Maintenance (A3 Platform): Other Volkswagen Golf Mk3

CABRIO

Maintenance information in this article also applies to 2000-02 Cabrio.

EARLY PRODUCTION 1999 GOLF, GTI, & JETTA

Information in this article applies up to early production 1999 Golf, GTI and Jetta vehicles. To identify early production vehicles, the 7th and 8th characters of the VIN are 1H.

Note. For information on late production Golf, GTI and Jetta models, see MAINTENANCE (A4 PLATFORM) article.

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
5. Battery condition static voltage minimum 12.5 volts (Recharge if necessary - if battery is dead, disconnected or below 10 volts, use VAG 1551 / 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
5. Drive vehicle minimum of one mile. Apply brakes several times at 20 mph to clean rotors
6. Verify disposable floor mats are in place
7. 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

See Service Circular Maintenance Schedule for appropriate model year. This is included in owner's manual information.

Engine oil level, checking

After switching engine OFF, wait at least 3 minutes to allow the oil to flow back into the pan.

1. Remove dipstick, wipe with a clean cloth and reinsert as far as stop. NOTE: Please note waste disposal requirements.
2. Remove dipstick again and read oil level: The oil level must be at the top edge of the shaded area (-A-) but on no account above this.

Note. Risk of damage to catalytic converter if oil level is above shaded area -B-. If below shaded area -A- fill to mark.

Engine oil, changing

Replace oil-drain plug seal if leaking. (See Parts Catalog for correct application. In some cases, seal and drain plug are combined; do not interchange with separate seal and drain plug.)

1. Capacities with filter change For 1.8L 4-Cyl. 5V Turbo, see OIL CAPACITIES . For 1.9L 4-Cyl. 2V ID1, see «OIL CAPACITY»(ref-203841-S34956139312005110800000) . For 1.8L 4-Cyl. 2V ACC, see LUBRICATION SYSTEM, SERVICING . For 1.9L 4-Cyl. 2V TDI-AAZ, 1Z, AHU, see «LUBRICATION SYSTEM, GENERAL INFORMATION»(ref-203841-S21053315572005110800000) . For 2.0L 4-Cyl. 2V ABA, see «LUBRICATION SYSTEM, GENERAL INFORMATION»(ref-203852-S00358145612005110800000) . For 2.8L VR6 2V AAA, see «OIL FILTER HOUSING, DISASSEMBLING AND ASSEMBLING»(ref-203859-S27642321202005110800000) .
2. Tightening torque of oil drain plug: 4-cyl. engines: 30 N.m (22 ft lb) 6-cyl. engines: 50 N.m (37 ft lb)

Gasoline engine

1. VW 502 00 or VW500 00 or VW501 01
2. ACEA A2 or ACEA A3
3. API Service SJ or API Service SL

Diesel engine

1. VW 505 00
2. ACEA B3 or ACEA B4
3. API Service CF4 or API Service CG4

Engine oils are graded according to their viscosity. The proper grade to be used depends on existing climatic or seasonal conditions.

The original oil has a viscosity grade of SAE 5W - 40. Use this oil over all temperature ranges for normal driving. If engine oil viscosity grade SAE 5W-40 is not available, use SAE 5W -30.

4-cyl. engines

1. Loosen oil filter with oil filter strap, Hazet 2171-1 or equivalent, and remove filter.
2. Clean sealing surface on engine.
3. Lightly lubricate rubber seal with clean oil.
4. Thread on new filter and tighten by hand. NOTE: Do not clean and re-use oil filter.

Scheme 20

1. Drain oil at drain screw -8-.
2. Remove lower filter housing -7-.
3. Install new filter element -5- and new O-rings -6-. Lightly lubricate O-ring with clean oil.
4. Tighten lower filter housing to 30 N.m (22 ft lb).
5. Tighten drain screw (with new O-ring) to 10 N.m (7 ft lb). NOTE: Do not clean and re -use oil filter element.

