Maintenance Procedures Audi TT 8N

Servicing

Note. The order in which the individual operations are given has been tested and represents the optimum working sequence. This sequence should therefore be followed to avoid unnecessary work interruptions. The sequence of operations given is based on that specified for the Inspection Service, which is the type of service most frequently required. Always inform the customer if faults or malfunctions, which require repair, are identified during the Inspection Service.

Engine specifications

1) Premium unleaded gasoline with 95 RON can also be used, but will cause a slight loss of power.

Overview of Oil Changes and Maintenance to my 2001

1) or 6 months after delivery, whichever occurs first.

2) or 12 months after delivery, whichever occurs first.

3) or 12 months after the least Maintenance Service, whichever occurs first.

The intervals shown in this table are based on vehicles operating under normal conditions. In case of severe conditions, such as extremely low temperatures, excessive dust, etc., it is necessary for certain operations to be carried out in between the given intervals. This applies particularly to engine oil changes and the cleaning or replacing of the air cleaner filter element.

Overview of Oil Changes and Maintenance from my 2002

1) Maintenance at 10,000 miles (16,000 km) or 1 year after delivery, whichever occurs first.

2) Maintenance at 20,000 miles (32,000 km) or 2 years after delivery, whichever occurs first.

The intervals shown in this table are based on vehicles operating under normal conditions. In case of severe conditions, such as extremely low temperatures, excessive dust, etc., it is necessary for certain operations to be carried out in between the given intervals. This applies particularly to engine oil changes and the cleaning or replacing of the air cleaner filter element.

30-day Inventory Maintenance

Check, correct if necessary

Exterior

1. Windows, doors, trunk, hood and sunroof are fully closed
2. Body surfaces clean and free of environmental damage, scratches, etc.
3. Engine compartment is clean
4. Tires for proper inflation pressure

1. Battery condition static voltage minimum 12.5 volts (Recharge if necessary - if battery is dead, disconnected or below 10 volts, use VAG 1551 / VAS 5051 to reset engine and transmission management systems to basic setting).

Interior

1. All accessories, lights turned off
2. Interior surfaces clean and free of damage
3. Start engine, check idle and A/C operation
4. Check automatic transmission shifting operation

1. Drive vehicle minimum of one mile. Apply brakes several times at 20 mph to clean rotors
2. Verify disposable floor mats are in place
3. Affix next 30 day sticker*

* Perform the 30-Day Maintenance every 30 days (i.e. 30, 60, 90, etc.) until the vehicle is purchased.

Pre-Delivery Inspection Procedure

> Service Circular Maintenance Schedule for appropriate model year

Oil Change and Maintenance Service

> Additional Information, Maintenance Schedule for appropriate model year

Emission Control Maintenance Schedule / Vehicle Maintenance Schedule

> Additional Information, Maintenance Schedule for appropriate model year

Lights, electrical equipment, switches, displays and other driver-operated controls, testing operation

The following components must be checked

1. Lighting, headlights, fog lights, turn signals, hazard warning lights, tail lights, rear fog light, reversing lights, brake lights, parking light function
2. Interior lights and reading lights (automatic cut-out for front interior light), glove box light, ashtray light, luggage compartment light, ignition key light
3. Warning buzzer indicating that lights and/or radio have been left on
4. All switches on console

1. Driver Information System (DIS)
2. Instrument cluster including all displays, counters, lights and illumination
3. Dual-tone horn
4. Windshield wiper/washer system, headlight washer system

1. Cigarette lighter
2. Electric exterior mirrors (heated, adjustable)
3. Electric window lifters
4. Central locking, remote control (radio-operated), automatic open/close function

1. Heated seats
2. Radio

Windshield wiper/washer system and headlight washer system, checking operation and adjusting washer jet settings

Note. If the wiper blades shudder or make a noise when tested, check the contact angle of the wiper blades. Refer to Wiper blade contact angle, adjusting .

Note. Do not use a pin or other sharp objects, as these will damage the washer jets.

Windshield washer jet settings

1. Mark the top of the area where the spray jets should contact the glass using a water-soluble marker pen.

Scheme 1

1. Adjust the height setting of the washer jet (fan-shaped spray pattern) using a screwdriver.

Note. The distance is measured from the washer jet.

Scheme 2

Distance

a - 400 mm

Headlight washer system, checking washer jet settings

The headlight washer jets are set by the manufacturer and therefore do not need to be adjusted.

Windshield washer/headlight washer system, topping off fluid

1. Fill container to the top with washer fluid.

Note. The water used must contain a pH-neutral windshield cleaner additive (antifreeze additive in winter).

Wiper blades, checking park position and checking for damage

Park position for windshield wiper blades

1. Switch windshield wipers on and off, allowing wiper arms to return to park position.

Scheme 3

1. Check the distances between the ends of the wiper blades -1- and the plenum chamber cover -2- at the bottom of the windshield. This distance should be as follows

Distance a = 15-25 mm

Note. The layout is symmetrically opposite for right-hand drive vehicles.

1. If necessary, loosen the wiper arm, align it correctly and tighten the securing nut again.
2. Operate "brief wipe" function and check the settings.

Wiper blade contact angle, adjusting

Note. Possible causes for wiper blade skip: Windscreen scratched Wiper blade rubber has become detached from arm or is split Wiper arm/blade loose or bent Wiper blades coated with wax or worn out

If the wiper blades are skipping and none of the causes listed apply, check and if necessary adjust the contact angle of the wiper arms before installing new wiper blades.

Scheme 4

Special tools, testers and auxiliary equipment required

1. Wiper adjuster 3358 B.

Checking contact angle

1. Move wiper arms to park position.
2. Remove wiper blades.

Scheme 5

1. Insert wiper arm -2- in wiper arm adjusting appliance 3358 B and secure with locking screw -3-.
2. Compare angle indicated with specification in the table

Contact angle specifications

Adjusting wiper arms

1. Move wiper arms to park position.
2. Remove wiper blade.

1. Insert wiper arm -2- in wiper arm adjusting appliance 3358 B and secure with locking screw -3-.
2. Place open ended wrench -1- (24 mm A/F) over adjusting appliance and adjust contact angle of wiper arm -2- (arrows) according to specifications. Specifications. Refer to «Contact angle specifications»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures)
3. Loosen locking screw -3- and remove wiper arm -2- from adjusting appliance.
4. Insert wiper arm -2- in wiper arm adjusting appliance 3358 B again and secure with locking screw -3-.

1. Compare indicated angle with specification. Refer to «Contact angle specifications»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures) .
2. If necessary, repeat setting and checking procedure until angle is as specified.
3. Remove adjusting appliance and install wiper blade.

Electric window lifters, checking positions

The electric window lifters "forget" their current positions and the automatic open/close function when the battery is disconnected.

Activate the automatic open/close function as follows

1. Switch ignition on.
2. Close windows all the way to their top positions using the electrical switches.
3. Operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
4. Press switch to open window.

The side window should move all the way down automatically.

Scheme 6

The clock is in the rev counter dial. Set the time with adjuster knob -1-.

Digital clock

Setting the hour

1. Pull the knob.

The hour display will flash.

1. Turn the knob clockwise or counter-clockwise to change the hour display as required.

Setting the minute

1. Pull the knob repeatedly until the minute display flashes.
2. Turn the knob clockwise or counter-clockwise to change the minute display as required.

Setting the date

1. Pull the knob repeatedly until the day, month or year flashes.
2. Turn the knob clockwise or counter-clockwise to change the day, month or year as required.

Switching date display on or off

1. Pull out the knob repeatedly until the date display flashes.
2. Turn the knob counter-clockwise to switch off the date display and turn clockwise to switch on the date display.

