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V7 | N1 |Winter 2015TechConnect
HVACCertified Collision RepairCamshafts do Double-Duty
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Six-Speed Secrets
*Professional driver on a closed course. Do not attempt.
TheVolkswagenofAmericaAfterSalesWholesaleTeamwasformedinMarch2014andconsistsofautomotivepartsprofessionalswithverydiversebackgrounds.Whentheteamwasbeingformed,wewerelookingforpeoplewhocouldbringvariousskillsetstothetable,statesScottBaroneSeniorManagerofVWoAWholesaleOperations.TheVWoAWholesaleTeammembershaveextensiveexperienceinlogistics,inventorymanagement,sales/marketing,productmanagement,communications,financeanddealerrelations.Theninememberteamworksunilaterallyandtheirapproachbehindeverythingtheydoistoshareknowledgewithoneanother.Thedaysofharboringthebestideasforself-servingreasonsarelonggoneandaverymyopicwayofthinking,saysJohnYoung,theVWoAWholesaleFieldOperationsManager.Wereconstantlydiscussingbestpracticesandhelpingoneanotherbecomemoreknowledgeableinallfacetsofthebusiness.Itistheonlywaytoseparateourselvesasateamandmaintainacompetitiveadvantageinaverytoughmarketplace.Theapproachappearstobeworking.Intheteamsfirstyear,VolkswagenofAmericarankedBestinClassinWholesaleMechanicaland2ndoverallinWholesaleCollision(1)among21participatingOEMbrands.
NowtheVWoAWholesaleTeamwantstotakeitsworkingapproachtoanewlevel.Everyoneisbeing
encouragedtocomeupwithnewandinnovativewaystohelpdealers,saysBarone.Asateam,welistentoourdealershipsandunderstandtheirchallengesbothinternallyandexternally.Wedonotattempttodictateanyspecificbusinessphilosophy..ever.
OneareawheretheVWoAWholesaleTeamhasadistinctadvantageisinitssalesandmarketingprograms.Concurrenttowhentheteamwasformed,VolkswagenwasdevelopinganenhancedCustomerRelationshipManagementtoolforitsdealership.Theresultshavebeenveryimpressive.Today,dealerswhoareseriousaboutthewholesalebusinessareactivelyusingCRMtohelpthemgrowthewholesalebusiness.Andthesedealersareseeingsignificantwholesalegrowthwhencomparedtonon-participatingdealers.TheideabehindCRMisstraightforwardbuildastrongerrelationshipwithyourwholesalecustomer..beitanindependentcollisionorrepairshop.
Today,thereareover100,000IndependentautomotiveshopsthroughouttheUSandregardlessofthevehiclemakeormodel,vehicleownerswantchoices.Itallrevolvesaroundserviceandconvenience,soifaVolkswagenownerdoesntreturntothedealershipforservice,thenextbestoptionistoensureheorshereceivesgenuineoriginalequipmentparts.Itisthatsimple.
Picturedfromlefttoright:TomPiefer,AshleyBiggs,AndrewBash,DarrellWright,ScottBarone,JohnHarrison,AlexMalyshev,CindyMoreenandJohnYoung.
(1) Research conducted in October 2014 - Carlisle North American Parts Manager Survey
VWoA Company Profile:
Wholesale Team+
16 VW Camshafts Do Double-DutyVWexhaustvalveshaveasplitpersonality
YourSourceforGenuineVolkswagenRepairInformation.
VolkswagenTechConnectisapublicationofVolkswagenGroupofAmerica,Inc.
Group [email protected]
Editorial [email protected]
Contributing [email protected]
Volkswagen Group of AmericaSenior Project [email protected]
Editorial andCirculation Offices:134BRiverRd.Montague,NJ07827Phone:330.620.3929www.automotivedatamedia.com
CoverimagecourtesyofSeanMaynard.
Caution:Vehicleservicingperformedbyuntrainedpersonscould result in serious injury to those persons or others.Information contained in this publication is intended forusebytrained,professionalautorepairtechniciansONLY.Thisinformationisprovidedtoinformthesetechniciansofconditionswhichmayoccurinsomevehiclesortoprovideinformationwhichcouldassisttheminproperservicingofthesevehicles.Properly trained technicians have the equipment, tools,safety instructions, and know-how to perform repairscorrectlyandsafely.Ifaconditionisdescribed,DONOTassumethatatopiccoveredinthesepagesautomaticallyapplies to your vehicle or that your vehicle has thatcondition.Forspecificwarningspertainingtotheservicingof specific Volkswagen systems and features, refer to:https://www.erwin.volkswagen.de/erwin/showhome.do.
10 Keep em ComfyDoyouhaveasolidunderstandingofhowthesesystemswork?Ifnot,yourdiagnosisandrepaireffortswillsuffer.
28 Authorized Volkswagen Dealers
V7 | N1 |Winter 2015
vwparts.com
4 Six-Speed Secrets
Volkswagensquestfortheperfecttransmissionbringsustheversatile,reliableand,yes,different,DSGsix-speedbox
22 Volkswagen Certified Collision Repair FacilityFixingtheCarandtheProcess
TechConnect
Multi-disc Clutch
Transmission Fluid Filter
Transmission Fluid Cooler
Trans-mission Fluid Pump
Mecha-tronics
Six-Speed SecretsVolkswagens quest for the perfect transmission brings us the versatile, reliable and, yes, different, DSG six-speed box+
vwparts.com V7 N1 Winter 2015
TechConnect Feature Article
Eversincethefirstautomobilewasbuilt,automakershavebeenlookingfortheidealtransmissionthatwouldtransmitpowerseamlesslyfromonegeartothenext,provideenoughratiossothattheresalwaysoneperfectlysuitedtoanydrivingcondition,andthatwilloperateatoptimalefficiency.Apluswouldbeatransmissionthatwouldoperateasanautomatic,butalsomakeavailablemanualshiftingforthosewholiketodrivewithlan.
Theproblemis,forthelasthundred-plusyearsthatcarshavebeentakingpeoplefromwheretheyaretowheretheyneedtobe,alltheruleshavecontinuedtochange.Todayssophisticatedelectronically-controlledenginesbearlittleresemblancetotheirforebears,wevegonefromrearwheeldrivetofrontwheeldrivetoallwheeldrive,wenowhaveemissionsandfueleconomystandardswithwhichtocomply,andwehavemotoristswhotodayhaveextraordinaryexpectationsfordriveabilityandreliability.
Sothedesignoftodaystransmissions,likethoseofotherautomotivepartsandsystems,arechallengedbymovingtargetsthatwilllikelyneverstoptotakearestwhiletechnologycatchesup.
Intheearly2000s,Volkswagenengineersproducedaunique6-speedtransmissionthatcouldbedriveninautomaticorsemi-automaticmode.Whatdistinguishedthistransmissionfromotherdesignswasthatitwasactuallytwomanualtransmissionsoperatinginconcert,withouttheneedforamanually-operatedclutch,makingitaDirectShiftGearbox(DSG).Itwasquiteaningeniousdesign,andofferedanumberoffeaturesnotfoundinothertransmissions:
Withsixspeeds,therewouldalwaysbeagearratioavailablefornearlyeverypossibledrivingconditionandavailabilityofenginetorqueandspeed.
Itcouldbeshiftedmanuallywithouttheneedforadriver-operatedclutch.
Beingbasedontwocomplementarymanualtransmissions,ithadfewerandstrongercomponents,andfewerandsimplercontrolsystems.
Itwasstillelectronicallycontrolled,forprecisionandinterfacewithothervehicledynamicsandthedemandsofvariousdrivingconditions.
Thestrengthanddurabilityofhelically-cutdrivegearshelpmakeforsmooth,quietoperationevenunderheavytorquedemands.
How do three plus three equal six?Actually,threeplusfourequalsseven,ifyoucount
reverse.TheessenceoftheDSGtransmissionistwomanualtransmissions--oneforfirst,third,fifth,andreverse,andtheotherforsecond,fourth,andsixthgear.Eachofthetwotransmissionshasitsownwetclutchassembly,andalltransmissionfunctionsarecontrolledbyaMechatronicselectroniccontrolunit,which,interestingly,isinternaltothetransmissionandisconstantlyimmersedintransmissionfluid.
Beingbasedontwomanualtransmissionunits,thedrivengearsarealwaysmeshedwiththeequivalentofaclustergear,sotheyrealwayswaitingforsynchronizeractiontomechanicallyconnectthemtotheirrespectivemainshaft,andreadyfortheclutchonthatmainshafttoengageandtransmitpowerontothedrivewheels.
TheingenuityoftheDSGisthateachofthetwotransmissionsisalwaysengagedinoneofitsgears,asdeterminedbytheMechatronicsunit.Soifpoweristransmittedthroughfirstgearinonegearbox,theothergearboxalreadyhassecondgearengaged.SoallthatsneededisinstructionsfromtheMechatronicsunittodisengagetheclutchatthefirsttransmissionwhileitsmoothlyengagestheclutchofthesecondtransmission..And,justlikethat,thecarhasshiftedfromfirstintosecondgear.
Now,asyouwouldexpect,oncethevehicleisbeingpropelledinsecondgear,theMechatronicsunitdirectsthefirsttransmissiontodisengagefirstgear,whichisnolongerneeded,andengagethirdgearsoitisreadyfortheMechatronicsunittopassthetorchonuptothirdgear.Andsotheprocesscontinuesupthroughallsixforwardspeeds.Thetwoclutchesaremountedconcentricallyonamainshafttofurtherpromotesmoothupshiftsanddownshifts.
Inthemeantime,theMechatronicsunitconstantlymonitorsdrivingconditions,sothatthetransmissionnotcurrentlyengagedshiftseitherupordowndependingonanticipatedpowerneedsanddrivingconditions.
Withenginespeednecessarilydroppingwhenupshifting,throttlemodulationisnotneeded,especiallysincethedual-clutchsetupcanchangegearsveryquicklyandsmoothly.However,whenthetransmissionisdownshifting,theECUissmartenoughtoknowtoblipthethrottletomatchrevstothenew,lowergear.Itsallquiteclever.
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Six-Speed
AparticularlyinterestingfeatureoftheDSGtransmissionisthesynchronizationofthevariousgears.First,second,andthirdgearsareactuallyequippedwithwhatVolkswagenreferstoastriplesynchronization.Wereallfamiliarwithhowasynchroringworksinaconventionalmanualtransmission.Asoft,taperedconicalringismovedintomeshwithamatingringand,asthetapersjoinup,thespeedofthetwodevicesmatchspeeds,providingthesynchronizationneededtoavoidclashingofgears.Thistriplesynchronizationprovidesmuchlargerheattransfersurfaces,necessarybecausetherotationalspeeddifferencesarehigherintheselowergears.Fourth,fifth,andsixthgearsallusethemoreconventionalsinglesynchronizer.
WithVWtriplesynchronization,therearethree,notjustone,synchrorings,sothatthefirstmatchesspeedwiththesecondone,thesecondmatchesspeedwiththethird,andthethirdmatcheswiththetaperedconeonthegearitself.
ThisDSGdesignalsoincludestwootherdriver-friendlyprovisions--ahillholderfunctionthatholdsthestoppedvehicleonanuphillroadevenifbrakepedalpressureisrelaxed,andalsoacreepfunctionthatallowsthecartoeaseforwardonlevelgroundifthebrakepedalisnotdepressed.
How smart is the brain?TheMechatronicsunitisquitesophisticated,
incorporatingnofewerthantwelveseparatesensors,inputfromwhichtheECUusestooperateighthydraulicgearactuators,sixpressuremodulationvalves,fivecontrolvalves,andthepressuresandcoolingofthetwowetclutchassemblies.Itisalsoasmartmodule,withthecapabilityoflearningthepositionsoftheclutchesandoftheactuatorsforeachgear,andthemaintransmissionfluidpressure.Itisalsoadaptiveandcanlearnoperatorsdrivinghabitsandadjustshiftcharacteristicsaccordingly.
Furthermore,VWengineersdidasurprisinglythoroughjobofanticipatingpossiblecomponentand
ThisDSGschematicshowsthedualgearsetsthatconveypowertothedifferential.
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systemfailure,and,asaresult,integratedahostoffail-safemodesandactionsintotheMechatronicsunit.Whatthismeansisthatdrivers,andsometimeseventechnicians,maynotbeawareofamalfunctionwithintheDSGtransmission,sincetheMechatronicsunitmayalreadybecompensatingforasensororothercomponentthatsnotdoingitsjob.