Fuel filter (Diesel engine), replacing

Note. Do not allow diesel fuel to contact coolant hoses. Wipe any diesel fuel off hoses immediately and wash hoses with soap and water.

Scheme 21

1. Remove retaining clip -1-.
2. Remove control valve -2- with fuel lines connected.
3. Remove fuel hose -3- (feed from fuel tank) and -4- (feed to injection pump). Direction of flow is indicated by arrows Do not reverse connections

Installing

1. Install control valve -2- with fuel lines connected. Use new O-ring
2. Attach retaining clip -1-.
3. Attach fuel hose connections -3- and -4- with hose clamps.

After installing filter

1. Check fuel system for leaks (visual inspection).
2. Rev engine several times and let idle. Fuel flow through transparent pipe must be free of bubbles.

Cooling system anti-freeze protection and coolant level, checking

Coolant anti-freeze, Part No. G 11 prevents frost and corrosion damage, lime deposits, and also raises the boiling temperature. For these reasons, the cooling system must be filled the entire year with anti-freeze and corrosion protection agent.

The concentration of the coolant must not be reduced by adding water, even during the warm season or in warmer climates. The coolant anti - freeze percentage must be at least 40%.

Because of its high boiling point, the coolant contributes to safe operation at high engine load, especially in warmer climates.

1. Check concentration of coolant anti-freeze. Anti-freeze protection must be approx. -25°C (- 13°F) for the US, and -35°C (-31 F) for Canada. For anti-freeze protection down to approx. -40°C (-40°F), the percentage of G 11 may be increased up to 60%. The percentage of G11 must not exceed 60%, as higher amounts will decrease frost protection and cooling capacity. If anti-freeze protection is not adequate, drain off the quantity indicated in the table below and top up with coolant anti-freeze G 11.

COOLING SYSTEM ANTI-FREEZE PROTECTION AND COOLANT LEVEL

1. After road test, check coolant concentration again.
2. Check coolant level.

If the coolant level is too low but the antifreeze protection adequate, add the missing quantity according to the following mixing ratios

Where applicable

The filter is located below the plenum chamber on the right.

Scheme 22

1. Remove plastic screws attaching the cover.
2. Remove rubber seal -1-.
3. Push front of cover upward.
4. Push spring catches -2- of filter element in direction of arrow and remove filter element.
5. Install new filter element.
6. Install rubber seal and cover.

Scheme 23

Scheme 24

1. Move selector lever into position "P" or "N" and apply parking brake (vehicles with automatic transmission).
2. Unclip cover for Data Link Connectors (DLC) under heating/ventilation controls.
3. With ignition switched OFF, connect VAG 1551 Scan Tool (ST) with VAG 1551/1 adapter harness as follows
4. First connect black connector from VAG 1551/1 adapter harness to black Data Link Connector (DLC).
5. Indicated on display. * Operating modes 1 and 2 are displayed alternately. NOTE: If no display appears, do not connect the white connector. In this case, check the voltage supply for the VAG 1551 Scan Tool (ST).
6. Connect white connector from VAG 1551/1 adapter harness to white Data Link Connector (blue connector is not used).

Scheme 25

Scheme 26

1. Remove front ashtray.
2. Slide small cover to the left -arrow-.
3. With ignition switched OFF, connect VAG 1551/3 adapter harness between Data Link Connector (DLC) and VAG 1551 Scan Tool (ST).
4. Indicated on display. * Operating modes 1 and 2 are displayed alternately.

Measurements

Check and, if necessary, adjust ignition timing, idle speed and CO content.

Oxygen Sensor (O2S) control

Check operation. The oxygen sensor control is operating property if no malfunction is displayed when the DTC Memory is checked.