Setting (on or off) will be stored after about 15 seconds.

Radio-controlled clock

Note

The radio-controlled clock can work in two different modes: either as a normal quartz clock or with a radio remote-control signal.

The clock automatically switches to the radio remote-control mode when it receives a strong enough radio signal. The radio control symbol (a radio tower with radio waves) will then appear in the display. If the clock cannot receive an adequate radio signal it will automatically switch to the normal clock mode after three days, and the radio control signal will disappear.

Air conditioner, checking operation and setting temperature to 72 ° F (22 ° C)

1. Check all air conditioner functions.

Refer to Owner's Manual

Scheme 7

1. Check whether display area -2- is set to 72 ° F. (22 ° C).
2. If necessary, adjust the temperature setting as follows
3. Press button -3- for automatic operation.

The letters AUTO should appear in display area -2-.

1. Set temperature to 72 ° F. (22 ° C).: turn control -1- counter-clockwise for "colder" and clockwise for "warmer."

Radio, activating anti-theft coding by entering fixed code number

The radio units are supplied with a fixed code. "Fixed code" means that each radio unit with an anti-theft coding is programmed with its own code number. This fixed code is not activated when the radio leaves the factory.

The security coding of the ready-to-operate radio is activated by entering the fixed code.

1. Activate the fixed code as follows

Radio "chorus," "concert:"

1. Switch radio unit on.
2. Press buttons FM2 and RDS simultaneously and hold until "1000" appears on the display, then release the buttons.
3. Use radio station buttons 1 to 4 enter the code number which is on the radio card. Button 1 is used to enter the first digit of the code number, button 2 for the second digit, and so on.
4. Press buttons FM2 and RDS simultaneously again and hold until "SAFE" appears on the frequency display.

1. Release the buttons. After a brief delay a frequency will appear automatically.

Connecting VAG 1551

1. Driver's storage compartment, bottom left.

Scheme 8

1. Check that ignition is switched off, then connect VAG 1551 scan tool using test lead VAG 1551/3.
2. Switch on the printer by pressing the PRINT button (indicator lamp in button should light up).

Indicated in display

1) appears alternately

1. Enter "1" to select "Rapid data transfer."

Checking DTC memory

1. Start engine and allow to run at idling speed.
2. Enter "00" to select the address word "Automatic test sequence" and confirm entry with -Q- button. The VAG 1551 will transmit all the known address words one after the other.

When a control unit answers with its identification the number of stored DTCs appears on the display or "No DTC recognized."

Any system malfunctions that are stored will be displayed one after the other and printed out. The VAG 1551 will then transmit the next address word.

When the following display appears the automatic test sequence is completed

1) appears alternately

1. Switch ignition off.

If DTCs have been stored they must be rectified. The DTC print-out will be needed to enable the work to be carried out.

Note. Leave VAG 1551 scan tool connected for resetting the service interval display and for the exhaust emissions test (if required).

Instrument cluster, setting language version

Vehicles with driver information system (DIS)

When a car is supplied to the customer the multi-function monitor display can be set to any of the following languages as required

1. German
2. English
3. French
4. Italian

1. Spanish
2. Portuguese

Cars are supplied by the factory with the multi-function monitor set to English.

The procedure for changing the language version is as follows

1. Connect VAG 1551. Refer to «Connecting VAG 1551»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__connecting-vag-1551) .
2. Switch ignition on.
3. Enter -1- to select "Rapid data transfer."
4. Enter -1- and -7- to select the address word "Dash panel insert" and confirm entry with -Q- button.

1. Press --> button twice to advance the program sequence.
2. Enter -1- and -0- to select the function "Adaptation" and confirm entry with -Q- button.
3. Enter -0- and -4- to select Adaptation channel 04 and confirm entry with -Q- button.

Indicated on display

1. Press --> button to advance the program sequence.

Indicated on display

1. Select the language version by entering the required code according to the following table

Note. The first four digits must be "0." If an incorrect code is entered the "Adaptation" function will be terminated automatically and must be re-started.

Example

1. Enter "00002."

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Press --> button to terminate Adaptation of language version.

Indicated on display

Service interval display, resetting

The "SERVICE" display must be reset as part of the Delivery Inspection and after every Service Inspection (oil change + inspection).

Delivery Inspection

There are two possible methods of resetting the "SERVICE" display

1. Using the adjustment buttons for the trip recorder and clock on the dash panel insert

1. Reset "SERVICE IN XXXX km" or "SERVICE". Refer to «Resetting service interval display with adjustment buttons for trip recorder and clock»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__resetting-service-interval-display-with-adjustment) .

or

1. Using VAG 1551 scan tool

1. Select Adaptation channel 02 and enter the Adaptation value "00000". Refer to «Resetting service interval display with VAG 1551»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__resetting-service-interval-display-with-vag) .

Oil change or inspection

The service reminder will first appear 2000 km before the next service is due. The display message comes up for 5 seconds in the central display.

Display message: "SERVICE IN XXXX km"

When service becomes due, the display will show: "SERVICE"

1. Connect VAG 1551. Refer to «Connecting VAG 1551»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__connecting-vag-1551) .
2. Switch ignition on.

Indicated in display

1) appears alternately

1. Enter -1- to select "Rapid data transfer."

Indicated on display

1. Enter -1- and -7- to select the address word "Dash panel insert" and confirm entry with -Q- button.

Indicated on display (example)

Resetting service interval display with VAG 1551

1. Press --> button to advance the program sequence.
2. Enter -1- and -0- to select the function "Adaptation" and confirm entry with -Q- button.

Indicated on display

1. Enter "02" to select "Adaptation" channel 02 and confirm entry with -Q- button.

Indicated on display: the display will indicate the service interval function

0 = reset service interval: dash panel display will then show "SERVICE IN 15000 KM"

1 = set service interval: dash panel display will then show "SERVICE"

1. Press --> button.

Indicated on display

1. Enter the Adaptation value as follows after completing the service

Indicated on display

The service interval is reset (adapted) by entering the following values

1. Enter the appropriate Adaptation value (00000) via the keypad to reset the service interval.
2. Press -0-, -0-, -0-, -0-, and -0- (5x) button.

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Confirm entry with -Q- button.

Indicated on display

1. Press --> button to complete resetting of service interval display.

Resetting service interval display with adjustment buttons for trip recorder and clock

1. Switch ignition off.

1. Press trip recorder reset button -3- on dash panel insert and at the same time switch on the ignition.

The central display -2- (in window for ambient temperature indicator) will show: "SERVICE IN XXXX km" or "SERVICE."

1. Release button.
2. Turn the clock adjuster knob -1- counter-clockwise or clockwise. This will reset the display "SERVICE IN XXXX km" or "SERVICE."

The display will now read: "SERVICE IN XXXX km." "XXXX" is the new fixed interval of 15,000 km.

1. Switch ignition off.

Scheme 9

1. Only grease the door arresters at the points shown in the illustration (arrow).

Lubricant: G 052 778 A2

1. Lubricate lock cylinders.

Lubricant: G 052 778 A2

Battery, checking electrolyte level and topping off with distilled water if necessary

The battery is located at the front left of the engine compartment.

Scheme 10

1. Open battery cover -A- (Velcro fastener) and push down slightly.

1. The electrolyte level should be between the MIN and MAX markings.

Note. On batteries with clearly visible MIN and MAX markings the electrolyte level can be checked visually from the outside of the battery. On batteries which do not have clearly visible MIN and MAX markings, or which have an opaque casing which makes it impossible to see the electrolyte level, remove the sealing plugs to check. Topping off with distilled water. Refer to Topping off with distilled water . The electrolyte must be level with the marking inside the battery (plastic separator). This corresponds to the MAX marking on the outside.