ThetechniciansjobismadeeveneasierbythefactthatmostofthecontrollingfunctionsofthistransmissionarefoundwithintheMechatronicsunit,whichislargelyself-diagnosing.Othermalfunctionsalsotendtobeintuitiveintheirdiagnosis.Mostly,tothebenefitofboththemotoristandthetechnician,thesetransmissionstendtohavefewfailures.
Zero in on the problemBecausemostofthesensors,
solenoids,controlvalves,andactuatorsareintegratedintotheMechatronicsunit,aCheckEnginelightwithanaccompanyingOBDIIfaultcodewillalertthedriverandtechniciantothespecificproblemarea.MoreseriousconditionsmaybebroughttothedriversattentionbyarepeatedflashingofthePRNDSindicators.Otherindicationsofaproblemwiththistransmissioncanincludeananomalyfoundduringatestdrive,observingthatthetransmissiongoesintolimp-inmode,shudderingwhenacceleratingfromastop,orbangingwhenthetransmissionshiftsintofirstgear.
Anastutedrivermayalsonoticethefailureofthetransmissiontoshiftupordownintothenextnumericalgear,orpossiblyoperateonlyinafail-safemodeof,perhaps,justsecondorthirdgear(outofthesixheorsheisaccustomedto).Similarly,slippageduringshiftingwouldalertanobservantdrivertoaclutchproblem,andwouldlikelybeaccompaniedbyaCheckEnginelightandappropriatefaultcode.
IftheCheckEnginelightilluminates,followtheappropriatediagnostictree.MostofthetimeyoullfindthattheMechatronicsunitisthesourceoftrouble,sinceitperformssuchavastanddiversearrayoffunctions.Theunitsarenotserviceable,andmustbereplacediffaulty.Notethattheseunitsarevehicle-specific,soifyoudeterminethatyouhavetoreplaceafaultyone,youllneedtoprovidetheVINtothepartsdepartmentofyourlocalVWdealershipandtheywillneedtoorderanewunitspecifictothatvehicle.
Thetriplesynchronizerisusedonthefirst,second,andthirdgears;thesinglesynchronizerisusedonfourth,fifth,andsixthgears.
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Six-Speed
Lesscommonareclutchfailures,whichrequireremovalofthetransmissionfromthevehicleandahostofspecialtoolsandprocedures.Anyotherfailurecallsforreplacementoftheentiretransmission.
But if it is the Mechatronics unitTheMechatronicsunitislocated
withthevalvebodywithinthetransmissionhousing,andisaccessibleafterremovalofthesidecover;thereisnoconventionalsumponthebottomtoremove.ReplacementoftheMechatronicsunitisnotasimpleprocedure,andVolkswagenhasproducedadetailedvideoandinstructionalprogramcoveringthepropertoolsandproceduresneededforthisjob,andthecompanyconsidersitessentialthattechniciansstudyboththevideoandthetrainingmaterialbeforeundertakingthisrepair.
Whilemostoftheelectro-hydraulicactuators,solenoids,andvalvesareintegralwiththeMechatronicsandare,therefore,non-serviceable,thereareafewsensorsandotherseparatecomponentsthatarelocatedremotelyandcanbeservicedseparately.Yourdiagnosticsoftwareprogramshouldidentifytheirroleandlocation,andyoucanalsofindsupportbyaskingthefolksatyourlocalVolkswagenpartsdepartment,whowillbefamiliarwiththesystemyoureworkingon.
TheMechatronicsunitismountedwithtenboltswhichmustberemovedandinstalledinsequence.Thesearesingle-useboltsandmustbereplacedateveryservice.
TheMechatronicsunitismountedbehindacoverplateandisimmersedintransmissionfluid.ThisfluidmustbedrainedbeforeaccessingtheMechatronicsunit.
ThisillustrationisrepresentatativeofthepowerflowinsixthgearoftheDSGtransmission.
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9Volkswagen TechConnect
Keep em ComfyDo you have a solid understanding of how these systems work? If not, your diagnosis and repair efforts will suffer.
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vwparts.com V7 N1 Winter 2015
TechConnect Feature Article
Earlymotorvehiclesdidntoffermuchinthewayofclimatecontrol.Awoefullyinadequateamountofheatwastypicallyductedfromovertheexhaustmanifold,andairconditioningdidntevenappearuntilthelate1930s--thatis,unlessyoucountplacingabucketoficeonthefloorinfrontofavent.
Wevecomealong,longway.Theneedforthedefrostfunctionsoyoucanseewhereyouregoinginicyweatherwasthefirstimpetusformakingdecentheatingmandatory,thencommonhumanityimpelledthecarmakerstodowhateverwasnecessarytorelievethesufferingofmotoringmankind.
Havewebecomespoiled?Perhapsso.Ontheotherhand,istherereallyanygoodreasonwhyweshouldhavetofreezeorbroilinthecabinofacar?NotwhensuchgreatHVACsystemsarestandardequipmentinmodernVolkswagenvehicles.Besides,studieshaveshownthatpeopledrivemoresafelywhencarinteriorsarekeptwithinacomfortablerangeoftemperatures.
WerenotgoingtogetintothetheoriesofthermodynamicsandrefrigerationbeyondmentioningthattheSecondLawofThermodynamicsstatesthatheatalwaystravelsfromawarmerobjecttoacolderobject.Whatweintendtosharewithyouherearesomeofthesubtletiesofcontrollingandmaintainingheating,ventilation,andairconditioningincommonVolkswagenmodelsofyearspast,whichiswhatyouareprobablyworkingonnow.
Hot boxAllmodernVolkswagenmodelshavewhatsknown
asahotbox.Inotherwords,coolantisalwaysflowingthroughtheheatercoreintheairdistributionhousing.Combinedwiththeactionoftheblenddoors,thismakesformuchmoreprecisecontrolofcabintemperaturethantheold-fashionedideaofrestrictingflowthroughthisheatexchanger,anditsalsolesspronetoproblemssuchasstuckorleakycoolant-controlvalves.
AlltheairthatreachestheventshaspassedthroughtheevaporatorwhetheritsforheatingorA/C.
Clean airOveradecadeago,VWadoptedabigadvancein
cleancabinair:adust,pollen,andodorfilter.Allfresh
Left:TheVWType1firstarrivedintheU.S.in1949--65yearsago!Air-cooledBeetlesgaveyouheatofftheexhaustmanifoldsalmostinstantly,justnotmuchofit.A/C?Inthosedays,itwasjustapipedream.
outsideairenteringthevehicleforbothheatingandairconditioningpassesthroughthisfilter.Itisconstructedwithanactivatedcharcoallayerbetweenthedustandpollenfilterelements.Theactivatedcharcoalremovesodorsandsomepollutantssuchasozone,whichisconvertedtooxygen.Thefiltershouldbereplacedaccordingtothemaintenanceschedule,ormoreoftenifthevehicleisdrivenindustyconditions.
WhileyoullprobablybeabletoendureswelteringinacarwithoutA/C,youmightnotsurvivefrigidweatherunlesstheheatingfunctionisworking.So,keepingtheinteriorabovethatatwhichfrostbiteoccursistheHVACengineerstoppriority.
Althoughthelowheat-rejectionofhyper-efficientVolkswagendieselsandFSIgasolineenginesmakeharvestingenoughexcessBtustokeepthecabinwarmmoredifficultthanitwasinthefuel-wastefulpast,Volkswagenhascomeupwithingeniousdesignsthathelpmaximizethisprocess,providingmorethanenoughheatforevenArcticconditions--whentheyreoperatingproperly.
Complaintsofinadequateheataretypicallycausedby: Lowcoolantlevel Afaultythermostat--orperhapsitwasremovedaltogether
Aheatercorepluggedwithdepositsordebris(tryingtoremovetheseeitherwithairpressure,orbytwistingaflexiblecablethroughthecoilsisusuallynotsuccessful).
Aninoperativeblower,eitherfromelectricalproblems,orbecausesomethinghasjammedthefan.Acorns?Amousenest?
Blockedairflowfromacloggedcabinfilter,or,again,arodentsnest.
Ablenddoorthatdoesntmovetotheproperpositionforwhateverreason
Checkoutthesebasicsbeforeyouembarkonanysophisticatedelectronicstroubleshooting.
Manual? Well . . .MostVolkswagenmodelssoldovertheyearshave
hadmanualHVACsystems.Despitewhatthenameimplies,modernmanualHVACsystemsdontrelyjustonlevers,cables,andvacuumswitches.Theresplentyofwiring,too.Theyrecalledmanualbecause
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12 HVAC
havestrip-typefusessecuredtothetop,somedont,dependingontheapplication.
Input verificationConsidera10-year-oldJettaVR6withmanual
A/C.Itscoolantfancontrolunithastwoconnectors,onefour-pinandanother14-pin.Onthefour-pinconnector,youwillhavetherelayspowersupplies,a
cabintemperatureisntcomputer-controlled.Thehumansaboardsimplytwistaknobtorequestalevelofheatingorcooling,andthesystemputsoutwhatitcantoachieveit.Someelectricalinputsareusedtohelpprotectthecompressor,however.Thereareambienttemperature,refrigerantpressure,andcoolanttemperaturesensorstomakesureconditionsarerightforengagingtheelectro-magneticclutch(theclutchlessvariable-displacementcompressorsfoundonsomelatemodelsareanotherstoryaltogether,whichwellcoverinafutureissueofTechConnect).Startingwiththe2000modelyear,acoolingfancontrolunitmonitorsallthesesensorinputsandmanagesthecompressorclutchcircuitaswellasthecoolingfans.
Withamanualsystem,alloftheseinputsneedtobeworkingproperlytoactivatethecompressor.Ifanyinputweretofail,thecompressorclutchcircuitwouldopen.Withoutacontrolunitwithself-diagnosticcapability,thismeanseachinputneedstobecheckedusingpinvoltages.Whetheryouwanttocheckthevoltagesignalsatthecoolingfancontrolunit,oreachindividualsensorisuptoyou.Theunitisusuallymountedonthedriverssidefrontframerail.OnaNewBeetle,thatwouldbeunderthebatterytray,notallthateasytogetto.Somecoolingfancontrolunits
ThetraditonalthreedialsoftheVolkswagenmanualHVACsystemcouldntbesimplertounderstandandoperate.ThisswitchunitprovidesvoltagetoPin#8onthecoolingfancontrolunitindicatingthatA/Chasbeenrequested.
Passat air distribution housing
ThistypicalVolkswagenPassatairdistributionhousingisamodernhotbox,withtemperaturecontrolbymeansofairflowflaps.Withautomaticsystems,theflapsarecontrolledbyelectricmotors.
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6.0mmsolidredinPin#1,anda2.5mmred/whitetracerinPin#3.Theyshouldhavebatteryvoltageatalltimes.InPin#2(2.5mmred/whitetracer)isthepowersupplyoutoftherelayforlow-speedfanoperation.Thefinal6.0mmred/whitetraceristhepowersupplyoutputforthehigh-speedfan.
The14-pinconnectoristhesourceofactivationfortheinternalrelays,notonlyforthecoolingfan,butalsofortheA/Ccompressorclutch.Pin#6isabrowngroundwire,andconstantbatteryvoltagecomesinonpin#4,red/greentracer.Powerfromtheignitionswitchcomesinoninpin#9,usuallyblackwithabluetracer.
Inorderforthecompressortoturnon,youneedtoseesomeinputs.Thefirstcheckyoushouldperformisonpin#8,black/redtracer.WhentheA/Cbuttonispressedandthebloweriscommandedon,youshouldseebatteryvoltage.Next,lookatpin#2,awhitewire.Thisisanunusualsignalinthatitisafive-voltsquarewavecreatedbytherefrigerantpressuresensor.Thedutycycleofthesignalwillchangewithrefrigerantcharge.Thisisheretoindicateifthechargeistoolowortoohightoturnthecompressoronandoff,andperhapsdamageit.Anothersignalthatmayinhibitcompressoractivationisthatoftheambienttemperatureswitch.Testforvoltagebetweenpins#5(black/red)and#14(green/black).Ifthesignalindicatestheairtemperatureistoolow,itwillnotallowthecompressortorun.Checktheseinputstothecoolingfancontrolunitwheneverthecompressorclutchwontengage.