Three Way Catalytic Converter (TWC)

1. Check operation
2. Run engine for at least 1 minute at 2500 + 200 RPM.
3. Measure CO content at CO tap tube (where applicable, upstream of catalytic converter) at 2500 +200/ -0 RPM and note reading.
4. Measure CO content at tail pipe (downstream of catalytic converter) at 2500 +200/ -0 RPM and note reading.
5. Calculate the percentage from the measurements. The three way catalytic converter is operating properly if the percentage is 50% or more Readings below 50% indicate a malfunction of the three way catalytic converter. It should then be replaced.

Procedures according to engine code letters

ENGINE CODE LETTERS: AAA

ENGINE CODE: AAZ

ENGINE CODE: ABA

ENGINE CODE: ACC

After completing the emission and idling test, note the following

1. Operate ancillary equipment such as power steering, automatic transmission, air conditioner and check for smooth engine operation.
2. Reconnect all hoses, plug connections that were detached or separated for the check/adjustment.

Motronic Multi-point Fuel Injection (MFI)

IGNITION AND FUEL INJECTION SPECIFICATIONS - 2.0L, ENGINE CODE ABA

Requirements

1. VAG 1551 Scan Tool (ST) and VAG 1551/3 connected (Function 04)
2. Engine temperature at least 80° C (176° F)
3. A/C OFF
4. Ground (GND) connections OK
5. Battery Positive Voltage (B+) OK
6. Exhaust system OK (no leaks)

Before performing the emission and idling test, refer to notes on, refer to EMISSION AND IDLING TEST, GASOLINE ENGINE .

Scheme 27

1. Connect VAG1367 ignition tester with VAG 1367/8 trigger clamp or VAG 1767 ignition tester.
2. Connect VAG 1363 A CO tester with VAG 1363/3 adapter to the CO tap tube (where applicable).
3. Detach hoses for crankcase breather from pressure control valve and seal hose opening to intake valve -arrow-.
4. Start engine and run at idle.

On VAG 1551 Scan Tool (ST)

Scheme 28

1. Press button -1- for "Rapid data transfer" mode.
2. Press buttons -0- and -1- to enter address word 01 for "Engine Electronics" and press -Q- button to confirm input.
3. Press --> button.
4. Press buttons -0- and -4- to select "Basic setting" function 04, and press -Q- button to confirm input.
5. Press button -0- twice to enter display group number 00, and press -Q- button to confirm input (the digits appearing in the display are of no significance for this test).
6. Check ignition timing at 2000-2500 RPM.

With TDC sender

The ignition timing is displayed directly on the tester.

Scheme 29

1. Aim strobe at ignition timing notch.
2. Adjust ignition timing, if necessary, by turning distributor.
3. Run engine at idle for at least one minute.
4. Check idle speed and CO content. NOTE: Idle speed and CO content cannot be adjusted. If deviation from specification exists, make the necessary repairs.
5. Press --> button (coolant fan must not start).
6. Press buttons -0- and -6- to select "End Output" function 08, and press -Q- button to confirm input.
7. Test operation of three way catalytic converter ( «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) ).
8. Refer to notes on «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) after completing emission and idling test.

Mono-Motronic Throttle Body Fuel Injection (TBI)

IGNITION AND FUEL INJECTION SPECIFICATIONS - 1.8L, ENGINE CODE ACC

1. VAG 1551 Scan Tool (ST) and VAG 1551/3 connected (Function 04)
2. Engine temperature at least 80 C (176 F)
3. A/C OFF
4. Ground (GND) connections OK
5. Exhaust system OK (no leaks)
6. Coolant fan must not run

Note. Before performing tests or adjustments, the DTC Memory must always be checked. Idle speed and CO content cannot be adjusted. If deviation from specification exists, perform repair measure.

Before performing the emission and idling test, refer to notes, refer to EMISSION AND IDLING TEST, GASOLINE ENGINE .

Scheme 30

1. Connect VAG 1367 ignition tester with VAG 1367/8 trigger clamp or VAG 1767 ignition tester.
2. Connect VAG 1363 A CO tester, VAG 1363/3 with adapter to CO tap tube (where applicable).
3. Start engine and run at idle.