1. If necessary, top off the battery cells to the MAX marking with distilled water.

Topping off with distilled water

Note. The center screw plugs on the battery are covered by the bracket for the main fuse box. To remove the screw plugs, first remove the main fuse box.

1. Obtain radio code on vehicles with coded radio.

1. Open lid -B- of main fuse box toward front of vehicle.

Scheme 11

1. Loosen hex nut -1- and disconnect battery Ground strap.
2. Remove hex nut -2- and disengage fuse box retainer brackets from battery casing.
3. Remove screw plugs.
4. Use only distilled water to top off the battery electrolyte.

Note. Distilled water prevents electrolyte contamination, which causes the battery to discharge more quickly.

1. After connecting battery Ground strap, program in the radio anti-theft code. Refer to «Radio, activating anti-theft coding by entering fixed code number»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__radio-activating-anti-theft-coding-by-entering) .
2. Activate the automatic open/close function for the electric windows. Refer to «Electric window lifters, checking positions»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__electric-window-lifters-checking-positions) .
3. Set clock to correct time. Refer to «Clock, setting correct time»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures) .

Battery, checking "no load" voltage before first engine start

Test equipment required

1. Digital multimeter VAG 1315 A

or

1. Mini tester VAG 1362

or

1. Hand multimeter VAG 1526 or VAG 1526 A

Note. The vehicle must not be started or driven with the battery that is to be tested for at least 2 hours before making the measurements. The battery must not be subjected to loads from electrical equipment in the vehicle for at least 2 hours before taking the measurements. The battery must not be charged for at least 2 hours before taking the measurements.

1. Open battery cover -A- (Velcro fastening).
2. Open lid -B- of main fuse box toward front of vehicle.
3. With ignition switched off, check voltage between battery terminals.

1. If the tester indicates a voltage of 12.5 V or more, the battery is okay.
2. If the voltage is less than 12.5 V, locate the source of the problem (repair measure).

Battery, checking battery cables for secure fit (only applies to vehicles kept in stock for long periods)

1. Open battery cover -A- (Velcro fastening).
2. Open lid -B- of main fuse box toward front of vehicle.

1. Make sure that battery cable clamps are securely fitted. If necessary, tighten nuts -1- and -3-.

Scheme 12

1. Check that battery is securely installed. If necessary, tighten securing bolt -3- on retainer plate -2-.

Engine cover, removing

1. Loosen nuts (arrows) and remove engine cover.

Scheme 13

4-cylinder gasoline engine ATC

Engine and engine compartment, visual check for leaks and damage (from above and below)

Carry out a visual check as follows

1. Remove engine cover. Refer to «Engine cover, removing»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__engine-cover-removing) .
2. Check engine and engine compartment for leaks and damage.
3. Check the pipes, hoses and connections of the following systems for leaks, chafing, porosity and brittleness

1. Fuel system
2. Cooling and heating system
3. Brake system

1. Carry out a visual check of the same components from below with the vehicle on a lift and the noise insulation removed.

Engine coolant system, checking antifreeze and topping off with coolant if necessary

Note. All engines are filled with antifreeze and corrosion protection fluid G 012 A8 D meeting specification TL VW 774 D. When topping off, always use G 12 (red fluid).

Checking coolant level and adding coolant if necessary

Scheme 14

1. Check coolant level on expansion tank while the engine is cold.

Delivery Inspection

Coolant level at MAX marking.

Inspection Service

Coolant level between MIN and MAX markings.

1. If coolant is too low, add required amount according to mixture ratio.

Mixture ratio

Note. If the fluid in the expansion tank is brown, this means that G 012 A8 D has been mixed with another type of coolant. In this case, flush out the cooling system and put in new coolant (repair measure). To flush the system, fill it with clean water and run the engine for about 2 minutes. This should remove practically all of the old coolant. G 012 A8 D and coolant additives marked "meeting specification TL VW 774 D" prevent frost and corrosion damage, stop scaling and at the same time raise the boiling point of coolant. For these reasons the cooling system must be filled all year round with the correct anti-freeze and anti-corrosion additive. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Notes (continued): Frost protection must be guaranteed to around - 25 ° C (in countries with arctic climates down to around - 35 ° C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40%. If greater frost protection is required in very cold climates, the amount of G 012 A8 D can be increased, but only up to 60 % (this gives frost protection to about -40 ° C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.

Checking anti-freeze and adding coolant additive if necessary

1. If the degree of frost protection is too low, drain off the required quantity as specified in the frost protection table (Refer to «Frost protection table»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures) ) and add coolant additive G 012 A8 D conforming to TL VW 774 D.

Note. Observe environmental requirements for disposal.

Frost protection table

1. After test drive check coolant additive concentration.

Air cleaner, cleaning housing and replacing filter element

4-cylinder gasoline engine ATC

All models

Scheme 15

1. Release hose clamp -3- and pull off air hose.
2. Disconnect connector -1- on air mass meter.
3. Loosen bolts -2- and lift off air cleaner cover.
4. Take out old filter element.

Note. Observe environmental requirements for disposal.

1. Clean filter housing and install new filter element.

Spark plugs, replacing

Special tools required

1. Spark plug wrench 3122 B

Note. Spark plug identification. Refer to 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA . Observe environmental requirements for disposal.

4-cylinder gasoline engine (turbo) ATC

1. Remove engine cover. Refer to «Engine cover, removing»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__engine-cover-removing) .
2. Disconnect vacuum hose -2- from vacuum reservoir.
3. Unbolt vacuum reservoir -3- and detach from bracket.
4. With ignition switched off, disconnect connectors from ignition coils.

Scheme 16

1. Unbolt ignition coils -1-.
2. Remove spark plugs with spark plug wrench 3122 B.
3. Screw in new spark plugs with spark plug wrench.
4. Install ignition coils. Replace the seals if damaged.

1. Check that ignition cables and spark plug connectors are securely fitted.

Hydraulic system, checking for leaks, checking fluid level and if necessary topping off hydraulic fluid

Fluid level for power-assisted steering

If fluid is cold

1. Do not start engine but bring front wheels to straight-ahead position.

If fluid is at operating temperature (above approx. 50 ° C)

1. Start engine and bring front wheels to straight-ahead position.

Scheme 17

1. Remove filler cap with dipstick using a screwdriver (arrow).
2. Clean dipstick off with a clean cloth.
3. Screw cap on hand tight and remove again.

1. Check fluid level.

If fluid is cold

1. The fluid level must be around the MIN marking (up to 2 mm above or below the marking).

If fluid is at operating temperature (above approx. 50 ° C)

1. The fluid level should be between the MIN and MAX markings.

Note. The cap must be fully screwed on in order to obtain an accurate fluid level reading. If the fluid level is above the area specified, the excess fluid must be extracted.

1. If the hydraulic system has no leaks, top off with G 002 000.
2. Screw cap on hand tight.

Dust and pollen filter element, replacing

The filter is located beneath the plenum chamber cover on the right.

1. Pull off rubber seal upward as far as center of vehicle.

Scheme 18

1. Lift movable section -A- of plenum chamber cover.
2. Press back the two retainer lugs -B- (only one of the lugs is visible in the illustration).
3. Remove dust and pollen filter element -C- from housing.

Note. Observe environmental requirements for disposal. The plenum chamber cover and the scuttle trim must be correctly fitted to ensure that no water enters the dust and pollen filter or the heating system. The dust and pollen filter must be installed the right way round in frame -B-, i.e. with the arrow markings -A- pointing in the air flow direction.