Whetherwiththemanualortheautomaticsystemwerejustgettingto,onecommonsourceoftroubleiswaterinfiltration.Itgetsintoconnectionsandcausescorrosionthatwillintroduceresistanceintothecircuit,orinterruptitcompletely.Therearelotsofwaysthiscanhappen.Forexample,asunrooforcowldraincanplugupallowingH2Otosoaktheinterior,andthereareoftenbranchedconnectionsunderthecarpetthatwillcorrodeawayifsoaked.Or,amoduleoroneofitsconnectorscanfailinthesameway.Itmakessensetocheckforthisbeforeyoustartspendingtimedoingelectronictesting.
Full auto and the scan toolClimatronicAutomaticclimatecontrolsystem
addsautomationinthataftersettingthetemperaturetoanumberofdegreesinthecabin,anelectronicunitmonitorsbothoutsideandcabintemperatureconditionsandusesaprogrammedplanforhowbesttoachieveandmaintainthechosensetting.ThesesettingsvaryfromfulldefrostheattoMAXA/C.Onceatemperatureisset,thecontrolunitwillautomaticallymanipulatemodedoors,temperatureblenddoorsandtherecirculationdoor.Therearemanualoverridesthepassengerscanselecttocontrolpositionsofthemodedoors,cabinairrecirculation,andA/Ccompressoroperation.Sincetheseelectronicsareoverseeingsystemoperation,Volkswagenhasimplementedthesameself-diagnosticfeaturesfoundinconjunctionwithothercontrolunits.
Youmaynotrealizewhatyourcurrentscantooliscapableof.Youmaynotevenrealizehowmuchusefulinformationyouhaveatyourfingertips.Byimprovingyourskillswiththismosthelpfulpieceofequipment,youwillreduceyourdiagnostictimeandmaybegetaheadofthecost-effectivediagnosisgame.Volkswagenautomaticclimatecontrolsystemsareendowedwiththesameextensiveself-diagnosticfeaturesasarefoundinpowertraincontrolsystems.Whilethescantool-baseddiagnosticfeaturesinauto-HVACsystemsareextensive,theinterfaceisproprietary,sowithoutknowingwhatyourelookingforitwillbedifficulttointerpretthedatabeingdisplayed.Sohowdoesthiswork?
Formanyyears,VAGhasbeenthefactoryproprietaryscantoolforVolkswagenvehicles.EvenifyoupurchasetheEuropeanbundleforyouraftermarketscantool,youshouldstillbeabletodisplaythisfactorysoftware.Thesoftwareinthescantoolallowsyoutocommunicatewithallofthevariouscontrolunitsinthevehicle.Eachcontrolunitisprogrammedtousethesamesoftwarearchitecture,sowhatwereabouttodescribewillworkalsoworkonABSandSRS.
Lowheat?Checkcoolantlevelfirst--anddontforgettobleedoutanytrappedair.
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controlunitactivatevariousoutputs.Youcanlistenfortheactivation,and/orperformelectricaltestingonthecomponentbeingactivated.Thisallowsyoutoverifythatthecontrolunitsdriveriscapableofturningonanycomponentinwhichyoumaysuspectafault.
Function04isreferredtoasBasicSettings.Ingeneral,thisprovidesaresetorre-syncofcomputer-controlledfeatures.Theautomaticclimatecontrolsystemneedstoknowthepositionsofthevarioustemperatureandmodedoorsinordertomanipulatethemifachangeisrequestedbytheoccupantordetectedbyatemperaturesensor.BasicSettingsrunsthecontrolunitthroughthere-learnprocess,butmoreonthislater.
Function05simplyclearscodes,andonceyouredonecommunicatingwiththeHVACcontrolunit,youshouldshutdownthiscommunicationbyselectingFunction06.Thishelpspreventcorruptionofsoftware
Youcanentertheself-diagnosticfeaturewithyourscantoolbysimplypickingtheaddresswordyouneed.So,whatsanaddressword?Withthefactoryscantool,aseriesofnumbersisusedtoidentifythevarioussystemsyoucanenter.Thesenumbersarecalledaddresswordsinyourtechnicalliterature.
Where do you want to go?Eachsystemhasitsownaddressword.OntheVolkswagenfactorytester,youneedtoknowwhataddresswordrepresentseachsystem.Aftermarketdiagnostictoolsgivetheaddresswordaswellasadescriptionofthesystem.Inthecaseofautomaticclimatecontrol,theaddresswordis08(Auto-HVAC).Onceyouveselectedthesystem,youwillbeaskedtochoosewhichfunctionyoudliketoperform:
Function01identifiesthecontrolunit.
Function02isforpullingcodes.
Function03isforactuationmode.
Function04providesbasicsettings.
Function05clearscodes.
Function06endscommunicationwiththecontrolunit.
Function07allowsyoutocodethecontrolunittotheparticularcaritisin.
Function08isforreadingdata.
Thereareafewotherfunctionstochoosefrom,butweregoingtofocusonthemostimportantones.
Startingwithfunction01,youwillseethatthismerelyidentifiesthecontrolunitinthevehicleaswellasitsversioncoding.Thisinformationisusefulifyouthinkthecodingmayhavebeenchangedinerror,orthatausedcontrolunitwasinstalledandmaynotmatchtherequirementsoftheoriginalone.Providingthecontrolunitistheproperone,youcancorrectcodingifnecessary.
Function02isprettyself-explanatory.Auto-HVACunitsarecapableofself-diagnosis,andcanidentifyfaultsinoneormorecomponents.Thesecomponentsareeithersensorinputsoractuatoroutputs.Inthecaseofactuatoroutputs,youdontalwayshavetoaccessthecomponentandstartyourtestingthere.Theotheroptionisscantoolactivation.
Function03isthemodewhereyoucantakeadvantageofthecapabilitiesofthescantoolandrequestthattheHVAC
Asthisschematicshows,automaticsystemsrelyonnumerousinputsfortheinformationneededtodecidehowtocommandoutputs.
Dontoverlookothercoolingsystembleedpoints.
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intheunit.Function07allowsyoutochangetheversioncoding.Versioncodingisawayforyoutotailorthecontrolunittothevehicleitsin.Vehiclescomewithmorethanoneoption.Eachcontrolunitmustbemadeawareoftheseoptionsinordertoperformproperly.Thiscomesinhandywheninstalling
usedparts.Althoughthereplacementcontrolunitmayhavethesamepartnumber,thecodingmustbechangedtoaccommodatetherequirementsofthevehiclebeingrepaired.
Finally,Function08(sometimesreferredtoasdatablocks,ormeasuringblocks)allowsyoutolookatdata,suchasatemperaturesensorreading,oractuatorposition.Thetrickypartisthatthesedatablocksarealsoidentifiedwithnumbersandaredisplayedinblocksoffour.Youmustlookupinatablewhatthedatablocksindicateforeachdisplaygroup.Thisinformationcanoftenbefoundinyourinformationsystem,orbypurchasingbooksfromaftermarketscantoolmanufacturers.
ResetOnceyouhavepulledcodes,diagnosedaproblem,
anddonearepair,youmayneedtoresettheclimatecontrolsystem,especiallyifamodedoormotorwasreplaced.ThiscanbeachievedthroughtheBasicSettingsfeature.Youwillbepromptedtoenterathree-digitcode.Leavethecode000inthedisplayandenterthismode.Thepositionsofthedoorsarerecorded,andtheywillthencycletotheirrespectiveendstops.Now,thecontrolunitknowswhatthemaximumandminimumpositionsareforeachmode/blenddoor.Whenitneedstomakeatemperatureadjustmentasaresultofchangingconditions,itcanmakethecorrectchange.Withoutknowingthecurrentpositionofthedoors,itwillmakethewrongadjustmentandoutputthewrongtemperature.
WehopethatknowingtheaboveinformationabouttypicalVolkswagenHVACsystemswillhelpyoukeepyourcustomershappywiththeircars--andwithyourwork.
Nosensedoinghigh-techdiagnosticsuntilcatastrophiccorrosionlikethisiscorrected.
...seriouswaterinfiltration.
Somethingasbasicasthispluggedcowldraincanleadto...
Therearemanyaddresswordsforallofthepossibleself-diagnosticsystemsonthevehicle.Selectaddressword08HVACandyoucantalktoanautomaticclimatecontrolsystem(notamanualsystem).
VW Camshafts Do Double-Duty
VW exhaust valves have a split personality+
vwparts.com V7 N1 Winter 2015
TechConnect Feature Article
Inthemid-2000s,Volkswagenintroduceda2.0Lversionofits1.8LSOHCEA888enginefamily.Thisnewturbochargedfuel-injectedgasolineengineincorporatedmanyofthefeaturesthathadprovensuccessfulandreliableinitspreviousiteration,withadualoverheadcam/4-valvedesign,andwasidentifiedasCCTA/CBFA.Subsequentengineeringledtoinnovativenewtechnologyforexhaustvalveactuationthatactuallyprovidedanexhaustcamshaftwithduallobesforeachvalveandasophisticatedswitchingmechanismtoalternatevalveoperationbetweentwomodes.ThisnewconfigurationbecameknownastheCBEAfamilyofengines.
Thedual-functionexhaustvalveactivationallowsfordifferingengineperformancecharacteristicsdependingondemandsandoperatingparameters,suchasthrottlepositionandotherinputsasdeterminedbyvarioussensorsandthevehiclesMotronicElectronicControlUnit(ECU).Atlowenginespeeds,whendemandforpowerismodest,anarrowprofilecamlobecontourmanagesexhaustvalvetiming.Inparticular,itprovidesforverylatevalveopening,suchthattheexhaustpulsecannotback-flowintothecylinderduringthevalveoverlapphaseofthecombustioncycle.
Atthesametime,underlightloads,thisdual-valvetechnologyallowstheintakecamtobedesignedinsuchawaythattheintakevalvesopensoonerthantheywouldotherwise.Thisprovidestwobenefits:Advancedvalvetimingtendstomovetheenginestorquecurvedownward,enhancinglow-speeddriveabilityandacceleration.Atthesametime,theearlieringestionoftheintakecharge,combinedwiththedelayedexhaustvalveopening,generatesamorepositivechargeinthecylinder,reducingthevolumeofspentexhaustgasesremaininginthecombustionchamberandretainingmoreoftheintakechargeinthecylinderatlowerenginespeeds.
What are the benefits?Specificbenefitsofthistechnologyincludeimproved
throttleresponseandhighertorqueatlowrpm,makingthetorquecurvesteeper,andreducingturbolagatlowerenginespeeds.
Conversely,athigherenginespeeds,theengineswitchestoanalternateexhaustcamshaftlobeprofilethatallowsformoreefficientcombustionandenhancedfueleconomy,withcorrespondinglylowerexhaustemissions.
Thedualoperationoftheexhaustcamshaftfunctionisaningeniousdesign,usingseparateexhaustcamelements,oneforeachcylinder(remember,thatasaDOHCengine,thereisaseparateintakecamthatisunaffectedbythedualexhaustcamlobefunction).Eachofthesefourexhaustcamelementsismountedonacommonsplinedexhaustcamshaft.Eachofthefourexhaustcamelementscontainstwolobesforeachoftwoexhaustvalves,suchthatthefourexhaustcamelementscontainatotalofsixteenlobes,sufficienttoprovidedualfunctiontoeachoftheeightexhaustvalves.
Inoperation,whenvariousconditionsaremet,theselectionofaparticularexhaustcamlobeisperformedbyelectro-mechanicalsolenoidsthatmovetheexhaustcamelementsside-to-side,dependingonthemodeselected.Therearetwosolenoidsforeachofthefourcamelements--onesolenoidselectsthelargecamlobe,andtheothersolenoidselectsthesmallcamlobe.Aspring-loadedmetaldetentpinhelpsholdtheelementintheappropriateposition.
Sinceitisthecamshaftelementsthatmoveside-to-sidecourtesyofthesolenoids,therockerarmswiththeirrollerfollowersremaininafixedposition.Ahelicalgrooveintheelementshelpsallowforasmoothtransitionfromonelobetoitsmate.