On VAG 1551 Scan Tool (ST)

1. Press button -1- for "Rapid data transfer" mode.
2. Press buttons -0- and -1- to enter address word 01 for "Engine Electronics," and press -Q- button to confirm input.
3. Press --> button.
4. Press buttons -0- and -4- to select "Basic setting" function 04, and press -Q- button to confirm input.
5. Press button -0- twice to enter display group number 00, and press -Q- button to confirm input (the digits appearing in the display are of no significance for this test).
6. Check ignition timing.

Continued on next page

The ignition timing is displayed directly on the tester.

Scheme 31

1. Aim strobe at ignition timing notch.
2. Adjust ignition timing, if necessary, by turning distributor.
3. Check idle speed and CO content. NOTE: Idle speed and CO content cannot be adjusted. If deviation from specification exists, make the necessary repairs.
4. Press --> button.
5. Press buttons -0- and -6- to select "End Output" function 06, and press -Q- button to confirm input.
6. Test operation of three way catalytic converter, refer to «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) .
7. Refer to notes on, refer to «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) after completing emission and idling test.

Motronic M2.9 Multi -point Fuel Injection (MFI)

Before performing the emission and idling test, refer to notes, refer to EMISSION AND IDLING TEST, GASOLINE ENGINE .

1. VAG 1551 Scan Tool (ST) connected

1. Connect VAG 1363A CO tester, with VAG 1363/3 adapter to CO tap tube next to the throttle valve body (where applicable).
2. Start engine and run at idle.

On VAG 1551 Scan Tool (ST)

1. Press button -1- for "Rapid data transfer" mode.
2. Press buttons -0- and -1- to enter address word 01 for "Engine Electronics" and press -Q- button to confirm input.
3. Press --> button.
4. Press buttons -0- and -4- to select "Basic setting" function 04, and press -Q- button to confirm input.

Press button -0- twice to enter display group number 00, and press -Q- button to confirm input

Example of readout in display

Scheme 32

Note. Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) is closed in the "Basic Setting" function.

Continue with the test only after engine temperature is above 80 °C (display field 2).

1. Briefly increase engine speed (blip throttle), and then run engine at idle speed for 2 minutes.
2. Note displayed figures for engine speed and ignition timing Display field 1 = engine speed Display field 4 = ignition timing
3. Test CO content on CO tester (if deviation exists, perform repair measure). If actual values differ from the specifications, make the necessary repairs. NOTE: Idle speed and CO content cannot be adjusted. If deviation from specification exists, make the necessary repairs.

On VAG 1551 Scan Tool (ST)

1. Press --> button.
2. Press buttons -0- and -6- to select "End Output" function 06, and press -Q- button to confirm input.
3. Test operation of three way catalytic converter, refer to «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) .
4. Refer to notes on «THREE WAY CATALYTIC CONVERTER (TWC)»(ref-203132-S02472234172005103000000) after completing emission and idling test.

Engine code: AAZ

EMISSION AND IDLING TEST (DIESEL ENGINE) - 1.9L, ENGINE CODE AAZ

Note. Tests should be performed following a road test and in the open if possible. To minimize the noise level, close the hood to the first detent during measurement. Engine speed can be measured with VAG 1500 or with VAG 1367 ignition tester via the TDC sender.

Idle speed and maximum RPM

1. Engine oil temp. 60 °C (140 °F) minimum
2. Cold start accelerator cable should not be tight
3. Electrical consumers OFF

Start of program (feed)

1. Engine oil temp. 60 °C (140 °F) minimum
2. Cold start accelerator cable should not be tight
3. Belt tension OK
4. Idle RPM OK

Exhaust check for particle percentages

1. Engine oil temp. 80 °C (176 °F) minimum
2. Cold start accelerator cable should not be tight
3. Idle and maximum RPM OK
4. VAG 1500 combustion tester connected according to the operating instructions.