1. Install new filter element.
2. Install the plenum chamber cover and rubber seal.

Scheme 19

Some models are supplied with transport locks fitted in the front suspension struts. These vehicles are identified by a warning tag on the mirror (arrow).

1. Relieve the load on the coil springs (e.g. by raising the vehicle on a lifting platform).

Note. It is not necessary to remove the wheels. Make sure not to damage the surfaces of the springs.

Scheme 20

1. Pull the transport locks (arrows) off the springs.

Noise insulation, removing

1. Remove screws (arrows) and remove noise insulation.

Scheme 21

4-cylinder gasoline engines

Manual transmission/final drive, checking oil level and topping off if necessary

1. Remove and remove oil filler plug (arrow).

Specification: oil level should be up to the bottom of the hole.

Scheme 22

5-speed manual transmission 02J front wheel drive

Scheme 23

5 and 6 speed transmission 02M All Wheel Drive

1. If the transmission has no leaks, top off with SAE 75 W 90 (synthetic oil), specification G 052 145 S2 (1 Liter).

Automatic transmission/final drive, checking oil level and topping off if necessary

6 speed transmission 02E Direct Shift Transmission

Scheme 24

1. Remove and remove oil filler plug (arrow).

Specification: oil level should be up to the bottom of the hole.

1. If the transmission has no leaks, top off with Gear oil for Direct Shift Transmission 02E, Part number - G 052 182 A2
2. Reinstall and tighten oil filler plug.

Scheme 25

Special tools and equipment

1. VAG 1331 Torque wrench
2. VAG 1551 Scan tool
3. VAG 1551/3A Cable
4. VAG 1628 Oil gun

1. Heavy-duty oil for Haldex clutch

0.25 liter container: Part No. G 052 175 A1

Safety measures when using testers

Checking oil level in Haldex clutch

1. Switch ignition off.
2. Use diagnostic cable VAS 5051 to connect vehicle diagnostic, testing and information system VAS 5051 or diagnostic cable VAG 1551/3A to connect VAG 1551 Scan Tool.

Note. The Data Link Connector (DLC) is located in the front left knee guard.

1. Select address word 22 for All Wheel Drive electronics.
2. Start function 08 for reading measured value block and select display group number 002. (Select display group number 001 if temperature is not displayed)

Indicated on display

The third display field indicates the oil temperature.

1. Oil temperature must be 20 to 40 ° C
2. Oil temperature can be attained by warming up the engine

Scheme 26

1. Remove oil inspection plug (arrow)

Oil level is OK if the Haldex clutch is filled up to the bottom edge of the inspection hole or to a minimum level of approx. 3 mm below the bottom edge of the inspection hole.

Note. If the oil level is incorrect, change the oil in the Haldex clutch: Refer to Changing oil in Haldex clutch .

1. Install plug (arrow).

Tightening torque

Changing oil in Haldex clutch

1. Switch ignition off.

1. Use diagnostic cable VAS 5051 to connect vehicle diagnostic, testing and information system VAS 5051 or diagnostic cable VAG 1551/3A to connect VAG 1551 Scan Tool.

Note. The Data Link Connector (DLC) is located in the front left knee guard.

1. Select address word 22 for All Wheel Drive electronics.
2. Start function 08 for reading measured value block and select display group number 002. (Select display group number 001 if temperature is not displayed)

Indicated on display

The third display field indicates the oil temperature.

1. Oil temperature must be 20 to 40 ° C
2. Oil temperature can be attained by warming up the engine

1. Place drip tray in position.

1. Remove oil drain plug (arrow) and drain oil.
2. Insert 0.25 liter oil cartridge in oil gun VAG 1628.
3. Have drain plug with new sealing ring ready.

Scheme 27

1. Insert tip of oil gun VAG 1628 (arrow) perpendicularly into oil drain hole.
2. Pump complete amount of oil in cartridge into Haldex clutch.
3. Place oil gun VAG 1628 aside and immediately thread in drain plug with new sealing ring.

Tightening torque

1. Check oil level in Haldex clutch. Refer to «Checking oil level in Haldex clutch»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__checking-oil-level-in-haldex-clutch) .

Changing oil filter for Haldex clutch

Special tools and equipment

Scheme 28

1. T10066 Wrench

Removing

1. Place drip tray in position.
2. Use wrench T10066 to loosen and remove oil filter.

Installation position: Oil filter -A- is located on the right side of the vehicle next to the front mounting bracket -B- (concealed by subframe).

Installing

1. Moisten gasket of new oil filter with oil for Haldex clutch.
2. Install oil filter -A- and tighten using wrench T10066.
3. Check oil level in Haldex clutch. Refer to «Checking oil level in Haldex clutch»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__checking-oil-level-in-haldex-clutch) and if necessary change oil in Haldex clutch. Refer to «Changing oil in Haldex clutch»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__changing-oil-in-haldex-clutch) .

Engine oil, draining or extracting, and oil filter, changing

Special tools required

1. Hazet strap wrench 2171-1

or

1. Oil filter wrench 3417
2. Oil extractor VAG 1307 A or VAG 1358 A

Note. Use suction probe VAG 1358 A/4 (outer diameter 10 mm) to speed up the extraction process. Observe environmental requirements for disposal.

4-cylinder gasoline engines

1. Remove noise insulation. Refer to «Noise insulation, removing»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__noise-insulation-removing) .
2. Loosen oil filter with strap wrench (e.g. Hazet 2171-1) or with oil filter wrench 3417 and remove oil filter.

Note. Observe environmental requirements for disposal.

1. Remove oil drain plug or extract engine oil.
2. Clean sealing surface on engine for oil filter.
3. Lightly oil rubber seal.
4. Screw in new filter and tighten.

1. Screw in new oil drain plug with new seal.

Note. Capacity with oil filter change. Refer to 17 ENGINE - LUBRICATION for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU, BEA 17 ENGINE - LUBRICATION for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC, AWP Fill up with engine oil; specifications. Observe notes for engines with turbocharger.

Brake system, visually checking for leaks and damage

1. Check the following components for leaks and damage

1. Brake master cylinder
2. Brake servo
3. ABS hydraulic unit
4. Brake calipers

1. Ensure that brake hoses are not twisted.
2. Ensure that brake hoses do not touch any vehicle components when steering is on full lock.
3. Check brake hoses for porosity, blistering and brittleness.
4. Check brake hoses and pipes for chafing.

1. Check brake pipe connections and mountings for correct seating, leaks and corrosion.

Brake pads, checking thickness

Scheme 29

Front disc brake pads

a - Pad thickness including backing plate

Wear limit: 7 mm

Scheme 30

Rear disc brake pads

a - Pad thickness including backing plate

Wear limit: 7 mm

All models

1. Determine thickness of outer pad by checking visually using a flashlight through wheel cut-out.
2. Determine thickness of inner pad by checking visually using a flashlight and mirror.

Under coating, visually checking for damage

1. When performing visual check, check floor plan, wheel housings and chassis members.

Tie rod ends, checking play, attachment and protective boots

Note. The check must be made with the vehicle raised on a lifting platform (wheels free to move).

1. Check play by moving tie rods and wheels.

There should not be any play.

Scheme 31

1. Check that lock nut -1- is properly tightened (50 Nm).
2. Check that protective boot (arrow) is not damaged and is properly seated.

Tires (including spare), checking condition and wear pattern

Checking tires

Note. For reasons of safety, all tires on the vehicle should be of the same type and tread pattern.

Delivery inspection

1. Check tire tread surfaces and side walls for damage and remove any foreign bodies.

Inspection service

1. Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.