Inoperation,whentheengineisfirststarted,theMotronicenginemanagementsystemdirectsthesolenoidstoselectthelargerexhaustlobesforeasierstartup.Immediatelyaftertheenginestarts,thesystemchangesovertothesmallerlobes.Undermostdrivingconditions,thesystemwillretaintheuseofthesmallerlobesuptoabout3,100rpm.Uponshut-down,thesystemrevertsbacktothelargercamlobesinpreparationforthenextstart-up.
Service considerationsInthenearlytenyearsthissystemhasbeeninservice,
ithasprovedtobebothdurableandreliable.Yettherearesomeitemsthattechniciansneedtobeawareof.Thesolenoidsthatactivatetheelementscan,uponoccasion,fail.Whentheydo,aCheckEnginelightwillhelpalertthedrivertoaproblem,andaDiagnosticTroubleCode(DTC)willadvisethetechnicianastowhichsolenoidrequiresattention.Oncetheplasticenginecoverisremoved,thesolenoidsarereadilyvisible,andareeasilyreplacedafterremovalofasingleTorxfastenerandelectricalconnector.
Similarly,thevehicleisequippedwithcamshaftrotationsensors,whichhavealsobeenknown
vwparts.com
18 Camshafts
todeveloptrouble.Again,aCheckEnginelightandDTCwilldirecttheservicingtechniciantotheappropriatesensor.Lesslikelyisaprobleminthecamphasersystem,butthistoowillbeidentifiedwiththeappropriateDTC.
Maintenance is especially criticalBecauseoftheprecisionof
thisdual-lobesystem,andthespeedwithwhichitmustrespondinordertohelpoptimizeengineperformanceandemissionscontrol,itisespeciallycriticalthatmaintenancebeperformedatleastasoftenasrecommended.Duetothetighttolerancesofthevariouscomponentsinthissystem,youcanmakeastrongcaseforownerstoscheduleoilchangesandotherroutinemaintenanceattheintervalsspelledoutinownersmanualsorelectronicservicereminders.Becertaintouseengineoilpreciselyasspecifiedforthisenginefamily,available,ofcourse,fromyourlocalVWpartsdepartment.
Anysludgeorcarbonbuild-upintheseenginescanadverselyaffecttheperformanceofthissophisticateddual-valvefunction.Thisdebriscancausebindingorgallingofthesplinesontheexhaustcamshaftsandelements,theycaninterferewiththeproperoperationofthedetentballsandsprings,and,ofcourse,theycancausewearonthecamshaftlobesandfollowers.WearordamageonthelobesofthecamshaftelementswillbeevidencedbyanenginemisfireDTC,whichwilldirectyoutotheerrantelementandlobe.
What about the cylinder head?Withpropermaintenance,
cylinderheadserviceisnotrequiredonthisenginefamilyanymorethanonothermodern-day
engines.ThecylinderheadgasketisarobustMLS(Multi-LayerSteel)design,andholdsupwell.However,withtheseengines,aswithallengineswithaluminumcylinderheads,overheatingcanquicklycauseacylinderheadtowarpandtheheadgaskettofail.
Ifremovalofthecylinderheadiscalledfor,youmustexercisevariouscautions--sometypicalof
V7 N1 Winter 2015
19Volkswagen TechConnect
cylinderheadsfromotherenginefamilies,andsomespecifictothisenginedesign.Forexample,youshouldperformappropriatediagnosisbeforebeginninganydisassembly.Mostlikelyacylinderleak-downtestcoupledwithDTCsthataredisplayedwillpointyoutotheparticularproblemarea.
YoullwanttosettheengineatTDCbeforebeginningdisassembly,andbesuretotakespecialnoteofmarkingsontiminggears/sprockets,includingcorrespondingmarkingsonthecylinder
heads,andalsomarkingsfordirectionofrotation,sincethesestepswillhelpyougreatlyduringreassembly.Likemostsophisticatedenginedesigns,thisenginefamilyisaninterferencedesign,soyoullwanttobecertainnottorotatethecrankshaftifthecylinderheadisonandthetimingchainisnotinplace.
Special cautionsYoullprobablynotbesurprisedtolearnthatthe
cylinderheadboltsontheseenginesareoftheTorque-To-Yield(TTY)type,whichmeanstheycanonlybeusedonceandthenmustbediscardedandreplacedwithnew.TheseheadboltsarenotincludedinVWheadgasketsets,andmustbepurchasedseparately.
Youmaybesurprisedtoknow,however,thatmanyoftheotherfastenersontheseenginesarealsoTTYbolts,andcannotbere-used.Suchboltsareusedinvariousplacesaroundtheengine,andalsoformountingoftheturbocharger.Assuch,thepartsprofessionalatyourlocalVolkswagenpartsdepartmentcanbeyourbestfriendhere,andcanhelpidentifythosefastenersthatmustbereplacedeverytime.
Anothernoteofcaution:Anycylinderheadservicewilllikelycallfordisconnectingthefuelrailfromthefuelinjectors.Anytimethefuelsystemisopenthereisthepotentialfordebristoenterthesystem.Sincemodernfuelinjectionsystemsworkwithinextraordinarilyclosetolerances,theintroductionofanydebrisintothesystemholdsthepotentialforcompromisedperformanceand/orcomponentdamage.So,beespeciallycarefultopluganyopeningsinthefuelsystemwhenperformingcylinderheadorrelatedservices.
vwparts.com
20 Camshafts
Timing chain tacticsTheseenginesusechain-drivencamshafts,so
noroutinereplacementoffibroustimingbeltsisrequired.Ifyoudoencounteroneoftheseengineswithsubstantialsludgebuild-up,however,itislikelythatthetimingchainwillalsowarrantreplacement.Thesetimingchainsrideonguiderails,andifthechainisworn,thentheguiderailsarelikelydueforreplacementaswell.Furthermore,theseenginesuseahydraulictimingchaintensionerbehindtheguiderails,andifthechainisbadlyworn,itispossiblethatthefreeplayinthechainexceedstheabilityofthetensionertocompensateforthatwear.Thiswouldbeevidencedbytimingchainrattle,which,sadly,isasoundthatmanytechniciansarefamiliarwith.
Timingchainreplacementontheseenginesisnotasimpletask.Inadditiontoremovalofthecylinderhead,theprocesswillalsorequireremovaloftheharmonicbalancer,thetimingcover,andothercomponentsthatrestrictaccesstothefrontoftheengine.
Finally,thoughitmayberoutine,andyoushouldmakeitsoifitisnot,youshouldbecertaintochaseallthreadsbeforereassembly,andalsotoremoveanyoilorotherdebrisorliquidfromtappedholesintheblock,head,andelsewhere.Itisentirelypossiblethattorquingafastenerintoanobstructedholecangenerateenoughmechanicalorhydrostaticforcetocrackanddestroythecomponenttheboltisbeingthreadedinto.Itsasimplestep,easilyoverlooked,butacriticallyimportantone.
Im A ConvertIm A ConvertIm A ConvertTo PPG Waterborne
2012 PPG Industries All rights reserved. www.ppgrefinish.com
Convert with Confi dence
Building a show-winning custom
demands perfection in every
detail. Thats why I chose PPGs
Envirobase High Performance.
The waterborne colors are much
more vibrant, clean and clear.
Charley HuttonCharley Huttons Color StudioNampa, Idaho
PPG is an approved supplier
to the Mercedes-Benz Certifi ed
Collision Center program.
Theoilflowthroughthisengineiscomplexandcircuitous,withmanylocationswhereharmfulsludgecanaccumulate.Thismakesregularmaintenanceespeciallycritical.
V7 N1 Winter 2015
21Volkswagen TechConnect Im A ConvertIm A ConvertIm A ConvertTo PPG Waterborne
2012 PPG Industries All rights reserved. www.ppgrefinish.com
Convert with Confi dence
Building a show-winning custom
demands perfection in every
detail. Thats why I chose PPGs
Envirobase High Performance.
The waterborne colors are much
more vibrant, clean and clear.
Charley HuttonCharley Huttons Color StudioNampa, Idaho
PPG is an approved supplier
to the Mercedes-Benz Certifi ed
Collision Center program.
Volkswagen Certified Collision Repair Facility+Fixing the Car and the Process
vwparts.com V7 N1 Winter 2015
TechConnect Feature Article
NewerVolkswagenvehiclesincludeextensiveuseofUltra-High-StrengthSteels(UHSS)andotherlightweightmaterials,plusadvancedelectronicsandoptionalrearviewcameratechnologiesthatmaybeembeddedinorattachedtobumperandbodypanels.Collisionrepairserviceprovidersmustupdatetheirequipmentandtechniciantrainingtoproperlyrepairthesenewmaterialsandtechnologies.TheVolkswagenCertifiedCollisionRepairFacility(CCRF)programishelpingcollisionrepairserviceprovidersadapt.
TheVolkswagenCCRFprogramprovidestechnicalinformationandtrainingtohelpcollisionrepairfacilitiesbetterservetheircustomers,givesdealersaprocessforensuringthattheyhavealocalcollisionserviceproviderthatcanrestoretheircustomersvehiclestoVolkswagenspecifications,andoffersassurancetovehicleownersthattheyhavebroughttheirdamagedcartotherightplace.
Information Is PowerThekeytosuccessisinformation.Automotive
technologyischangingalmostasfastascomputers.Eventhebesttechnicianneedscontinuoustrainingjusttokeepup.
Volkswagenusesadvancedhot-formedhigh-strengthandultra-high-strengthsteelsonmanyvehiclemodels.Eachrequiresdifferentrepairmethods.
Forexample,boron(atypeofhigh-strength-steel),hasalowtoleranceforheat.MIGweldingisnotrecommendedduetothisheatsensitivity.Instead,squeeze-type-resistancespotweldingispreferred,withorwithoutadhesivebondingandriveting,dependingonthecomponent.
Ifbent,boroncannotbestraightened.Itmustbereplacedasacompletestructuralmember.
ManytechniciansarenowawarethatSqueeze-TypeResistanceSpotWelding(STRSW)isthebestwaytoweldmosthigh-strengthsteel.Youneedapplication-specifictraininghowever,toknowwhetherastructuralUHSSpartcanberepairedormustbereplaced,orwheretosectionapartinordertohelpmaintaintherequiredstrengthofthefinishedrepair.
Youneedinformationthattellsyouexactlywhereandhowaframerailisattachedtootherstructuralcomponents.Withoutsuchinformation,youmaycrackorfractureaflangeseam,weakeningthebondandcompromisingthesafetyofthevehicle.
Worse,youmayattempttostraightenapartthatshouldonlybereplaced,orweldpartstogetherthatshouldbeattachedinsteadusingadhesivebondingandriveting.Someadvancedorultra-high-strengthsteelsrespondtoheatinamannerthat,unlikeregularsteel,weakensthem.
Anewdoormaylooklikeatraditionalpanel,butmaybemadeofamaterialthatyouveneverworkedon,orthatrequirescoldstraighteningratherthanheattoremovedamage.Anewroofpanelmayfeaturelayeredconstructionthatrequiresspecialattachmentmethods.
VolkswagenCCRFparticipantscanlinktoVWtechnicalandrepairinformation,researchapart,anddownloadstep-by-steprepairorreplacementinstructions.
Winning on PriceVolkswagenwantstohelpensuretheuseofGenuine
VWpartsinafter-collisionrepairsbecausetheyhelpkeeprepairqualityhigh.CCRFparticipantsmustusenewVolkswagenpartsforaminimumof90percent(indollars)ofthefinalrepairorder.
Tohelpmakeiteasierforserviceproviderstomeetinsurerdemands,VWoffersapricematchingprogram.PartoftheVWOEPartsConnection,theprogramallowsCCRFparticipantstopurchaseGenuineVWpartsatalowerpricethatsatisfiestheinsurer.
Thisprice-matchingarrangementisawholesalesupportprogramfordealers.Itisalsoabusiness-buildingfeatureforcollisionfacilities,anditisavailableonlytoCCRFprogramparticipants.
Like a Factory RobotAsrecentlyasfifteenyearsago,mostcollisionshops
usedframemachinesthatattachedtothevehicleateachcornerandperhapsafewadditionalpoints.Asaresult,apullinthefrontmayhaveaffectedmeasurementsintheoppositecornerattherear.
Todaysdedicatedframebenchhasmanymoreattachmentpoints.Thetechniciantypicallypullsasectionthatisrarelymorethanafootawayfromthenearestanchorpointalongthecomponentslength.Itisnolongernecessarytoinspectormeasuretheotherendofthevehicleaftereverypull.