Note. Do not place combustion tester test probe in exhaust pipe for idle speed and RPM test or adjustment procedures.

1. Test idle speed and adjust, if necessary, by turning the idle speed adjusting screw -1-.
2. Test maximum engine speed (RPM) without load and adjust if necessary, as follows
3. Loosen locking nut of adjusting screw -2-.
4. Apply full throttle and set engine speed with adjusting screw -2-.
5. Tighten locking nut to lock adjusting screw.
6. Place test probe onto exhaust pipe.
7. Blip throttle at least 2 x 5 times, but not more than 5 x 5 times.

1. If the opacity level is already equal to or less than 20% (10%) after blipping throttle 2 x 5 times, end measurement.
2. If the opacity level is greater than 20% (10%), and remains so after blipping throttle 5 x 5 times, determine the cause and make the necessary repairs.

Check condition of V-belt for

1. Splits in base material (cracks, core fractures, cross-section fractures)
2. Separation of layers (top layer, tensile cords)
3. Bursting on base material
4. Fraying of cords
5. Flank wear (material flaking, frayed flanks, hardening of flanks [glassy surface], surface cracks)
6. Traces of oil or grease

Note. If faults are found, the V -belt must be replaced.

Checking/adjusting V -belt tension

Check V-belt tension by applying firm thumb pressure to the area of the belt between the two pulleys that are furthest apart.

Checking

Deflection for used V-belt: approx. 5 mm (0.197 in.).

Adjusting

When loosening securing bolts -1- and -2- and clamping bolt -3-, loosen tensioning bar securing nut -4- (if equipped) at least one turn.

Note. The VAG 1410 torque wrench and ring insertion tool (size 22) can be used for V -belt adjustment.

Scheme 33

1. VAG 1410/2 (see -A-).
2. Tension V-belt by tightening the tensioning nut to 4 N.m (35 in lb) (used belts) and tensioning nut clamping bolt -3- to 25 N.m (18 ft lb).
3. Tighten securing bolt -1- to 45 N.m (33 ft lb).
4. Tighten securing bolt -2- and tensioning bar securing nut -4- (if equipped) to 25 N.m (18 ft lb).

Check condition of poly-ribbed belt for

1. Splits in base material (cracks, core fractures, cross-section fractures)
2. Separation of layers (top layer, tensile cords) Bursting on base material
3. Fraying of cords
4. Flank wear (material flaking, frayed flanks, hardening of flanks (glassy surface), surface cracks)
5. Traces of oil and grease

Note. If faults are found, the belt must be replaced.

Checking/adjusting V -belt tension, belt drive without tensioning pulley

Vehicles with 1.8 liter, without A/C

Note. It is not necessary to check and adjust the poly - ribbed belt tension on engines with tensioning pulley. Optimal belt tension is assured by means of the integral spring-loaded tensioning device.

Scheme 34

1. Loosen Generator (GEN) securing bolts.
2. Insert tensioning lever 3297 and secure with locking pin.
3. Swing Generator (GEN) down (use e.g. torque wrench as drive for 3297). Push Generator (GEN) as far as stop at least three times to ensure optimal ease of operation.
4. With the Generator (GEN) loosened, let engine at idle for at least 10 seconds.
5. Tighten Generator (GEN) to 25 N.m (18 ft lb).

Check condition of toothed belt for

1. Tears, cross-section fractures
2. Separation of layers (toothed belt body, tensile cords)
3. Bursting on toothed belt body
4. Fraying of tensile cords
5. Surface cracks (plastic surface)
6. Traces of oil and grease NOTE: If faults are found, the toothed belt must be replaced.

Adjusting tension

1. Remove upper belt cover.
2. Use tester VW 210 to measure toothed belt tension between camshaft sprocket and injection pump gear.