Checking tire wear pattern

1. The wear pattern of the front tires indicates whether the toe and camber need checking

1. "Feathering" on tread indicates incorrect toe setting.
2. One-sided tread wear is usually caused by incorrect camber.

Note. If the above types of wear are found, carry out a wheel alignment check (repair measure) to determine the cause.

Tires (including spare), checking and recording tread depths

1. Check tire tread depth.

Minimum permissible tread depth: 1.6 mm

Note. This figure may vary for individual countries according to legislation. The minimum tread depth is reached when the tires have worn down level with the 1.6 mm high tread wear indicators positioned at intervals around the tire. If the tread depth is approaching the minimum permissible depth, the customer must be informed.

Scheme 32

The correct inflation pressures for summer tires are listed on the sticker on the inside of the fuel tank filler flap.

Note. The pressures listed on the sticker apply to cold tires. When the tires are warm the actual pressures will be higher but must not be reduced. When using winter tires, pressures should be increased by 0.2 bar.

Spare wheel

Temporary (compact) spare wheel: the correct inflation pressure is indicated on the side wall.

Note. Check the valve extensions for damage and dirt which could cause leaks. Replace if necessary.

Wheel bolts, tightening to specified torque

Trim cap

Scheme 33

Puller -A- for removing the trim cap is in the vehicle tool kit.

Wheel bolts

The adapter for loosening and tightening the anti-theft wheel bolts is in the vehicle tool kit.

Note. Ensure that wheel bolts are tightened diagonally and alternately to the following tightening torque

1. After completing the work, replace adapter and puller in vehicle tool kit.

Engine oil, filling up

A high-quality multigrade oil is put in at the factory: this can be used all year round, except in extremely cold climates.

Oil Capacities > 2000

Note. Oil system capacity with filter change: 4.8 qts. (4.5 liters) Oil system capacity without filter change: 4.2 qts. (4.0 liters)

Oil Capacities 2001 >

> Additional Information, Fluid Capacity Chart for appropriate model year

Viscosity grades

Scheme 34

Select the viscosity grade of the oil according to the chart.

A - High-lubricity multigrade oils; specification. Refer to Oil specifications for vehicles with gasoline engine .

B - Multigrade oils; specification. Refer to Oil specifications for vehicles with gasoline engine .

Note. The oil does not need changing for brief variations of temperature outside the temperature ranges shown.

Viscosity grades and oil specifications

The specifications listed here must appear on the container - either singly or together with other specifications.

Note. When topping off it is permissible to mix different types of oil.

Oil specifications for vehicles with gasoline engine

A - High-lubricity multigrade oils, specification VW 500 00 1)

B - Multigrade oils, specification VW 501 011)

Multigrade oils, specification API-SJ2) or API-SL2)

1) The date given after the VW specification must be not earlier than 10.91.

2) Only use these grades of oil if the approved grades are not available.

1. Fill up with engine oil.

Engines with turbocharger

1. When the engine oil and oil filter have been changed, note the following points after starting the engine for the first time

1. Leave the engine idling and do not press the accelerator until the oil pressure warning lamp in the dash panel insert goes out. Pressing the accelerator could cause serious damage to the turbocharger.
2. The warning lamp will not go out until the full oil pressure has built up. Do not press the accelerator until the light has gone out.

1. Finally, check the engine oil level. Refer to «Engine oil, checking oil level»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__engine-oil-checking-oil-level) .

Engine oil, checking oil level

Requirements for test

1. Engine oil temperature at least 60 ° C
2. Vehicle must be level (horizontal)
3. After switching off the engine, wait a few minutes to allow the oil to flow back into the sump

1. Pull out the dipstick, wipe off with a clean cloth and insert it again as far as it will go.
2. Pull out the dipstick again and read off the oil level.

Scheme 35

Markings on oil dipstick

a - Do not top off oil.

b - Oil can be topped up. The oil level may rise as far as area -a- after topping off.

c - Oil must be topped up. It is sufficient if the oil level is somewhere in area -b- (grooved area on dipstick) after topping off.

Note. The oil level must not be above marking -a- on the dipstick.

Brake fluid level (depending upon brake pad wear), checking

Use only new genuine VW/Audi brake fluid in accordance with US standard FMVSS 116 DOT 4.

1. Check the following points

Delivery Inspection

Scheme 36

1. Fluid level must be at MAX marking

Note. The fluid level must not be above the MAX marking otherwise the fluid will overflow.

Inspection Service

When the vehicle is driven the brake fluid level will go down slightly with use and as a result of the automatic adjustment of the brake pads.

1. When checking the brake fluid level, always take into account the amount of wear on the brake pads

1. If the brake pads are new or a long way from reaching the wear limit, the brake fluid level should be between the MIN and MAX markings.
2. If the brake fluid level is at the MIN marking or slightly above it and the brake pads have almost reached the wear limit, it is not necessary to top off with brake fluid.

Brake fluid, changing

Special tools and equipment required

Scheme 37

1. VAS 5234 Brake filler and bleeder unit
2. VAS 5234/1 adapter

Scheme 38

1. Brake pedal depressor VAG 1869/2

Use new brake fluid with part number B 000 700 A (corresponds to US standard FMVSS 116 DOT 4)

Note. Part numbers are for reference only! Check with parts department for correct part number. Only use new brake fluid conforming to US standard FMVSS 116 DOT 4 Genuine VW/Audi brake fluid conforms to this specification.

Note the following

For this reason the brake fluid pressure at the VAS 5234 Brake filler and bleeder unit must be adjusted down to 1 bar. See instruction manual for VAS 5234.

1. Observe instruction manual for VAS 5234!

Scheme 39

1. Remove brake fluid reservoir cap -1-.

Scheme 40

1. Insert suction hose from VAS 5234 to extract as much brake fluid as possible from brake fluid reservoir.
2. Install VAG 1869/2 brake pedal depressor between driver's seat and brake pedal and apply tension.

Scheme 41

1. Install VAS 5234/1 adapter -1- to brake fluid reservoir then connect filler hose -2- from VAS 5234 to VAS 5234/1 adapter.

Vehicles with manual transmission

1. Pull cover cap off clutch slave cylinder bleed screw.

Scheme 42

1. Connect collecting bottle bleeder hose -1- to bleeder screw of clutch slave cylinder (arrow), open bleeder screw and allow approximately 0.1 liter (100 ml) to flow out. Close bleeder screw and install cover cap.
2. Operate clutch pedal several times.

Continued for all vehicles

1. Remove all bleeder screws.

1. Connect collecting bottle bleeder hose -1- to rear right bleeder screw, open bleeder screw and allow the appropriate quantity to flow out, then close bleeder screw.
2. Repeat procedure on rear left bleeder screw.

1. Connect collecting bottle bleeder hose -1- to front right bleeder screw, open bleeder screw and allow the corresponding quantity to flow out (see following chart), then close bleeder screw.
2. Repeat procedure on front left bleeder screw.
3. Install cover caps on brake caliper bleeder screws.

1. Move filler lever on VAS 5234 to position -B- (see operating instructions).
2. Take filler hose off VAS 5234/1 adapter.
3. Remove adapter from brake fluid reservoir.
4. Check brake fluid level and top off if necessary.

1. Reinstall brake fluid reservoir cover.
2. Remove brake pedal depressor VAG 1869/2.
3. Check pedal pressure and brake pedal free play. Free play: max 1/3 of pedal travel.

1)Total quantity: 1000 ml (2.1 quarts) (not including amount extracted from brake fluid reservoir).