TheVolkswagenCertifiedCollisionRepairFacilityprogramrequirestheuseofabenchwithfixturesthatarespecifictoindividualVolkswagenmodels.Fixturesandjigsholdthevehicleinplaceandhelp
PhotosCourtesyofJimEllisCollisionCenter,aVWCCRFinAtlanta,Georgia.
vwparts.com
24 Collision
allowthetechniciantoplacethestructuralmemberbeingrepairedorreplacedinonlyonepositionwithfactorymeasurementprecision.
CeletteandCar-O-LinerarethetwoframebenchesapprovedintheCCRFprogram.CelettemanufacturesaVolkswagen-dedicatedbench,andCar-O-Linermakesauniversalbenchthat,withoptionalVW-specificfixturesandjigs,canpinpointaframerailaswellasafactoryrobot.
BothmanufacturersdeveloptheirequipmentusingVolkswagenchassisblueprints.Eachbenchofferszerotoleranceplacementsofstructuralcomponents,andcandetectdamagesosmallthatitmaynoteasilybefoundwithotherequipment.
Themodel-specificjigsaddtimetotheprocessofsettingupthebench,soshopsmustrecoverthatcost.ShopestimatorspresentinsuranceadjusterswiththestructuralcomponenttolerancelimitspublishedinVolkswagenvehiclespecifications,plusthenecessityofadedicatedfixturebenchtoaccomplishrepairswithinthosefactorytolerances.Ithelpsadjustersrecognizetheneedtoallowextralabortimeforsetup.
Selling Peace of MindCCRFparticipantspromotetheprogramdirectlyto
vehicleownersasassurancethattheyarebringingtheirvehiclestotherightplace.TheyeducatetheircustomersabouthowtheirVolkswagen-trainedtechnicians,accesstoOEMtechnicalandrepairinformation,anduseofgenuineVolkswagencollisionpartscombinetohelpensurethattheircollision-damagedvehiclewillberestoredtolike-newcondition.
SellingpeaceofminddirectlytothevehicleownergivesCCRFparticipantsapotentialallyinanydiscussionwiththeinsuranceadjusteraboutwhetherornotaspecificrepairprocedureorpartisnecessary.Ifyouveexplainedthatthetraditionalframemachineisnotasaccurateasyourcompany-approveddedicatedCar-O-LinerorCelettebench,andthatthegenuineVWpart,likeasuitthathasbeenalteredtofityourbody,isexactlywhatyourcustomerscarneeds,ithelpsovercomepriceargumentstheadjustermaypitchtothevehicleowner.
The Smart WayInadditiontoaframebenchthatsdedicatedtoVW
vehicles,Volkswagenlistsafewothercommon-senserequirementsforthecollisionrepairfacility.Therearemorespecialtoolsrequired,butthelistbelowhitsafewhighlights.
Fullyencloseddowndraftpaintspraybooth
Dedicatedpaintmixingroomwithairextractionavailable
Company-approvedpaintsupplier(seebelow) Squeeze-Type-Resistance-Spot-Welder(STRSW) SmartSpotWelder
Checkyourrepairinformationforlocationsofsound-deadeninginsulationintherepairarea,andreplaceitifmissingordamaged.
VolkswagenprovidescreativesignagethathelpspromotetheCCRFprogramtovehicleowners.
DuPont Refinish Standox Spies Hecker Akzo Nobel-Sikkens
Akzo Nobel-Lesonal PPG NEXA BASF-Glasurit RM-Diamond
VWoA Approved Paint Suppliers
ASmartSpotWelderisdesignedfortwo-sidedorsingle-sidedspotweldingonmultipletypesofmetal,includingadvancedhigh-strengthsteels.Asmartspotweldersensesthesheetthicknessandmaterialtype(HSS,UHSS,boron,etc.)andautomaticallyselectsthecorrectweldpower,timeandtippressureforthematerialbeingwelded.Theresnoguessworkrequired,evenwherethereiscorrosionprotectionbetweenmetallayers.
Boronsteelishardenoughthatitcanquicklywearoutthecuttingedgesofconventionalspotwelddrills,cutters,andreciprocatingsaws.Youllneedstrongerspotweldbitsanddrillbitsformakingrivetholesinboron.
Volkswagendoesnotusealotofaluminumforstructuralcomponentsandbodypanels.So,unlikecertifiedcollisionrepairprogramsformanyotherOEMs,thereisnorequirementforamajorinvestmentinequipmentandtoolsforworkingaluminum.
Market OpportunityVolkswagenisnotputtingacertifiedcollisioncenter
oneverycorner.Therearemanymarketswithno,oronlyoneortwo,VolkswagenCCRFparticipants.Inthosemarkets,thecertifiedshopsdrawbusinessfromawiderareathanthetypicalnon-certifiedcollisionrepairfacility.
VWdealersthathavenoin-housebodyandpaintcapabilityrefertheircustomerswithcollision-damagedvehiclestoCCRFshops.IndependentcollisionshopsthathavenothadVolkswagenrepairtrainingsendvehicleswithdamageinsensitiveareastoCCRFshops.
Yellowarrowsshowwherethefrontwheelapronisseparatedfromtheenginemountsupportthatconnectstotheupperinnerstructure.Ifthedentisminor,thepartmaybestraightenedandwelded.Ifthemetalhasahardline,orkinkinsteadofaslightdepression,theapronmustbereplaced.Ifhowever,themetalhasonlyaslightcurvature,thedamagemaybelightenoughtoallowstraightening.
Thisfactory-appliedseamsealeronthewheelapronprovidescorrosionprotection.Themetalhastorninseveralareas,butmayberepaired.Itwillbereattachedusingadhesivebondingandriveting.
Notethedamagedandmissingpaintabovetheweldandtheimpressionsinthemetalwheretheboltswereoriginallytorqueddown.Theblackimpactbar(bumpersupport)hasbeendamagedinafrontcollisionandmustbereplacedtomeetsafetyrequirements.Iftheimpactalsobenttherailenoughtocreateakinkinthemetal,thatcancauseworkhardeningandbrittleconditionsinthedamagedarea.Ifso,therailcannotbestraightened,andmustbereplaced.
vwparts.com
26 Collision
weldingoradhesivebondingandrivetingtechniques,andhowotherfactorssuchasnearbysensitiveelectronicsmayaffectthechoiceofrepairprocedure.
TalktotheownersoffacilitiesthathavealreadyqualifiedfortheCCRFprogram,andtheywilltellyouitisworthit.
Helpyourcustomersbetterunderstandcollisionrepairissues,andthereasonsthatOEpartsarerecommended.
Smartshopownersdonotwanttheriskthatcomeswithworkingonavehicleforwhichtheirtechnicianshavenotbeentrained.Theliabilityifastructuralcomponentorelectricalsystemisnotrepairedproperlyisastrongincentivetonottaketherisk.
A Certified TeamTobecomeacertifiedVWcollisionrepaircenter,a
shopmustalsoagreetokeepitstechniciansup-to-dateasnewtechnologyisintroducedonVolkswagenvehicles.Thetrainingexplainshowtoworkwiththedifferentmetalsonspecificvehiclemodels,whentousecertain
TheCar-O-LinerQuick42isabenchthatofferstheprecisionanddurabilityrequiredforcollisionrepairs,andisapprovedbyVW.ItiscompatiblewithspeciallydesignedfixturesintheVAS6528systemthatmakeitadaptableforbothstructuralandcosmeticVWrepair.PhotocourtesyofCar-O-Liner.
TheCelettebenchallowsquickattachmentandadjustmentofitsstraighteningbrackets,gaugesystem,crossmembers,towersandwedges.ItpositionsthefixturesatthepropermeasurementpointsforpreciserepaironanyVWmodel.PhotocourtesyofWarrenBarbee,VolkswagenCollisionTraining.
Youllneedasqueeze-type-resistant-spot-welder(STRSW)suchastheElekTronSpotWelder,whichisapprovedbyVW.STRSWequipmentcanworkusinglessheatthanaMIGwelder,makingitflexibleenoughforuseonavarietyofmetals,includingultra-high-strengthsteel(UHSS).
V7 N1 Winter 2015
27Volkswagen TechConnect
28 AuthorizedVolkswagenofAmericaDealers
AlabamaBirminghamSerra Volkswagen(205) 856-6520
HuntsvilleHiley VW of Huntsville(265) 881-1881
MobileDean McCrary Imports(251) 471-3326
MontgomeryJack Ingram Motors, Inc.(334) 277-5700
TuscaloosaVolkswagen of Tuscaloosa(205) 345-8040
Vestavia HillsRoyal Volkswagen(205)978-4141
AlaskaAnchorageKendall VW of Anchorage(907) 272-5522
ArizonaAvondaleLarry H. Miller VW Avondale(623) 215-1600
FlagstaffFindlay Volkswagen(928) 522-2735
GilbertBerge Volkswagen(480) 835-5010
SanTan Volkswagen(480) 786-8900
PeoriaPeoria Volkswagen(623) 875-4005
PhoenixCamelback Volkswagen(602) 277-8081
Volkswagen North Scottsdale(480) 538-4760
ScottsdaleChapman Volkswagen(480) 949-7600
TucsonChapman Volkswagen(520) 748-1000
Larry H. Miller VW Tucson(520) 670-3600
ArkansasFt. SmithBill White Imports(479) 648-3510
Little RockOwens-Murphy Volkswagen(501) 661-0303
N. Little RockNorth Point Volkswagen(501) 955-5314
RogersVW of Northwest Arkansas(479) 631-0101
CaliforniaAlhambraVolkswagen Alhambra(626) 407-0500
BakersfieldFamily Volkswagen(661) 617-6200
CarlsbadBob Baker Volkswagen(760) 438-3113
Cathedral CityVolkswagen of Palm Springs(760) 770-1100
CerritosMcKenna Cerritos VW(562) 653-9000
ChicoChico Volkswagen(530) 891-6275
City of IndustryPuente Hills Volkswagen(626) 839-8438
ClovisClovis Volkswagen(559) 314-1465
ColmaSerramonte Volkswagen(650) 746-3000
CoronaCardinale Way Volkswagen(951) 279-1220
CovinaBozzani Motors(877) 589-2611
DublinDublin Volkswagen(925) 829-0800
El CajonMossy Volkswagen El Cajon(619) 401-5000
Elk GroveElk Grove Volkswagen(916) 405-2650
EncinitasHerman Cook VW, Inc.(760) 753-4439
EscondidoMossy Volkswagen(760) 745-8012
FairfieldVolkswagen of Fairfield(707) 402-7100
FolsomFolsom Lake Volkswagen(214) 507-6730
FresnoMichael Volkswagen(559) 431-7511
Garden GroveVolkswagen of Garden Grove(877) 331-5415
GlendaleNew Century Volkswagen(818) 552-6265
HawthornePacific Volkswagen(310) 531-9471
HaywardTeam VW of Hayward(510) 300-2732
Huntington BeachMcKenna Volkswagen(714) 842-2000
IndioCoachella Valley Volkswagen(760) 200-4000
IrvineFladeboe Volkswagen(949) 830-7300
Long BeachTimmons Volkswagen(888) 489-5001
Los AngelesVW of Downtown L.A.(213) 747-7246
MercedMerced Volkswagen(209) 384-2000
ModestoCentral Valley Volkswagen(209) 526-3503
Moreno Valley Volkswagen of Moreno Valley(951) 485-4188
MurrietaVolkswagen of Murrieta(951) 894-4723
NapaHanlees Volkswagen(707) 253-1467
National CitySouth Bay Volkswagen(619) 336-4030
NewarkWinn Volkswagen(510) 668-8080
North HillsGalpin VW of SF Valley(818) 895-3800
OaklandVolkswagen of Oakland(510) 834-7711
OntarioOntario Volkswagen(909) 230-5659