Specification: Scale reading = 12 - 13

If the actual value is not to specification, tension the toothed belt as follows

Scheme 35

1. Loosen tensioning pulley securing nut.
2. Turn tensioning pulley to the right with nut turner, (e.g. Matra V 159 or similar) -arrow- until the correct specification is achieved.
3. Tighten tensioning pulley securing nut to 45 N.m (33 ft lb).
4. Install upper belt cover.

5-speed transmission 020

Vehicles with 1.8 liter, 1.9 liter Diesel or 2.0 liter engines

1. Remove oil filler plug -arrow-.
2. Check oil level; oil should be up to the lower edge of the filler hole.
3. If necessary, top off by adding G50 synthetic oil, SAE 75W90
4. Re-install oil filler plug.

5-speed transmission 02A

Vehicles with 2.8 liter VR6 engine

1. Remove oil filler plug -arrow-.
2. Check oil level; oil should be up to the lower edge of the filler hole.
3. If necessary, top off by adding G50 synthetic oil, SAE 75W90
4. Re-install oil filler plug.

Final drive oil level, checking

1. Remove speedometer drive and wipe off with a non-fluffy cloth.
2. Install speedometer drive and remove; measure oil level. Oil level must be between the min and max marking.
3. If necessary, add gear oil (specification G50, SAE 75W90). NOTE: The quantity of oil between the min and max markings is 0.1 liter. Excess oil poured in can be extracted with VAG 1358 A.
4. Install speedometer drive.

1. Engine at normal operating temperature
2. Vehicle stationary
3. Front wheels in the straight ahead position.

1. Vehicle raised, wheels off the ground

1. Check play by moving tie rods and wheels. Specification: no play
2. Check attachment.
3. Check dust boots for damage and correct seating.

Tire inflation pressure, checking and correcting

Refer to data label on vehicle.

Underbody sealant, checking

When performing the visual inspection for damage to the underbody sealant, also check the underbody, wheel housings and sill panels.

Any faults found must be repaired.

Air deflector strap, removing

Vehicles with VR6 engine

Air deflectors for cooling the front brakes are installed on models with VR6 engines. As the front spoiler is not installed during transit, the air deflectors are attached with a strap to the bumper -D- to avoid damage.

Before installing the front spoiler

Scheme 36

1. Remove air deflector -A- and cut off the strap -B- where indicated by dashed line -C-.
2. Attach air deflector to the front spoiler with self-tapping combination screws. NOTE: Combination screws are shipped with the air deflector.

Door check straps and securing bolts, greasing

1. Grease door check strap -A- with lubricant G 000 400.
2. Grease securing bolt -B- with lock cylinder spray G 000 400 01.

1. Tires inflated to the correct pressure.
2. Lenses clean and in proper condition.
3. Reflectors in proper condition.
4. Springs settled (load vehicle with approx. 75 kg (165 lbs.) on driver's seat roll several yards).
5. Vehicle and headlight beam adjusting equipment standing on level ground and properly aligned.
6. Set beam angle.

Main headlights

Low beam setting

New test screen (without 15 setting line)

Adjust headlights so that the light/dark border touches setting line -1- on the screen. Breakpoint -2-, between the left (horizontal) area and the right (rising) area of the light/dark border must align with central mark -3-. The bright spot of the light beam will fall to the right of central mark -3-.

Scheme 37

Note. To make it easier to find the break point, cover and uncover the left half of the headlight alternately (in direction of travel). Then check low beam again.

High beam setting

After correctly adjusting low beam, the center of the high beam must be on the central mark -3-, refer to CHECKING HEADLIGHT ADJUSTMENT .

Scheme 38

1. Older test screen (with 15 °setting line)
2. When using this screen to adjust low beam, ignore 15 °setting line.

Fog lights

The upper light/dark border of the beam must fall on the setting line and run the full width of the screen horizontally.

Scheme 39

Other headlights

Retrofitted headlights of other systems must be set according to the applicable regulations.