Headlights, aiming using Hella Universal Beamsetter IV

Service

Align vehicle headlamps using the VAS 5107 (Hella Universal Beamsetter IV) and the following procedure

Additional instructions and diagrams. Refer to Instruction Manual for the Hella Beamsetter Series IV

Scheme 43

1. Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications

1. 0.5mm or less slant from front wheel to back wheel of the Beamsetter -A-.
2. 1mm or less slant per meter for the length of the vehicle -B-.

1. Clean headlight lenses.
2. Adjust vehicle tire pressure to specifications.

Have a second technician sit in the driver's seat while aligning the headlights.

1. Bounce front and rear of vehicle up and down several times to settle vehicle suspension.

Setting low beam alignment of driver's side headlight

1. Move Beamsetter into position in front of the vehicle so it is aligned with the vehicle and Beamsetter box is 30 to 70cm (12 to 28 in.) from the driver's side headlight.
2. Switch headlights ON in low beam position.
3. Align Beamsetter box so it is centered on the headlight (align vertically then horizontally).

Note. Use the arrows on the Beamsetter box as a guide. You may want to use a straight edge or tape measure, because alignment must be within 3cm (1.2 in.) of the center of the headlight.

1. Without moving the Beamsetter, slide Broad-band sight toward center of vehicle (Broad-band sight can also be moved up and down for a better position).

Use Broad-band sight to make final alignment of Beamsetter box to vehicle by

1. Loosening hand-wheel that locks column in place.
2. Sighting down through the slit in the Broad-band sight and rotating Beamsetter box and column until two similar points on vehicle are aligned.

Note. Try using corners of the headlight housings or two screws that are the same height and as far apart as possible on the vehicle.

1. Carefully tighten hand wheel without changing Beamsetter position.
2. Set inclination to 1.0%.
3. Set Beamsetter "Scaled wheel" to the proper low beam inclination %.
4. Adjust height (vertical) alignment first. Turn headlight height adjuster screw to align the upper edge of the flat portion of the beam with the center horizontal line of the grid on the Beamsetter pattern screen.

Note. VOL is the correct beam pattern for both right and left headlights.

Scheme 44

1. Adjust lateral (horizontal) alignment of driver's side headlight so that the peak (highest point) of the headlight beam pattern aligns with the right edge of the target box of the grid on the pattern screen (it should match the VOL pattern shown on the Beamsetter box).

Note. If the height alignment changed, readjust.

Checking driver's side headlight high beam alignment

1. Switch headlights ON in high beam position.
2. Realign Beamsetter box with the high beam headlight if necessary.

Scheme 45

1. Set Beamsetter "Scaled wheel" to 0%.
2. Cover low beam lamp (use hand or small piece of cardboard) and check that the "hot spot" of high beam pattern is centered on the square target box of the pattern screen.

Note. High beam pattern is built into the reflector design and cannot be adjusted separately.

If high beam pattern is way out of adjustment

1. Inspect for reflector damage.
2. Replace reflector if needed.

Note. Always align headlight in the low beam position.

Aligning fog lamp

1. Switch fog lamps ON.
2. Align Beamsetter box with fog lamp (make sure it is between 30 and 70cm from the fog lamp lens).

Scheme 46

1. Set Beamsetter scaled wheel to 1.4%.

Adjust fog lamp so the top of the beam pattern aligns with the center line of the target grid on the beam pattern screen.

Passenger's side headlight, alignment

1. Move Beamsetter to the passenger side of the vehicle and follow the same procedures to align the Beamsetter box to the headlight.
2. Align headlight low beam, check high beam and align fog lamp.

Note. Make sure to reset the Beamsetter "Scaled wheel" to the proper setting each time you change from low beam to high beam or to fog lamp.

1. Ensure that headlights and vehicle body are clean and free of fingerprints.

Headlights (halogen), adjusting

1. Checking and adjusting requirements observed. Refer to «Headlights, aiming using Hella Universal Beamsetter IV»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__headlights-aiming-using-hella-universal-beamsetter)

Scheme 47

1. Using Phillips-head screwdriver or hex wrench, turn adjustment screws -2- and -3- with same number of turns in same direction, until headlight beam adjustment is OK.

Headlights (gas charged Xenon), adjusting

1. Checking and adjusting requirements observed. Refer to «Headlights, aiming using Hella Universal Beamsetter IV»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures__headlights-aiming-using-hella-universal-beamsetter)

1. Connect VAG 1551 scan tool. Refer to «On Board Diagnostic (OBD), checking DTC memory with VAS 5051 or VAG 1551 scan tool»(/audi/tt/8n-1998-2003/remont/procedures/#maintenance-procedures) .
2. Switch ignition on.
3. Switch low beams on.

Indicated in display

1) appears alternately

1. Enter -1- to select "Rapid data transfer."

Indicated on display

1. Press button -5- then -5- again (2x) to insert "H. lamp vert. aim control" address word 55 and confirm input by pressing the -Q- button.

Indicated on display

Note. Note correct coding on vehicle (dependent on equipment).

Coding table

Carry out coding

Refer to 01 ON BOARD DIAGNOSTIC (OBD)

1. Press --> button.

Indicated on display

1. Press buttons -0- and -2- to select function "Check DTC Memory" and confirm input by pressing the -Q- button.

Indicated on display

1. Press --> button.

or

Indicated on display

If the printer is switched on, the stored DTCs are indicated and printed out in sequence.

After the final DTC is displayed and printed out

1. Press --> button.

Indicated on display

1. Press buttons -0- and -5- to select function "Erase DTC Memory" and confirm input by pressing the -Q- button.

Indicated on display

1. Press --> button.

Indicated on display

1. Press buttons -0- and -4- to select function "Basic Setting" and confirm input by pressing the -Q- button.

Indicated on display

1. Press buttons -0-, -0- and -1- to input display group number "001" and confirm input by pressing the -Q- button.

Indicated on display

The headlights move into adjustment position.

1. Press --> button.

Indicated on display

Note. The headlights are now in the adjustment position. Turn on the headlights. Basic setting 1 switches off control operation, and "Headlights not set" appears in the display.

1. Using Phillips-head screwdriver or hex wrench, turn adjustment screws -2- and -3- with same number of turns in same direction, until headlight beam adjustment is OK.

Fog lights

1. Switch fog lights on.

Scheme 48

Vehicle must stand at a distance x = 10 m on flat surface in front of vertical wall -Y-.

Scheme 49

For correct fog light adjustment, the light must project on the vertical wall -Y- as follows

Shaded surface: light beam of fog lamp

b - Height of optical axis (focal point) of fog lamp: adjustment dimension = 650 mm.

a - Adjustment dimension = 135 ± 15 mm below center point -b

Note. The height adjustment of the fog lights is performed with adjustment screw -1-.

1. Press --> button.

Indicated on display

1. Press buttons -0- and -4- to select function "Basic Setting" and confirm input by pressing the -Q- button.

Indicated on display

1. Press buttons -0-, -0- and -2- to input display group number "002" and confirm input by pressing the -Q- button.

Indicated on display

Note. The control module has now learned the position as the "control position." The entry in DTC memory "Headlights not set" is erased and the control operation begins again.

1. Press --> button.

Indicated on display

1. Press buttons -0- and -6- to select function "End Output" and confirm input by pressing the -Q- button.

Road test

To what extent the following can be checked is dependent upon the vehicle equipment and local conditions (urban/country).

