Repair manual
Wiring diagrams
Volkswagen Golf Mk3 Repair Manual
Step-by-step repair and maintenance instructions for the Volkswagen Golf Mk3 (1991–2000): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
67sections
582articles
ENManual language
- Designation
- Gears
- Conversion ratio "i," calculating
- General Repair Instructions
- Gaskets and seals
- Circlips
- Spring pins
- Screws, bolts, and nuts
- Bearings
- Synchronizer rings
- Pedal cluster, servicing
- Removing
- Installing
- Clutch control, servicing
- Clutch cable, removing and installing
- Clutch cable tensioned
- Balance weight modification
- Repairing
- Clutch, servicing
- Vehicles with 1.8 or 1.9 liter engine
- Vehicles with 2.0 liter engine
- Flywheel versions
- Clutch pressure plate versions
- Shift linkage, servicing
- Removing eccentric adjuster
- Removing and installing selector rod with retainers (arrows)
- Reworking selector rod
- Shift linkage, adjusting
- Rubber boot
- Transmission, removing and installing
- Cabrio only
- Continued for all vehicles
- Transporting transmission
- Transmission gear oil level, checking
- Transmission housing cover and 5th gear, removing and installing
- Transmission housing and selector shaft, removing and installing
- Input shaft, output shaft, differential and shift forks, removing and installing
- Available circlips
- Transmission housing, servicing
- Removing selector shaft seal -A
- Installing selector shaft seal
- Extracting selector shaft ball sleeve
- Installing selector shaft ball sleeve
- Installing output shaft needle bearing
- Clutch housing, servicing
- Extracting input shaft needle bearing
- Transmission housing cover, servicing
- Removing needle bearing
- Driving in oil seal for clutch pushrod
- Extracting bushing for clutch pushrod
- Pressing off deep groove ball bearing
- Pressing off operating sleeve and synchronizer hub for 3rd and 4th gear
- Removing stop ring
- Installing stop ring
- Checking synchronizer rings
- Marking of 1st gear synchronizer ring with 110° tooth angle
- Pressing off inner race of large tapered roller bearing
- Shim S3
- Determining thickness of shim S3
- Available shims
- Bearing preload, checking
- Drive flange oil seals, removing and installing
- Removing tapered roller bearing inner race
- Pressing on inner race of tapered roller bearing for differential housing
- Installing final drive gear
- Attaching final drive gear to differential housing
- Installing differential pinion gears
- Shims S1 and S2
- Determining thickness of shim S1
- Cabrio
- Early Production 1999 Golf, GTI, & Jetta
- ABS - Teves 04
- ABS/EDL - Teves 04
- Teves 04
- ABS only
- ABS/EDL
- ABS control module
- Necessary technical information
- ABS control module -J104- Ground (GND) connections
- Vehicles from 08.93 & up
- Requirements
- Ending output
- ABS control module, removing and installing
- Removing
- Installing
- Multi-pin connectors, terminal assignment
- Brake light switch, adjusting
- ABS - Teves 20 GI
- Distinguishing features
- ABS/EDL - Teves 20 GI
- Function
- Teves 20 GI ABS control module -J104
- Complaint: "Vehicle does not have EDL function"
- List of selectable functions
- Code Control Module (VAG 1551 function 07)
- Coding table
- Display group 001-ABS wheel speed sensor assignment
- Display group 002-ABS wheel speed sensor signals
- Example
- Display group 003-brake light switch ABS and ABS/EDL function
- ABS/EDL hydraulic unit, bleeding using Basic Setting (VAG 1551 function 04)
- Multi-pin connector terminal assignments
- VAG 1551 scan tool
- Diagnostic Trouble Code (DTC) memory
- Safety precautions and fundamental points regarding troubleshooting
- Test requirements
- VAG 1551 scan tool, connecting and selecting function
- List of selectable scan tool functions
- Diagnostic Trouble Code (DTC) memory, checking
