the bolts on the subframe and
fuel tank can be reused in this action
Reuse of these bolts is only permitted
for Service Action Campaign 97R7!
⇐ Use a permanent marker or paint pen to mark the
subframe bolts with an “X”, as pictured
Note:
Bolts marked with an “X” indicates
that they have been reused one time
and should not be reused again
Replacement of bolts marked with
an “X” is not covered under this
action
•
Raise rear subframe
⇐ One at a time, remove locating pins T10096 and
reinstall subframe bolts -arrows•
Perform same on opposite side
•
Torque bolts 90 Nm + 90º turn
•
Remove engine and transmission jack
V.A.G 1383 A (or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 17 of 31
•
Reinstall center and rear exhausts
⇐ Fit dual clamping sleeves in such a way that the
screw end -arrow- does not protrude over lower
edge of clamping sleeve, then torque to M8 = 25 Nm
and M10 = 40 Nm
⇐ Align rear exhaust system so that distance -a- right
and left are equal; then, proceed to Section E
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 18 of 31
Section D – 4MOTION® Vehicles
Tip:
Install tie wrap or equivalent to front
part of exhaust to prevent it from
falling when exhaust is disconnected
Support rear exhaust using engine
and transmission jack V.A.G 1383 A
(or equivalent)
⇐ Loosen two nuts for exhaust clamp -1- and slide
clamp forward
⇐ Unbolt front exhaust hanger -2- by removing bolts -3⇐ Disconnect exhaust retaining loop -4- from exhaust
⇐ Unbolt rear exhaust hangers -5- by removing bolts
-6- and lower rear exhaust from vehicle
WARNING!
Flex joints of front exhaust pipes must not be
bent more than 20 degrees – danger of
damage
A second technician is required for removal
Damage to exhaust components are not
covered under this action
•
Support rear axle with an engine/transmission jack
V.A.G 1383 A, with universal support plate V.A.G
1359/2 below subframe and secure with strap
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 19 of 31
Note: Only one side of vehicle is shown, for
illustrative purposes only
⇐ One at a time, remove bolts from positions -1and -2- on rear subframe and install locating pins
T10096, then torque pins to 20 Nm
⇐ Perform same on opposite side
Tip: DO NOT DISCARD bolts, as they will be
reused
Note: Locating pins T10096 may only be
tightened to a maximum of 20 Nm;
otherwise, damage will occur to threads
of locating pins
Note: Locating pin T10096 properly installed
with taper side down prevents
misalignment of subframe to the body
•
Position of subframe is now secured
•
Lower rear subframe 60-65 mm to allow access to
battery cable hold down on driver side rear
WARNING!
Do not lower subframe greater than 65 mm or
damage to center heat shield and drive line
may occur
Damage to these components are not covered
under this action
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 20 of 31
•
Support fuel tank with engine and transmission jack,
V.A.G 1383 A (or equivalent)
⇐ Unclip the fuel lines -arrow-
•
Detach fuel tank securing strap on driver side and
loosen strap on passenger side to allow fuel tank to
lower slightly
⇐ Unclip corrugated harness -arrow- (cable for
regulator motor of brake caliper housing)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 21 of 31
Tip: To aid in removal of original cable, cut in
location pictured
•
Disconnect battery cable hold-downs and remove
positive battery cable
Tip: For easier installation, tie together the
front part of the cable (before the Ypiece) with a zip tie and remove rubber
grommet
•
Carefully route new positive battery cable via the
rear axle
Note: Do not damage the fiberglass
reinforced area -arrow-
•
Push cable through opening in trunk and position it
on the side member
•
Clip cable in rear axle area
•
Reinstall wheel well liner
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 22 of 31
•
Route cable along brake lines, corrugated harness
and fuel tank
Note: Take care when routing cable along
brake lines. Damage to brake lines not
covered under this action
Tip: Use tool number 80-200 pry lever (or
equivalent) to clip battery cable clips
properly in place
•
Route cable according to its original routing and clip
properly in place
•
Raise fuel tank back into position and reattach fuel
tank securing strap on passenger side and driver
side
•
Remove engine and transmission jack V.A.G 1383 A
(or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 23 of 31
⇐ Secure corrugated harness -arrow- (cable for
regulator motor of brake caliper housing) back into
position
⇐ Clip fuel lines -arrow- back into place
Note: Contrary to the specifications in the repair
manual, the bolts on the subframe and
fuel tank can be reused in this action
Reuse of these bolts is only permitted
for Service Action Campaign 97R7!
•
Use a permanent marker or paint pen to mark the
subframe bolts with an “X”, as pictured
Note:
Bolts marked with an “X” indicates
that they have been reused one time
and should not be reused again
Replacement of bolts marked with
an “X” is not covered under this
action
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 24 of 31
•
Raise rear subframe
⇐ One at a time, remove locating pins T10096 and
install new subframe bolts -arrows•
Perform same on opposite side, then torque bolts
90 Nm + 90º turn
•
Remove engine and transmission jack V.A.G 1383 A
(or equivalent)
•
Raise rear exhaust back into position
WARNING!