OrangeVolkswagen of Orange(714) 453-3800
PalmdaleAntelope Valley Volkswagen(661) 274-2524
PasadenaVolkswagen Pasadena(866) 654-8591
Redwood CityBoardwalk Volkswagen(650) 364-0100
RichmondHilltop Volkswagen(510) 283-6300
RiversideRiverside Volkswagen(951) 688-9420
RosevilleRoseville Volkswagen(916) 774-2777
SacramentoNiello Volkswagen(800) 423-1453
SalinasCardinale Volkswagen(831) 449-0118
San BernardinoVW of San Bernardino(909) 380-8030
San DiegoCity Volkswagen(800) 927-2277
Volkswagen Kearny Mesa(858) 300-8160
San FranciscoRoyal Motor Sales(415) 241-8154
San JoseCapitol Volkswagen(408) 265-4400
Volkswagen of Stevens Creek(408) 248-6500
San Juan CapistranoCapistrano Volkswagen(949) 493-4511
San Luis ObispoPerry VW of San Luis Obispo(805) 544-5200
San RafaelSonnen Motorcars, Inc.(800) 660-6521
Santa AnaCommonwealth Volkswagen(714) 565-7503
Santa BarbaraSanta Barbara Volkswagen(805) 966-6164
Santa CruzVolkswagen of Santa Cruz(831) 426-5100
Santa MariaCommunity Volkswagen(805) 348-3221
Santa MonicaVolkswagen Santa Monica(310) 828-0553
Santa RosaHansel VW of Santa Rosa(707) 578-1320
SeasideCals VW of Monterey(831) 394-6666
StocktonVolkswagen of Stockton(209) 242-9700
SunnyvaleSunnyvale Volkswagen(408) 739-7321
Thousand OaksNeftin Volkswagen(805) 497-9404
TracyTracy Volkswagen(209) 229-7920
VacavilleVacaville Volkswagen(866) 947-2787
ValenciaParkway Volkswagen(661) 253-4441
Van NuysVolkswagen of Van Nuys(818) 780-7137
VenturaVentura Volkswagen(805) 642-6707
Walnut CreekDirito Bros. Walnut Creek VW(925) 934-8224
Woodland HillsLivingston Volkswagen, Inc.(818) 992-5951
ColoradoAuroraTynans Volkswagen, Inc.(303) 341-3213
BoulderGebhardt Volkswagen(303) 444-1644
Colorado SpringsAl Serra Volkswagen(719) 380-6085
Bob Penkhus Volkswagen(719) 473-9901
DenverEmich Volkswagen(303) 758-7739
Fort CollinsEd Carroll Motor Company, Inc.(970) 226-3000
Glenwood SpringsElk Mountain Motors(970) 384-5354
GreeleyEhrlich Vehicles, Inc.(970) 346-3571
LakewoodLarry H. Miller VW Lakewood(303) 234-1311
LittletonMcDonald Automotive Grp VW(303) 795-1100
ThorntonOMeara VW of Thornton(303) 438-5200
ConnecticutCantonMitchell Volkswagen(860) 693-5904
DanburyDanbury Volkswagen(203) 546-6530
EnfieldLia Volkswagen(860) 745-2000
GlastonburyGene Langan VW, Inc.(860) 633-0261
GreenwichNew Country VW of Greenwich(203) 302-1390
HartfordVolkswagen of Hartford(860) 543-6000
MeridenLangan VW Meriden, LLC(203) 237-0261
New MilfordNew Milford VW, Inc.(860) 354-3977
North HavenMontesi Motors Inc.(203) 281-0481
Old SaybrookVolkswagen of Old Saybrook(860) 388-3400
PlainfieldCentral VW of Plainfield(860) 564-4014
PlainvilleCrowley Volkswagen, Inc.(860) 747-1607
StamfordPrestige VW of Stamford(203) 327-2500
StratfordCurran Volkswagen, Inc.(203) 378-6516
VernonLangan VW of Vernon, LLC(860) 645-0261
WatertownValenti Motors, Inc.(860) 274-9846
DelawareDoverWinner Volkswagen of Dover(302) 734-4761
WilmingtonSmith Volkswagen, Ltd.(800) 637-8093
District of ColumbiaWashingtonOurisman VW of Bethesda(301) 652-2452
FloridaBradentonBoast Volkswagen(941) 755-8585
ClearwaterLokey Volkswagen(727) 450-7991
Coconut CreekGunther VW of Coconut Creek(954) 590-3835
DavieRick Case VW Weston(954) 903-5500
Daytona BeachFields Volkswagen(386) 523-0500
Delray BeachAutoNation VW Delray(561) 266-2712
Fort LauderdaleGunther Volkswagen(954) 797-1646
Fort MyersVolkswagen of Fort Myers(239) 433-8308
Fort Walton BeachLee Volkswagen(850) 243-3171
GainesvilleVolkswagen of Gainesville(352) 433-4926
HolidayVW of New Port Richey(727) 234-4200
JacksonvilleOSteen Volkswagen(904) 322-5100
Tom Bush Regency Motors(800) 874-7129
Volkswagen of Orange Park(904) 269-2603
Lake ParkSchumacher Automotive, Inc.(561) 622-8220
LakelandLakeland Volkswagen(863) 688-8111
LeesburgLeesburg Volkswagen(352) 360-7150
MelbournePrestige Volkswagen(321) 309-8989
MiamiDeel Volkswagen(305) 444-2222
Esserman International VW(305) 477-6666
Palmetto57 Volkswagen(305) 474-8989
South Motor Company of Dade County(305) 256-2370
NaplesVolkswagen of Naples(239) 435-3202
OcalaVolkswagen of Ocala(352) 861-0234
OrlandoDavid Maus Volkswagen(407) 581-4321
David Maus VW North(407) 644-2222
Napletons VW of Orlando(407) 591-3990
PensacolaPete Moore Imports(850) 457-1000
Pompano BeachVista Motor Company(954) 942-3517
Port CharlottePort Charlotte Volkswagen(941) 743-8883
Saint AugustineVW of Saint Augustine(904) 495-7070
SanfordNapletons VW of Sanford(407) 365-3300
SarasotaSuncoast Volkswagen(941) 923-1700
SpringfieldVolkswagen of Panama City(850) 763-2388
St. PetersburgBert Smith International(727) 527-1111
StuartWallace Volkswagen(772) 219-0007
TallahasseeCapital Volkswagen(850) 574-3777
TampaBrandon Volkswagen(813) 630-4000
Kuhn Volkswagen(800) 678-3275
Reeves Import Motorcars, Inc.(813) 933-2817
West Palm BeachSchumacher Volkswagen(561) 615-3319
GeorgiaAlpharettaNalley VW of Alpharetta(678) 795-3472
AtlantaJim Ellis VW of Chamblee(770) 458-6811
BogartVolkswagen of Athens(706) 549-6600
For a dealer location in your area you can also go to http://www.vw.com/find-a-dealer/.
BufordGunther VW Mall of Georgia(678) 745-9950
ColumbusCarl Gregory Volkswagen(706) 243-3979
DaltonAl Johnson Volkswagen, Inc.(706) 278-9200
KennesawJim Ellis VW of Kennesaw(770) 370-4900
Lithia SpringsHeritage Volkswagen(770) 745-1470
MaconButler Volkswagen, Inc.(478) 781-7701
MariettaJim Ellis VW of Marietta(770) 955-2580
MartinezGerald Jones VW, Inc.(706) 228-6900
SavannahVaden Volkswagen(912) 629-6989
SnellvilleStone Mountain Volkswagen(770) 979-2000
Union CityHeritage Volkswagen, Inc.(770) 774-0758
ValdostaPipkins Motors, Inc.(229) 242-9920
HawaiiHonoluluHonolulu Volkswagen(808) 687-6289
WaipahuTony Volkswagen(808) 680-7177
IdahoBoiseBoise Volkswagen(208) 377-4977
Idaho FallsTeton Volkswagen(208) 522-4501
Post FallsParker VW of North Idaho(208) 773-4939
Twin FallsTwin Falls Volkswagen(208) 735-3900
IllinoisBensenvilleLarry Roesch VW of Bensenville(630) 279-8806
ChicagoFletcher Jones Volkswagen(312) 628-4997
The Autobarn City VW(773) 794-7850
CountrysideAutobarn VW of Countryside(708) 354-6600
Crystal LakeVolkswagen Of Crystal Lake(815) 455-4330
DixonDixon Volkswagen(815) 288-3366
Downers GrovePugi Volkswagen(630) 598-9900
EvanstonThe Autobarn Ltd. - VW(847) 570-3081
GlenviewJennings Volkswagen, Inc.(847) 729-3500
GurneeGurnee Volkswagen(847) 855-1500
Highland ParkVolkswagen of Highland Park(847) 433-7900
JolietDArcy Volkswagen(815) 741-1100
LibertyvilleLiberty Import Center(847) 680-8000
MarionVolkswagen of Marion(618) 551-5100
Mount ProspectAutobarn VW of Mount Prospect(888) 744-3820
NapervilleBill Jacobs Volkswagen(800) 519-4879
NormalVW Bloomington Normal(800) 345-1679
OFallonAuffenberg Volkswagen(618) 622-4645
Oak LawnMike Haggerty VW, Inc.(708) 425-8989
Orland ParkVolkswagen of Orland Park(708) 428-5000
OttawaSierra Volkswagen, Inc.(815) 433-1666
PeoriaVolkswagen of Peoria(309) 243-1101
RockfordLou Bachrodt Volkswagen(815) 332-3001
SchaumburgFox Valley VW Schaumburg(224) 353-2481
SpringfieldGreen On Dirksen, Ltd.(217) 523-3643
UrbanaOBrien Volkswagen(800) 386-6767
West ChicagoFox Valley Volkswagen(630) 818-4181
IndianaBloomingtonRoyal VW of Bloomington(812) 332-9251
ClarksvilleSam Swope VW of Clarksville(812) 948-1541
EvansvilleD-Patrick, Inc.(812) 473-6500
Fort WayneVorderman Volkswagen(260) 969-6065
GreenwoodDreyer & Reinbold of Greenwood(317) 885-4809
HighlandHighland Volkswagen(219) 237-2200
IndianapolisFalcone Volkswagen(317) 263-0002
Tom Wood Volkswagen(317) 688-6109
LafayetteMike Raisor Imports(765) 447-0808
MerrillvilleTeam Volkswagen(888) 805-3689
MishawakaGurley-Leep Volkswagen(574) 254-7130
MuncieVolkswagen of Muncie(765) 216-3320
IowaCedar FallsDick Witham Volkswagen(319) 277-8123
DavenportVolkswagen of Quad Cities(563) 386-1511
HiawathaVolkswagen of Cedar Rapids(319) 743-6050
Iowa CityCarousel Motors(319) 354-2550
JohnstonLithia VW of Des Moines(515) 253-0333
Mason CitySchukei Volkswagen(641) 423-5402
Sioux CityVolkswagen of Sioux City(712) 255-3000
KansasLawrenceCrown Volkswagen(785) 843-7700
OlatheBud Brown Volkswagen(913) 393-8183
TopekaSunflower Motors, Inc.(785) 266-8480
WichitaSteven Volkswagen(316) 681-1211
KentuckyFlorenceKerry Volkswagen(859) 371-8191
LexingtonDon Jacobs Volkswagen(859) 260-2621
LouisvilleBachman Volkswagen(502) 719-7250
Neil Huffman VW, Inc.(502) 448-6666
LouisianaBaton RougeSouthpoint Volkswagen(800) 291-0032
Bossier CityMoffitt Volkswagen, Inc.(318) 746-2175
LafayetteSouthwest Volkswagen(337) 456-7535
Lake CharlesVolkswagen of Lake Charles(337) 419-1818
MandevilleNorthshore Volkswagen(985) 626-1067
MarreroRay Brandt VW Westbank(504) 349-7272
MetairieWalker Volkswagen(504) 465-2000
MaineAuburnRowe Volkswagen(207) 784-2321
AugustaOConnor Volkswagen(207) 622-6336
BangorDarlings, Inc.(207) 941-1330
BrunswickMorong Brunswick(207) 725-4323
FalmouthMorong Falmouth VW(207) 781-4020
SacoPrime Volkswagen(207) 283-2900
WatervilleThompson Volkswagen, Inc.(207) 873-0777
MarylandAnnapolisFitzgerald Automall(410) 224-3480
BaltimoreHeritage VW Parkville(410) 661-3400
Russel Volkswagen(410) 744-2300
BethesdaOurisman VW of Bethesda (202) 537-3000