The following points must be checked during the road test

1. Engine: performance, misfiring, idling, acceleration
2. Clutch: pulling away, pedal pressure, odors
3. Gear selection: ease of operation, gear lever position
4. Brake pedal and parking brake: operation, travel and effectiveness, puling to one side, shuddering, squeal, operation of ABS

1. Steering: operation, steering free play, steering wheel centered when wheels are in the straight ahead position
2. Cruise control system operation
3. Radio: quality of reception, SVC (Speed Compensated Volume), interference
4. Driver Information System (DIS): functions

1. Air conditioner: operation
2. Vehicle: moving off line when travelling straight ahead (level road)
3. Imbalance: wheels, drive shafts
4. Wheel bearings: noises

1. Engine: hot starting behavior

RAPGARD ® , inspection, removal and disposal

From my 2002

Service

Within 48 Hours after arrival at Dealer

Inspection

1. Inspect RAPGARD ® for damage or peeling.

If RAPGARD ® is disturbed (dented, scratched, etc.)

1. You must note the damage on the Carrier Delivery Receipt, including damage type, extent and location. Failure to note damage on the Carrier Delivery Receipt will result in non-payment of the repair.

Note. RAPGARD ® must be removed from the vehicle no later than six months after application. See sticker (location on vehicle body varies) for detailed information.

Within 72 Hours prior to delivery to the Customer

1. Remove RAPGARD ® from vehicle.
2. Wash vehicle exterior.
3. Inspect paint surfaces, moldings and glass.
4. Protect the paint surface of all new vehicles by applying 3M Perfect-It ™ Paste Wax (3M Part No. 39526) or equivalent.

Removal

1. Vehicle must be at room temperature.
2. The ideal body surface temperature for RAPGARD ® removal is 60 ° F (15.5 ° C) to 80 ° F (26.6 ° C).

If body surface temperatures are below 60 ° F (15.5 ° C) or above 80 ° F (26.6 ° C) then

1. Removal procedure should be performed indoors after surface temperatures have been allowed to stabilize within the given range.

1. Rinse vehicle thoroughly with water to remove surface dirt or dust and to help stabilize body surface temperatures.
2. Starting at the corners of each panel, carefully remove RAPGARD ® from vehicle.

RAPGARD ® , paint inspection after removal

1. Inspect painted surfaces under one of the following lighting conditions

1. Indoors under fluorescent lighting.
2. Outdoors under bright sunlight.

Important!

If any defects on the exterior have been identified (scratches, dings, dents and other types of body damage)

1. Contact your Service Manager and arrange to repair defects immediately.

Note. After removal of RAPGARD ® , some vehicles may exhibit temporary paint discoloration or paint swelling (caused by trapped moisture under the RAPGARD ® ). This temporary swelling is caused by the paint finish absorbing moisture trapped under the RAPGARD ® film. This swelling will disappear with exposure to the sun or heat lamps within 2 - 3 hours. Severe Paint swelling may require 2 - 3 days to recover.

DO NOT buff or refinish paint for this condition!

Adhesive residue removal

If RAPGARD ® adhesive residue remains on paint finish, remove with a non-abrasive polishing product such as, (3M Part No. 5995) light colors or (3M Part No. 5996) dark colors.

Thick lines of adhesive residue can be removed with general purpose adhesive cleaner (3M Part No. 08987-aerosol, or Part No, 08984-qt. can) or equivalent.

Note. Paint discoloration (looks like shaded or dark magic marker lines) can be removed with a heat gun using the following procedure

1. Hold heat gun approximately 3 in. away from affected paint surfaces and apply heat using slow oscillating motions until discoloration is gone.
2. If discoloration remains, wipe the heated area with Isopropyl alcohol and repeat procedure to increase surface drying.

Important!

After inspecting and removing RAPGARD ® , washing vehicle, inspecting and repairing any defects in paint surfaces, moldings and glass

1. Protect the vehicle paint surface by applying 3M Perfect-It ™ Paste Wax (3M Part No. 39526) or equivalent.

RAPGARD ® Disposal

RAPGARD ® can be disposed as normal paper waste. If unsure about proper disposal procedures in your area, check local regulations.

New Protective Vehicle Transit Coating, Liquid Film, inspection, removal and disposal

From my 7.2001

Condition

Scheme 50

A new "liquid film" polyurethane (PE) protective vehicle transit coating will be used on some TT models beginning with 7/2001 production.

Service

At the latest 72 hours prior to delivery

1. Inspect liquid film.
2. Remove liquid film from vehicle.
3. Wash vehicle exterior.
4. Inspect paint surfaces, moldings and glass.
5. Protect the paint surface of all new vehicles by hand-applying 3M Perfect-It ™ Paste Wax (3M Part No. 39526) or equivalent.

Note. Liquid film must be removed from the vehicle no later than six months after application. See sticker (location on vehicle body varies) for detailed information. Vehicles stored outside for longer than six months must be protected with a conventional wax (3M Perfect-It ™ Paste Wax or equivalent). To avoid swirl marks and/or scratches, always apply and remove wax by hand. Do not use a high-speed buffer!

Liquid film inspection

1. Inspect film for damage or peeling.

If film is disturbed (dented, scratched, etc.)

1. Note any damage on the Carrier Delivery Receipt, including damage type, extent, and location. Failure to note damage on the Carrier Delivery Receipt will result in non-payment of the repair.

Liquid film removal

1. Body surface temperature must be within 14 ° to 122 ° F(-10 ° to 50 ° C) range.
2. To avoid damage to the paint, surface temperature of paint should not exceed 176 ° F (80 ° C).

1. If necessary, rinse vehicle with cool water to lower body surface temperature.
2. Starting at the corners of each panel, remove liquid film in one steady motion.

Paint inspection after film removal

1. Inspect painted surfaces under one of the following lighting conditions

1. Indoors under fluorescent lighting.
2. Outdoors under bright sunlight.

Temporary paint discoloration or swelling, caused by residual water in the film material diffusing into the paint, may become visible after film removal.

Depending upon ambient temperature, the discoloration or swelling will disappear after approximately 24 hours regeneration time.

Severe paint discoloration or swelling can be removed with a heat gun or hair dryer as follows

1. Hold heat gun approximately 3 in. away from affected paint surfaces and apply heat using slow oscillating motions until discoloration is gone.

Removal of liquid film residue or overspray

Thick lines of adhesive residue can be removed with general purpose adhesive cleaner (3M Part No. 08987-aerosol or 3M Part No. 08984-qt. can) or equivalent.

Adhesive residues remaining on the paint after removal of the film can be easily removed after approximately 12 hours. Use a non-abrasive polishing product (3M Part No. 5995 for light colors or 3M Part No. 5996 for dark colors).

Film overspray (i.e. film sprayed into gaps) can be removed with an isopropyl alcohol cleaning solvent, VW Part No. D 009 401 04.

Disposal of liquid film

Liquid film can be discarded as normal paper waste. If uncertain about proper disposal procedures, check local regulations.

Transportation wiper blades, removing at vehicle delivery

From my 2002

Service

For all Models arriving at your dealership with transportation wiper blades

Transportation wiper blades are shorter than original equipment wiper blades and colored blue or yellow.

To ensure customer satisfaction, leave transportation wiper blades on vehicle until time of retail vehicle delivery.

Transportation wiper blades, removing

Transportation blades can easily be removed as follows

Scheme 51

1. Grasp blade as shown and rotate in direction of arrow (toward windshield).

Scheme 52

1. Rotate blade in opposite direction (black arrow) then, carefully slide blade off wiper arm.

Note. Wiper arm/blade alignment has been preset at the factory, then checked and adjusted (if necessary) during the PDI. DO NOT twist or bend the wiper arm. If wiper arm/blade alignment is incorrect, chattering and/or streaking will occur.

If arm has been bent

Refer to 92 WINDSHIELD WIPER & WASHER SYSTEM

1. Install original equipment wiper blades (located in trunk) at the time of retail vehicle delivery.

Note. Wiper blade with air deflector (arrow) must be installed on driver's side with deflector on bottom of wiper blade.