Flex joints of front exhaust pipes must not be
bent more than 20 degrees – danger of
damage
A second technician is required for removal
Damage to exhaust components are not
covered under this action
⇐ Bolt rear exhaust hangers -5- by installing bolts -6and torque to 25 Nm
⇐ Reconnect exhaust retaining loop -4- to exhaust
⇐ Bolt front exhaust hanger -2- by reinstalling bolts -3and torque to 25 Nm
⇐ Reposition clamp properly into position, then torque
the two nuts for exhaust clamp -1- to M8 = 25 Nm
and M10 = 40 Nm
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 25 of 31
Section E – All Vehicles
⇐ Reinstall noise insulation cover -1- by installing
screws -2- and torque to 2 Nm
⇐ Reinstall screws -3- (if equipped) and torque to
6 Nm
⇐ Reinstall sound dampening trim (pictured) on driver
side
•
Remove special tool T10038 (or equivalent), if
previously installed
•
Remove transmission jacks from front of vehicle, if
previously installed
•
Lower vehicle on hoist
•
Clip T-fitting into side member
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 26 of 31
•
Install rubber grommet for starter motor on the
positive battery cable
•
Install cable on starter motor and torque to 15 Nm
•
Reinstall connector on starter
⇐ Install cable and retaining nut onto position 1
-arrow- and torque to 15 Nm
•
Close cap of the jump start junction block
⇐ Reinstall air filter box carrier -arrow- and screws -1and torque to 10 Nm
⇐ Reconnect harness onto carrier -A-
⇐ Reinstall air filter housing and duct work and
reinstall screws -3- and torque to 5 Nm
⇐ Reinstall clamp -2- using tool V.A.G 1921 hose
clamp pliers (or equivalent)
⇐ Reconnect Mass Air Flow Sensor -1-
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 27 of 31
⇐ Route battery cable properly into position and
install retaining nut -circle- for positive battery cable
and torque to 15 Nm
•
Close cap of fuse box
⇐ Reconnect battery terminal of ground cable -1- on
negative battery terminal and torque to 6 Nm
(Wagon):
⇐ Pull trim -9- inward and back into position
⇐ Reinstall expanding rivet -8- and reinstall clamping
pin -7- using screwdriver with hex socket head
(3mm)
⇐ Reinstall coat hook bracket -6- and bolt -5- and
torque to 4.5 Nm
⇐ Reinstall tie down -4- and two bolts -3- and torque
to 6 Nm
⇐ Reinstall tie down -2- and two bolts -1- and torque
to 6 Nm
•
Replace battery service cover
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 28 of 31
⇐ Reinstall lock carrier cover -2- downward and onto
lock carrier
⇐ Reinstall the two bolts -1- and torque to 1.5 Nm
(Sedan):
⇐ Reinstall side trim and the four press buttons
-arrows⇐ Reinstall bolts -3- and torque to 1.5 Nm
⇐ Reinstall anchor point -2- and two bolts -1- on
bottom rear of side trim and torque to 6 Nm
•
Replace battery service cover
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 29 of 31
⇐ Reinstall lock carrier cover -1- downward and onto
lock carrier
(All Vehicles):
• Reinstall spare wheel and vehicle tool kit mount
• Reinstall floor covering into vehicle
Section F – Work Steps After Connecting Battery
Note: After connecting battery and switching
on ignition, the ASR/ESP Control Lamp
-K155- and Electro-mechanical Power
Steering Indicator Lamp light up
continuously
Control lamps go out automatically when
vehicle is driven a distance straight
ahead at 15 to 20 km/h which
reactivates Steering Angle Sensor -G85• Switch on ignition using ignition key or start button
and switch off again
• Read DTC memory and clear faults
• Clock: Check clock time setting; set anew if
necessary
• Electrical window regulators:
- Open and close windows to each end stop
respectively
- With window closed, pull switch until relay
switches audibly
-
Check comfort switching of power window.
While comfort switching is operated, window
must close without holding the switch
• Generating readiness is not necessary
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 30 of 31
Campaign Completion
⇐ Fill out and affix Campaign Completion label, part
number CAMP 010 000, next to the vehicle
emission control information label
SAGA CODE:
DLR #:
REPAIR DATE:
CAMP 010 000
Tip: Ensure Campaign Completion label
does not cover any existing label(s)
Section G – Parts Return/Disosal
• Properly destroy and dispose of removed parts in
accordance with all state/local/provincial
requirements
ALL WORK IS COMPLETE
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle.
These procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition
described. To determine whether this information applies, contact an authorized Volkswagen dealer. 2010 Volkswagen Group of America, Inc. and Volkswagen Canada Inc. All
Rights Reserved.
April 2010
97R7/T2 Page 31 of 31