Capitol HeightsPohanka VW of Ritchie Stn.(301) 899-7900
CockeysvilleVolkswagen of Hunt Valley(410) 666-7777
FallstonCook Volkswagen, LLC(410) 877-1500
FrederickFitzgerald Volkswagen(301) 696-9200
GaithersburgKing Volkswagen(240) 403-2300
HagerstownSharrett Volkswagen(301) 739-9999
LaurelOurisman VW of Laurel(800) 288-6985
Owings MillsHeritage Volkswagen(410) 581-6696
PasadenaAntwerpen Volkswagen(410) 553-0843
RockvilleOurisman VW of Rockville(301) 340-7668
SalisburyPohanka VW of Salisbury(410) 548-3400
Silver SpringDARCARS Volkswagen(301) 622-7000
WaldorfWaldorf Volkswagen(301) 843-8950
MassachusettsAuburnPatrick Motors(800) 367-7222
BedfordMinuteman Volkswagen, Inc.(781) 275-8000
BraintreeQuirk Volkswagen(781) 917-1537
BrocktonPaul Clark, Inc.(508) 587-9040
DanversKelly Volkswagen(978) 774-2600
Fall RiverMattie Imports, Inc.(508) 678-5555
HanoverCoastal Volkswagen(781) 871-4600
HyannisTracy Volkswagen, Inc.(508) 775-3049
LawrenceCommonwealth Volkswagen(978) 687-3001
MedfordColonial VW of Medford(781) 475-5208
North AttleboroVW of North Attleboro, Inc.(508) 695-0321
NorthamptonNorthampton Volkswagen(413) 586-3102
NorwoodVolkswagen Gallery(800) 240-0382
PittsfieldFlynn Volkswagen(413) 443-4702
RaynhamMetro Volkswagen(508) 967-2800
TewksburyAtamian Volkswagen, Inc.(978) 851-4356
WatertownBoston Volkswagen(617) 783-1300
WellesleyWellesley VW, Incorporated(781) 237-3553
West SpringfieldFathers & Sons, Inc.(413) 737-7766
WestboroughColonial Volkswagen(508) 366-8383
MichiganAnn ArborVolkswagen of Ann Arbor(888) 822-8707
Bay CityThelen Volkswagen(989) 684-2980
DearbornLaFontaine VW of Dearborn(313) 996-6000
EscanabaHalbinsel Volkswagen(906) 789-9650
Farmington HillsSuburban VW of Farmington Hills(248) 471-0800
Grand BlancVolkswagen of Grand Blanc(810) 694-5600
Grand RapidsBetten Imports, Inc.(616) 301-2100
Gezon Volkswagen(616) 361-7361
HollandCrown Volkswagen(616) 393-0400
KalamazooMaple Hill Volkswagen(269) 327-0816
LansingWilliams Volkswagen, Inc.(800) 258-2853
LivoniaRalph Thayer Volkswagen(734) 425-5400
MonroeElite Volkswagen(734) 242-3900
MuskegonVolkswagen of Muskegon(231) 799-2886
Rochester HillsFox Volkswagen(248) 656-0400
Sterling HeightsVyletel Volkswagen, Inc.(586) 276-4650
Traverse CityTraverse City Volkswagen(231) 946-5540
TroySuburban Volkswagen, Inc.(248) 649-2074
MinnesotaAlbert LeaDave Syverson VW, Inc.(507) 373-1438
BrainerdAuto Import, Inc.(218) 829-3307
Brooklyn ParkBrookdale Volkswagen(763) 331-6400
BurnsvilleBurnsville Volkswagen, Inc.(952) 892-9470
HermantownVolkswagen of Duluth(218) 722-6989
Inver Grove HeightsVolkswagen of Inver Grove(651) 204-4607
MankatoMankato Volkswagen(507) 625-5641
MaplewoodSchmelz Countryside VW(651) 484-0424
RochesterRochester Motors, LLC(507) 282-9468
Saint CloudEich Motor Company, Inc.(320) 251-1737
Saint Louis ParkLuther West Side Volkswagen(952) 374-0700
MississippiDlbervilleVW of South Mississippi(228) 864-6622
JacksonVolkswagen Jackson(601) 368-3691
MissouriBallwinThe Dean Team of Ballwin(636) 227-0100
ColumbiaJoe Machens VW of Columbia(816) 668-1818
GladstoneNorthtowne Volkswagen(816) 436-2275
HazelwoodBommarito VW of Hazelwood(314) 731-7777
Kansas CityMolle Volkswagen(816) 941-9500
KirkwoodThe Dean Team of Kirkwood(314) 966-0303
SpringfieldVolkswagen of Springfield(417) 886-6000
St LouisSuntrup Volkswagen(314) 892-7790
St. PetersBommarito VW of St. Peters(636) 928-2300
MontanaBillingsVolkswagen Billings(406)655-7500
BozemanVolkswagen of Bozeman(406) 586-1771
Great FallsTaylors Automax VW (406) 727-0380
MissoulaKarl Tylers Missoula VW(406) 721-2438
WhitefishDePratu Volkswagen(406) 863-2520
NebraskaLa VistaPerformance Volkswagen(402) 502-8671
LincolnSchworer Volkswagen(402) 435-3300
OmahaStan Olsen Auto Center(402) 397-8200
NevadaHendersonFindlay Volkswagen(702) 558-6600
Las VegasAutoNation VW Las Vegas(702) 942-4000
Findlay North Volkswagen(702) 982-4800
RenoLithia Volkswagen of Reno(775) 851-5826
New HampshireGreenlandSeacoast Volkswagen, Inc.(603) 436-6900
KeeneNoyes Volkswagen, Inc.(888) 355-2488
LebanonMiller Volkswagen(603) 448-6363
ManchesterQuirk Volkswagen(800) 842-9600
MerrimackAutofair VW of Nashua(603) 943-8700
RochesterVolkswagen of Rochester(603) 332-6242
TiltonAutoServ Volkswagen(800) 775-3141
New JerseyBernardsvillePaul Miller VW of Bernardsville(908) 766-1600
BridgewaterOpen Road VW of Bridgewater(908) 685-1068
BurlingtonBurlington Volkswagen, Inc.(609) 386-0084
Cape May Court HouseBurke Brothers, Inc.(609) 463-4903
Cherry HillCherry Hill Volkswagen(856) 654-5660
CliftonGensinger Motors, Inc.(973) 778-8500
EdisonReydel Volkswagen, Inc.(732) 287-2444
Englewood CliffsEast Coast Volkswagen(201) 568-0053
FairlawnJack Daniels Motors, Inc.(201) 398-1209
FlemingtonFlemington Volkswagen(908) 782-2400
FreeholdVolkswagen of Freehold(732) 339-6910
Hamilton SquareHamilton Volkswagen(800) 348-8816
LyndhurstThree County VW Corp.(201) 933-6566
MonroevilleVolkswagen of Salem County(856) 358-8103
NeptuneWorld Volkswagen(732) 922-1500
NewtonVolkswagen of Newton(800) 842-0562
PleasantvilleAtlantic Volkswagen(609) 646-8600
Pompton PlainsCrestmont Volkswagen(973) 839-6444
PrincetonPrinceton Volkswagen(609) 921-6401
RamseyJoe Heidt Motors, Corp.(201) 327-2900
RockawayTrend Motors, Ltd.(866) 448-7363
RoselleLinden Volkswagen(908) 486-6201
ShrewsburyShrewsbury Volkswagen(732) 741-8500
SummitDouglas Motors Corp.(800) 672-1172
Toms RiverWorld VW of Toms River(732) 575-1800
TurnersvillePrestige Volkswagen(856) 629-9200
UnionUnion Volkswagen(908) 687-8000
New MexicoAlbuquerqueUniversity Volkswagen, Inc.(505) 761-1900
Uptown Volkswagen(505) 260-5057
Las CrucesSisbarro Autoworld, Inc.(575) 524-3561
Santa FeVolkswagen of Santa Fe(505) 471-7007
New YorkAmherstNorthtown Volkswagen(716) 836-4600
AmityvilleLegend Volkswagen(631) 691-7700
BaysideBayside Volkswagen(516) 482-3346
BowmansvilleSchmitts Volkswagen(716)683-3343
BronxTeddy VW of the Bronx, LLC(718) 920-1400
BrooklynBay Ridge Volkswagen(718) 351-7000
Volkswagen of Brooklyn(718) 646-6700
CiceroBurdick Volkswagen(800) 233-2002
East RochesterVW of East Rochester(585) 586-2225
EndicottGault Volkswagen(607) 321-6450
FayettevilleRomano VW of Fayetteville(315) 637-4668
GlenmontCapital Cities Imported Cars, Inc.(518) 463-3141
GreenburghLash VW of White Plains(914) 931-9700
HicksvillePlatinum Volkswagen(516) 822-4800
Huntington StationVolkswagen of Huntington(631) 470-8100
IthacaMaguire Volkswagen(607) 257-1515
KingstonVolkswagen of Kingston(845) 336-6600
LathamMartin Nemer VW Corp.(518) 785-5581
LockportBasil Volkswagen of Lockport (716) 625-8444
LynbrookSunrise Volkswagen, Inc.(516) 596-5970
MiddletownCompass Volkswagen(845) 344-4440
Mohegan LakeMohegan Lake Motors, Inc.(914) 528-2528
New YorkOpen Road VW of Manhattan(646) 358-8100
NyackPalisades Volkswagen(845) 689-3536
OneontaVolkswagen Oneonta(607) 432-8100
Orchard ParkVolkswagen of Orchard Park(716) 662-5500
PleasantvillePrestige Imports(914) 769-5100
QueensburyGarvey Volkswagen, Inc.(518) 793-3488
RensselaerCooley Motors Corp.(518) 283-2902
RiverheadRiverhead Bay Volkswagen(631) 727-5590
RochesterDorschel Volkswagen(585) 334-9440
RomeVolkswagen of Rome, Inc.(315) 337-8900
SayvilleDonaldsons, Inc.(631) 567-8100
SchenectadyFuccillo VW of Schenectady(518) 374-9161
St. JamesSmithtown Volkswagen(631) 724-6600
Staten IslandOpen Road VW of Staten Island(718) 513-7515
Wappingers FallsHudson Valley Volkswagen(845) 298-2365
WatertownF.X. Caprara Volkswagen(315) 788-7400
West IslipAtlantic Volkswagen(631) 650-3400
WoodsideKoeppel Volkswagen, Inc.(718) 728-5300
YorkvilleSteet Ponte Volkswagen(315) 736-8291
North CarolinaAshevilleVolkswagen of Asheville(828) 232-4002
BurlingtonFlow VW of Burlington(336) 290-7878
CaryLeith Volkswagen(919) 297-1640
CharlotteCarolina Volkswagen(800) 489-2336
VW of South Charlotte(704) 552-6500
ConcordHendrick VW of Concord(704) 456-3300
DurhamSouthern States VW of Durham(888) 998-0075
FayettevilleValley Volkswagen(910) 867-7000
GoldsboroFrema Motors, Inc.(919) 778-1010
GreensboroFlow Motors of Greensboro(336) 856-9050
GreenvilleJoe Pecheles VW, Inc.(252) 756-1135
HickoryParamount Automotive Group(828) 328-4012
HuntersvilleKeffer Volkswagen(704) 766-2129
JacksonvilleNational Volkswagen(910) 938-1417
RaleighLeith Volkswagen of Raleigh(919) 828-0828
WilmingtonBob King Volkswagen(910) 392-3889
Winston-SalemFlow Motors of W-S, LLC(336) 761-3698
North DakotaBismarckVolkswagen of Bismarck(701) 258-1944
FargoValley Imports, Inc.(701) 277-1777
OhioAkronDave Walter Volkswagen(330) 434-8989
AmherstSpitzer Volkswagen(440) 988-4444
BedfordGanley VW of Bedford(440) 439-3444
BoardmanVolkswagen of Boardman(330) 726-8948
BrunswickBrunswick Volkswagen(330) 273-3300
CantonKempthorn Volkswagen(330) 580-4916
CincinnatiBeechmont Volkswagen(513) 347-4477
Kings Volkswagen(513) 677-2710
Northland Volkswagen(800) 521-7278
ColumbusByers Imports(614) 552-5410
Hatfield Volkswagen(614) 465-8989
DaytonEvans Volkswagen(937) 890-6200
White-Allen European Auto Grp(937) 291-6000
DublinMidwestern Auto Group(800) 394-2571
FairfieldFairfield Volkswagen(888) 932-4734
HudsonCollection VW of Hudson(330) 342-7000