Scheme 53

1. Passenger's side wiper blade may be curved, install with curved ends of blade pointing up.

Scheme 54

A - Vehicle identification number

Stamped on the rear cross panel of the engine compartment and visible through a window in the plenum chamber cover

B - Type plate

Attached to the plenum chamber behind the right-hand suspension strut dome

Meaning of vehicle identification number

Vehicle data sticker

The vehicle data sticker can be found in the customer's Service Schedule, and also at the rear of the vehicle in the spare wheel well or on the luggage compartment floor.

Scheme 55

The sticker gives the following vehicle data

1 - Vehicle identification number

2 - Model identification code / production control number

3 - Model number

4 - Engine output/emissions standard/transmission

5 - Engine and transmission code letters (not specified on some export versions)

6 - Paint number/interior equipment identification number

7 - Identification numbers for optional extras

8 - Curb weight/fuel consumption/CO2 emission level (not specified on some export versions)

Engine code and engine number

Note. The engine code is also given on the vehicle data stickers in the Service Schedule and in the spare wheel well or on the luggage compartment floor.

There is also a sticker on the toothed belt guard giving the engine code and engine number.

Scheme 56

4-cylinder gasoline engines

The engine number (engine code and serial number) is at the front of the joint between the engine and the transmission.

Vehicle, lifting

Trolley jack

1. To prevent damage always use a suitable rubber or wooden block.
2. The trolley jack may only be applied at the lifting points shown in the illustrations.
3. On no account should vehicle be lifted at the engine sump, transmission or on front or rear axle as this may cause serious damage.

Vehicle, lifting

Vehicle lift

Scheme 57

Make sure there is sufficient clearance between the lowest parts of the vehicle underbody and vehicle lift before driving onto lift.

Lifting points for vehicle lift and floor (trolley) jack

Front

Scheme 58

Locate lifting blocks at protective lift pads (see (arrow) in above illustration) between longitudinal member and rocker panel.

Scheme 59

Lift point

Rear

Scheme 60

Locate lifting blocks at protective pads (see (arrow) in above illustration) located in the access area provided in rear floor section

Tow-starting/towing

1. Attach tow rope or tow bar only to the following towing eyes

Front towing eye

Scheme 61

1. Pull off cover (arrow) on lower part of bumper on the right.
2. Take towing eye from vehicle tool kit.
3. Screw in towing eye as far as it will go and tighten with wheel bolt wrench.

Note. After towing, remove towing eye and replace in vehicle tool kit. The towing eye must always be carried with the vehicle.

Rear towing eye

Scheme 62

The anchorage for the rear towing eye (arrow) is located below the rear bumper on the right.

1. Take towing eye from vehicle tool kit.
2. Screw in towing eye as far as it will go and tighten with wheel bolt wrench.

Note. After towing, remove towing eye and replace in vehicle tool kit. The towing eye must always be carried with the vehicle. The tow-rope should be slightly elastic to reduce the risk of damage to both vehicles. It is advisable to use synthetic fibre ropes or ropes of similar elastic material. However, it is safer to use tow-bar. Avoid excessive towing effort and do not jerk. During towing operations on unsurfaced roads there is always a danger that the attachment points will be overstressed and damaged. The vehicle should only be tow started if it is not possible to start the engine using jump leads.

If the vehicle has to be towed or tow started, always note the following points

1. Regulations concerning towing must be observed.
2. Both drivers must be familiar with towing procedures. Inexperienced drivers should not attempt to tow start or tow.
3. When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
4. The driver of the vehicle being towed must ensure that the tow rope is always taut.

1. Both vehicles must switch on their hazard warning lights (unless otherwise specified by local regulations).
2. The ignition must be switched on so that the steering wheel is free and the turn signals, horn and if necessary the windshield wiper and washer can be used.
3. Because the brake servo only works when the engine is running, considerably more pressure is required on the brake pedal when the engine is not running.
4. The power assisted steering only works when the engine is running. Therefore more force is required to turn the steering wheel when the engine is not running.

1. If the transmission (manual or automatic) has no lubricant in it, the vehicle must be towed with the drive wheels raised off the ground.

When tow starting vehicles with manual transmission the following points must be noted

1. Before moving off, depress clutch pedal and hold then engage 2nd or 3rd gear.
2. Switch ignition on.
3. When both vehicles are moving, release clutch pedal.
4. As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing vehicle.

Note. Vehicles with a catalytic converter (gasoline engines only) must not be tow-started over a distance of more than 50 m with the catalytic converter at operating temperature, otherwise unburnt fuel may enter the catalytic converter and cause damage.

Exhaust emission test

Note. Emissions test specifications. Refer to 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA . The following exhaust emissions test applies only to countries in which no emissions test is required to be conducted in compliance with national regulations. Malfunctions stored in the DTC memory must be repaired and DTC memory must be erased before the emissions test is carried out.

Required test equipment

1. VAG 1767 ignition tester (or VAG 1367)
2. MGA 1400 digital 4-gas exhaust analyzer or equivalent
3. VAG 1551 Scan Tool (ST)

Visual inspection

1. Inspect emissions components to make sure they are

1. Installed
2. Complete
3. Free of leaks
4. Free of damage

Connecting VAG 1551

1. Apply parking brake.

1. With the ignition switched off, connect V.A.G. 1551 with V.A.G. 1551/3 adapter cable.

Connecting MGA 1400 digital 4-gas exhaust analyzer

1. Connect exhaust tester as stated in operating instructions.
2. Insert test probe in exhaust tailpipe.

Test procedure

Note. The A/C system must be switched off during test. The Oxygen Sensor (O2S) control is working properly if no DTCs are stored in DTC memory. After the exhaust emissions test is completed, any hoses or connectors which were disconnected for the test must be connected. After the exhaust emissions test is completed, equipment such as power steering, air conditioning, and the automatic transmission should be operated in order to check whether the engine runs smoothly when subjected so the additional loading from these systems. The ignition timing point is determined by the ECM and cannot be displayed or adjusted. Idle speed and CO content cannot be adjusted. If test results differ from the test specifications the appropriate repairs must be carried out.

1. Continue running engine at idle after DTC memory has been checked and erased.

Indicated on display

1. Press buttons -0- and -8- to select "Read Measuring Value Block" function 08.
2. Press -Q- button to confirm input.

Indicated on display

1. Press buttons -0-, -0- and -1- to input display group 001.
2. Press -Q- button to confirm input.

Indicated on display

1. Read idle speed indicated in display field 1.
2. Read CO content indicated on exhaust tester.
3. Press --> button.

Indicated on display

1. Press buttons -0- and -6- to select "End Output" function 06.
2. Press -Q- button to confirm input.

See also:
• 24 MULTIPORT FUEL INJECTION (MFI)
• 24 MULTIPORT FUEL INJECTION (MFI)
• 01 ON BOARD DIAGNOSTIC (OBD)
• 17 ENGINE - LUBRICATION
• 17 ENGINE - LUBRICATION
• 01 ON BOARD DIAGNOSTIC (OBD)
• Wiper blade contact angle, adjusting
• Contact angle specifications
• Connecting VAG 1551
• Resetting service interval display with adjustment buttons for trip recorder and clock
• Resetting service interval display with VAG 1551
• Topping off with distilled water
• Radio, activating anti-theft coding by entering fixed code number
• Electric window lifters, checking positions
• Engine cover, removing
• Safety measures when using testers
• Changing oil in Haldex clutch
• Checking oil level in Haldex clutch
• Noise insulation, removing
• Oil specifications for vehicles with gasoline engine
• Engine oil, checking oil level
• Headlights, aiming using Hella Universal Beamsetter IV