- Diagnostic Trouble Code (DTC) table
- Teves 04 ABS and ABS/EDL electrical test
- Test equipment and aids required
- Electrical test table
- Data link connector (DLC) for voltage supply and On Board Diagnostic (OBD) with the VAG 1551 scan tool (from 08.93)
- Troubleshooting with VAG 1551 scan tool
- Erasing DTC memory
- Test sequence
- Read Measuring Value Block (VAG 1551 scan tool function 08)
- Output Diagnostic Test Mode (DTM) (VAG 1551 scan tool function 03)
- Teves 20 GI ABS and ABS/EDL electrical test
- Notes on electrical test table
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Golf, Jetta Up to 07.95
- Cabrio Up to 07.95
- Golf, Jetta 08.95 and Up
- Cabrio 08.95 and Up
- Muffler Assembly and Mountings
- Exhaust Gas Recirculation (EGR) System Components, Removing and Installing (California Only)
- Exhaust Gas Recirculation (EGR) Valve and EGR Temperature Sensor -G98-, Checking
- Secondary Air Injection (Air) System, Servicing
- Function, Vehicles 06.96 and Up
- Secondary Air Injection System Components, Removing and Installing
- Special Tools, Testers and Auxiliary Items
- Test Sequence
- Checking Requirement
- Fuel Supply System Components, Removing and Installing
- Safety Precautions
- Rules of Cleanliness
- Fuel Tank with Attaching Parts and Fuel Filter, Removing and Installing, Vehicles Up to 1999
- Fuel Tank with Attaching Parts and Fuel Filter, Removing and Installing, Vehicles 2000 and Beyond
- Installation Position of Flange for Fuel Pump (Fp) Module
- Fuel Pump Module, Removing and Installing
- Installing
- Vehicles 06.99 and Up
- Test Conditions
- Test Sequence
- Checking Conditions
- Leak Diagnosis, Functional Description
- Evap System Components, Servicing, Vehicles Up to 1996
- Evap System Components, Servicing, Vehicles 1997-1999
- Evap with Orvr System Components, Servicing, Vehicles 2000 and Up
- Evaporative Emissions System, Overview, Vehicles Up to 1996
- Evaporative Emissions System, Overview, Vehicles 1997-1999
- Evaporative Emissions System, Overview, Vehicles 2000 and Up
- Checking Evap Canister
- Special Tools and Equipment
- Checking Requirements
- Functional Check
- Special Tools
- Function Test
- Leak Checking
- Evap Canister Purge Regulator Valve -N80-, Checking, Vehicles Up to 1996
- Evap Canister Purge Regulator Valve -N80-, Checking, Vehicles 1997-1999
- Evap Canister Purge Regulator Valve -N80-, Checking, Vehicles 2000 and Up
- Leak Detection Pump, Checking
- Engine Code
- Engine Specifications (Golf, Gti, Jetta)
- Engine Specifications (Cabrio)
- Safety Precautions
- Rules of Cleanliness
- Engine, Removing
- Vehicles with A/c
- Vehicles with Manual Transmission
- All Vehicles
- Engine, Installing
- Tightening Torques
- Engine/transmission Mounts, Tightening Torques
- Front Engine/transmission Mount
- Right Rear Engine/transmission Mount
- Right Engine/transmission Mount (Cabrio Only)
- Left Rear Engine/transmission Mount
- Engine, Disassembling and Assembling
- Part I
- Part Ii
- Part Iii
- Ribbed Belt, Removing and Installing
- Removing
- Installing
- Drive Belt, Removing, Installing and Adjusting Tension
- Required Tools
- Removing Ribbed Belt and V-Belt
- Installing V-Belt and Ribbed Belt
- Tightening Torque
- Sealing Flange and Flywheel/driveplate, Removing and Installing
- Crankshaft, Removing and Installing
- Crankshaft Dimensions
- Piston and Connecting Rod, Disassembling and Assembling
- Piston Dimensions
- Checking Cylinder Bore
- Piston and Cylinder Dimensions, Models Up to 07.95
- Piston and Cylinder Dimensions 08.95-07.96
- Piston and Cylinder Dimensions 08.95 and Up
- Cylinder Head, Servicing
- Cylinder Head, Installing
- Compression Pressure, Checking
- Compression Pressure Values
- Valve Train, Disassembling and Assembling (Models Up to 11.94)