MentorClassic Volkswagen(440) 205-6504
North OlmstedGanley Westside Imports, Inc.(440) 734-2000
PerrysburgEd Schmidt Volkswagen(419) 874-4331
SpringfieldBill Marine Auto Center, Inc.(937) 325-7091
SteubenvilleSunset Motors Incorp(740) 264-1696
Willoughby HillsEastside Volkswagen(440) 944-8700
WoosterVolkswagen of Wooster(330) 264-1113
OklahomaNormanFowler VW of Norman(405) 310-3700
Oklahoma CityCable Volkswagen(405) 787-0095
Oklahoma CityVolkswagen of Edmond(405) 529-5600
TulsaDon Thornton VW of Tulsa(918) 712-8989
OregonBeavertonHerzog-Meier Volkswagen(503) 372-3298
BendVolkswagen of Bend(541) 382-1711
CorvallisVolkswagen of Corvallis(541) 757-1415
EugeneSheppard Motors(541) 343-8811
GladstoneArmstrong Volkswagen(503) 656-1215
McMinnvilleMac Volkswagen(503) 472-4657
MedfordLithia Volkswagen(541) 774-7500
PortlandDick Hannahs VW of Portland(503) 256-3700
SalemVolkswagen of Salem(503) 581-1421
PennsylvaniaAllentownFaulkner-Ciocca Volkswagen(800) 554-7165
ArdmorePiazza VW of Ardmore(601) 642-4275
ButlerMikan Volkswagen(724) 287-4763
ColmarNorth Penn Imports, Inc.(800) 887-2111
DanvilleJack Metzer Volkswagen(570) 275-2212
DevonFred Beans Volkswagen(800) 803-9829
DowningtownJeff DAmbrosio Volkswagen(610) 873-2400
EastonYoung Volkswagen, Inc.(610) 991-9140
EdgemontYBH Sales and Service, Inc. (610) 356-9000
ErieNew Motors, Inc.(800) 352-1052
FeastervilleColonial Volkswagen, Inc.(215) 355-8856
GreensburgSendell Volkswagen(724) 837-9500
HarrisburgSutliff Volkswagen(877) 203-5832
HollidaysburgFiore Volkswagen(814) 695-5533
KingstonWyoming Valley Motors(570) 288-7411
LancasterAutohaus Lancaster, Inc.(717) 299-0325
LanghorneVolkswagen Langhorne(800) 298-4300
LebanonH.A. Boyd, Inc.(717) 273-9385
LeesportVolkswagen Reading(610) 777-6500
McMurrayThree Rivers Volkswagen(724) 941-6100
MechanicsburgFaulkner VW of Mechanicsburg(717) 697-9448
MonroevilleDay Volkswagen(724) 327-4950
MontoursvilleFairfield Volkswagen(570) 368-8121
Moon TwpDay Apollo, Volkswagen(412) 264-0253
New KensingtonHillcrest Volkswagen, Inc.(724) 335-9847
Newton SquareY B H Sales & Service, Inc.(610) 356-3493
NorristownWynn Volkswagen(610) 539-4622
OrwigsburgJ. Bertolet, Inc.(570) 366-0501
Philadelphia Chapman Volkswagen(215) 698-7000
PittsburghCochran Volkswagen(412) 245-3333
ScrantonKelly Volkswagen(570) 347-5656
State CollegeVolkswagen State College(814) 237-0368
WarringtonThompson Volkswagen(215) 343-1600
West Chester (Chadds Ford)Garnet Volkswagen(610) 361-0624
WexfordCochran VW of Wexford(724) 940-1000
WhitehallGilboy VW of Whitehall(610) 434-4211
YorkYork Volkswagen, Inc.(866) 893-2337
Puerto RicoSan JuanFlagship Volkswagen(787) 620-7010
Volkswagen Kennedy(787) 782-4087
Rhode IslandEast ProvidenceScott Volkswagen(401) 434-8678
WakefieldSpeedcraft Volkswagen(401) 792-3300
West WarwickBalise Volkswagen(401) 822-4400
South CarolinaColumbiaMcDaniels Volkswagen(803) 786-6408
Wray Volkswagen(800) 424-0183
FlorenceVolkswagen of Florence(843) 292-4200
GreenvilleSteve White Volkswagen(864) 288-8300
HardeevilleHilton Head Volkswagen(843) 288-0500
Mount PleasantLow Country VW, LLC(843) 881-8555
Myrtle BeachEast Coast Volkswagen(843) 215-6500
North CharlestonStokes Volkswagen(843) 767-2525
SpartanburgVic Bailey Volkswagen(864) 585-2492
SumterGoodwin Volkswagen, Inc.(803) 469-2595
South DakotaRapid CityLiberty Volkswagen(605) 718-1000
Sioux FallsGraham Automotive(605) 336-3655
TennesseeBristolWallace Volkswagen(423) 764-1145
ChattanoogaVillage VW of Chattanooga(423) 855-4981
ClarksvilleGary Mathews North, Inc.(931) 552-1111
FranklinHallmark VW at Cool Springs(615) 236-3200
Johnson CityWallace VW of Johnson City(423) 952-0888
KingsportFairway Volkswagen(423) 378-1800
KnoxvilleHarper Volkswagen, Inc.(865) 691-5569
MadisonHallmark Volkswagen, Inc.(615) 859-3200
MemphisGossett Volkswagen(901) 388-8989
Gossett VW of Germantown(901) 333-8989
MurfreesboroSoutheast Signature Motors, Inc.(615) 898-0700
TexasAbileneVolkswagen of Abilene(325) 673-4663
AmarilloStreet VW of Amarillo(806) 350-8999
ArlingtonRandy Hiley VW of Arlington(817) 575-6100
AustinMaund Automotive Group(512) 420-2409
Onion Creek Volkswagen(512) 814-2900
BeaumontVolkswagen of Beaumont(409) 833-7100
BrownsvillePayne Volkswagen(956) 350-4488
BryanGarlyn Shelton Imports(979) 776-7600
Corpus ChristiVW of Corpus Christi(361) 653-8400
DallasAutoNation VW Park Cities (214) 561-8100
El PasoHoy-Fox Automotive Market(915) 778-7788
Rudolph VW of El Paso(915) 845-8500
Fort WorthAutobahn Motorcar Group(817) 336-0885
GarlandRusty Wallis Volkswagen(972) 271-6767
GeorgetownHewlett Volkswagen(512) 681-3510
HoustonArcher Volkswagen(713) 272-1750
DeMontrond Automotive Grp, Inc.(281) 872-3909
Momentum Volkswagen(713) 596-3380
Momentum VW Jersey Village(281) 925-5160
Momentum VW of Clear Lake(281) 848-5660
West Houston Volkswagen(281) 675-8600
IrvingMetro Volkswagen(800) 527-7287
KilleenAutomax Volkswagen(254) 699-2629
LaredoAncira Volkswagen of Laredo(956) 712-2400
LewisvilleLewisville Volkswagen(972) 538-0550
LongviewGorman-McCracken VW(903) 753-8657
LubbockGene Messer Volkswagen(806) 793-8844
McKinneyRandall Reeds VW of McKinney(800) 565-9807
MissionPayne Mission(956) 584-6300
OdessaSewell VW of Midland-Odessa(432) 498-0189
RichardsonAutoNation VW Richardson(214) 453-5020
San AntonioAncira Volkswagen(210) 681-5050
North Park Volkswagen(210) 581-1000
VW of Alamo Heights(210) 824-1971
TempleGarlyn Shelton Volkswagen(254) 773-4634
TexarkanaOrr Volkswagen of Texarkana(903) 792-4174
The WoodlandsVW of The Woodlands(936) 321-6500
TylerCrown Motor Company(903) 561-3422
WeatherfordVolkswagen of Weatherford(817) 458-5400
Wichita FallsHerb Easley Motors, Inc.(940) 723-6631
UtahLaytonCutrubus Motors VW(877) 725-1234
OremKen Garff Motors(801) 374-1751
Salt Lake CityStrong Volkswagen, Inc.(801) 433-2269
South JordanVolkswagen SouthTowne(801) 676-6409
St. GeorgeFindlay Volkswagen(435) 986-8850
VermontBarreWalker Volkswagen(802) 223-3434
Manchester CenterHand Volkswagen(802) 362-1754
RutlandKinney Motors, Ltd.(802) 775-6900
South BurlingtonVW South Burlington(802) 658-1130
VirginiaAlexandriaAlexandria Volkswagen(703) 684-7007
CharlottesvilleFlow Volkswagen(434) 296-4147
ChesapeakeSouthern VW Greenbrier(757) 366-0833
FairfaxFairfax Imports, Inc.(703) 273-6700
FredericksburgVW of Fredericksburg(540) 898-1600
LynchburgTerry Volkswagen(434) 239-2601
Newport NewsCasey Volkswagen(757) 988-1275
RichmondBrowns Volkswagen(804) 379-6610
West Broad Volkswagen(804) 270-9000
RoanokeFirst Team Volkswagen(800) 277-0717
South ChesterfieldPriority Volkswagen(804) 518-9329
SpringfieldSheehy VW of Springfield(703) 451-2389
StauntonValley Volkswagen(540) 886-2357
SterlingLindsay VW of Dulles(703) 880-8160
ViennaStohlman Volkswagen, Inc.(703) 287-4115
Virginia BeachCheckered Flag Volkswagen(757) 490-1111
WinchesterBeyer Volkswagen(540) 868-3000
WoodbridgeKaren Radley Volkswagen(703) 550-0202
WashingtonAuburnAuburn Volkswagen(800) 827-2787
BellevueChaplins Bellevue VW(425) 641-2002
BellinghamRoger Jobs Volkswagen, Inc.(360) 734-5230
BremertonParr Volkswagen(360) 377-3855
BurlingtonKarMart Volkswagen(360) 757-0815
EdmondsCampbell Nelson VW, Inc.(425) 778-1131
EverettPignataro Volkswagen(425) 348-3141
KennewickOverturf Motor Company, Inc.(509) 586-3185
KirklandVolkswagen of Kirkland(425) 898-2500
OlympiaVolkswagen of Olympia(360) 508-0223
Port AngelesDan Wilder Volkswagen, Inc.(360) 452-9268
SeattleCarter Volkswagen, Inc.(206) 782-7474
University Volkswagen(206) 634-3322
Spokane ValleyAutoNation VW Spokane(509) 892-2243
TacomaRobert Larsons Autohaus(253) 671-6420
Volkswagen of Puyallup(253) 268-1802
VancouverDick Hannah Volkswagen(360) 314-0450
YakimaSteve Hahn Performance VW(509) 248-4700
West VirginiaClarksburgVolkswagen Clarksburg(304) 623-7827
HuntingtonMoses Volkswagen(304) 736-5244
ParkersburgLarry Simmons, Inc.(304) 485-5451
South CharlestonJoe Holland Volkswagen(304) 720-9257
WheelingWheeling Automotive(304) 242-7313
WisconsinAppletonVolkswagen Appleton(920) 733-3333
BrookfieldHall Volkswagen(888) 420-4255
Eau ClaireVolkswagen of Eau Claire(715) 852-2361
FranklinBoucher Volkswagen(414) 525-1100
Green BayBroadway Imports(920) 498-6666
JanesvilleFrank Boucher VW of Janesville(608) 757-6120
La CrosseBob Burg Volkswagen(608) 782-8806
MadisonZimbrick VW of Madison(608) 443-5781
Menomonee FallsErnie Von Schledorn VW(262) 253-8976
MiddletonZimbrick Volkswagen(608) 836-7777
MilwaukeeConcours Motors(414) 290-1400
OshkoshVolkswagen of Oshkosh(920) 966-2000
RacineFrank Boucher Volkswagen(262) 886-2886
SheboyganMotorville, Inc.(920) 457-8844
Stevens PointScaffidi Motors(715) 344-4100
WausauKocourek Wausau Imports, Inc.(715) 359-1669
WyomingCasperFremont Volkswagen(307) 233-4300
Chip Foose has been wowing enthusiasts for years with his innovative color solutions.
BASF has been doing the same with its unique color management system, led by
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Like Chip Foose, BASF Brings A Little Extra To The Party.
Foose, Chip Foose, Foose Design and the Chip Foose signature are registered trademarks of Foose Design Inc., and are used with permission.
2012 BASF Corporation.