- Reconditioned Cylinder Heads with Camshaft Bearing Shells
- Valve Dimensions
- Camshaft Identification and Timing
- Valve Seats, Refacing
- Hydraulic Valve Lifters, Checking
- Valve Guide Wear, Checking
- Valve Guides, Removing and Installing
- Valve Train, Disassembling and Assembling (Models from 12.94 and Up)
- Lubrication System, General Information
- Oil Capacities Up to MY 2000
- Oil Capacity
- Oil Specifications
- Lubrication System, Components
- Checking Oil Pump Backlash
- Checking Oil Pump Axial Clearance
- Oil Pressure and Oil Pressure Switches, Checking
- Fuel injection system, servicing
- Fuel injection system, components
- Intake manifold, upper, removing and installing
- Intake manifold, lower, removing and installing
- Air Cleaner (ACL), removing and installing
- Safety precautions
- Rules for cleanliness
- Technical data
- Idle speed, checking
- Functional check
- Continuation
- Evaluating display group 025
- Evaluating display group 115
- Relevance of values in 8-digit number block
- Evaluating display group 116
- Evaluating display group 016
- Throttle valve control module, checking
- Checking voltage supply
- Checking Closed Throttle Position (CTP) switch
- Evaluating display group 037
- Evaluating display group 036
- Checking Throttle Position (TP) sensor
- Evaluating display group 003
- Basic setting, initiating
- Evaluating display group 002
- Check conditions
- Checking activation
- Checking resistance of fuel injectors
- Checking spray pattern and checking for leaks
- Fuel pressure regulator and residual pressure, checking
- Checking regulating flap
- Checking temperature regulator
- Function
- Malfunction Indicator Lamp (MIL), significance
- Equipped with
- Engine Control Module (ECM) functions
- Work sequence
- Relevance of 8-digit number block for readiness code
- Readiness code, creating
- Work step: 1
- Work step: 2
- Work step: 3
- Work step: 4
- Work step: 5
- Work step: 6
- Work step: 7
- Work step: 8
- Work step: 9
- Procedure
- Work step: 10
- Work step: 11
- Work step: 12
- Work step: 13
- Work step: 14
- Work step: 15
- Work step: 16
- Work step: 17
- Work step: 18
- Work step: 19
- Work step: 20
- Evaluating display group 000
- Selectable functions for address word "33 CARB / OBD II"
- Current data, mode 1
- Relevance of figures in 8 digit number block
- Freeze frame data, mode 2
- Oxygen sensor signal (B1-S1), mode 5
- Cabrio
- Early Production 1999 Golf, GTI, & Jetta
- Notes on exchanging radio
- Additional information
- Connecting
- Functions, selecting
- Radio version, checking
- List of available functions
- Prerequisites
- End output (function 06)
- Control module (radio) version, coding (function 07)
- Coding
- Coding possibilities
- Read measuring value block (function 08)
- Table of selectable display group numbers
- Function
- List of selectable functions
- Requirements
- Ending output
- Evaluating display group number 001
- Evaluating display group number 002
- Ignition keys, matching (adaptation)
- Lost key procedure
- Establishing secret number
- Engine Control Module or Fuel Cut-off Valve Control Module, procedure after replacing
- Procedure
- Immobilizer Control Module, adjusting after replacing (code control module)
- Coding control module
- Lock set or Immobilizer Control Module, replacing procedure
- Malfunction
- Possible cause
- End Output
- Example for a measuring value block
- Engine Control Module (ECM), procedure after replacing
- Immobilizer control module, replacing procedure
- Manufacturer's Suggested Scheduled Maintenance
- Removal & Installation
- Removal (Standard Tensioner - Up to 1997)
- Installation (Standard Tensioner - Up to 1997)
- Removal (Thermo Tensioner Roller - 1997 & Up)
- Installation (Thermo Tensioner Roller - 1997 & Up)
- Standard Tensioner - Up to 1997
- Thermo Tensioner - 1997 & Up