Adjusting headlights

Headlights are adjusted from the front with a Phillips-head screwdriver. Right headlight shown.

Screws for left main headlight are a mirror-image.

A - Vertical adjustment

B - Lateral adjustment

Scheme 40

1. To reduce the headlight beam range, insert screwdriver into opening -A- to contact thumbwheel and turn thumbwheel to the right. NOTE: The setting can be made from inside the engine compartment if the thumbwheel is accessible. If adjusting from inside the engine compartment, turn the thumbwheel to the left to reduce headlight range. The same applies to the lateral adjustment, which can be made through the opening (-B-).

Adjusting fog lights

1. Remove towing eye cover.
2. Turn setting screw -1- to the left to reduce foglight beam range. No lateral adjustment is possible.

Scheme 41

1. Vehicle must have been standing for at least two hours in the no -load state prior to measurement (no engine starts, no charging and discharging).
2. Ignition switched OFF. Measure voltage with hand-held multimeter (Fluke™ 83, US 1119 or equivalent) between the poles of the installed battery.

If the instrument indicates 12.5 volts or higher, the battery is OK.

If the voltage is below 12.5 volts, determine the cause and repair or replace as necessary.

Windshield washer jets, adjusting

Adjusting jets (with tool VAG 3125)

Note. Never use a needle or similar tool adjust jets, as damage to the jets may result.

Windshield

a = 280 mm (11.03 in.) d = 560 mm (22.05 in.)

b = 300 mm (11.81 in.) e = 400 mm (15.75 in.)

c = 430 mm (16.93 in.) f = 400 mm (15.75 in.)

Tolerance +/- 20 mm (0.79 in.)

Scheme 42

Note. If the spray is uneven or cannot be set to the specified dimensions, replace spray jet.

Rear window

Spray jet in middle of swept area

1. Fill reservoir for windshield cleaning system.
2. Always add a windshield cleaner to the water (antifreeze in winter).

Wiper blade contact angle, checking and adjusting

1. Eliminate following possible causes of wiper blade skip before replacing wiper blades. Windshield scratched Wiper blade rubber detached, split or loose Wiper arm/blade loose or bent Wiper blades coated with wax, deformed or worn out

If none of the four items listed above are the cause of the problem the contact angle of the wiper arms must be checked and adjusted as necessary using wiper arm adjustment tool 3358.

Scheme 43

1. Bring wiper arm to rest position.
2. Remove wiper blade.
3. Place wiper arm -2- in wiper arm adjusting tool 3358 and secure with retaining screw -3-.
4. Compare angle indicated with specification in table: WIPER ARM CONTACT ANGLE SPECIFICATION Contact angle Golf, GTI, Jetta, Cabrio Driver side 0 ° (1) / -3° Passenger side 0° Rear window wiper + 3° Tolerance +/ - 2° (1) Wiper blade with plastic spoiler

Adjusting wiper arm

1. Use 24 mm open end wrench -1- on wiper arm adjusting tool 3358 and twist wiper arm -2- in direction of arrows until setting matches specification in table, refer to «WIPER BLADE CONTACT ANGLE, CHECKING AND ADJUSTING»(ref-203132-S30034248782005103000000) .
2. Loosen retaining screw -3- and remove wiper arm adjusting tool 3358 from wiper arm -2- then reinstall and recheck.
3. Compare angle indicated with specification in table.
4. If necessary, repeat setting and checking procedure until specification in table is met.
5. Remove adjusting tool and re-install wiper blade.

Wiper blades, adjusting parked position

Parked position

Windshield

1. Adjust wiper blades to the markings in the windshield. a - Marking for vehicles with LHD b - not applicable Tightening torque of wiper arms: 20 N.m (15 ft lb). Rear window
2. Adjust wiper blade to clearance -a-. Dimension -a- = 25 mm (0.98 in.) Tightening torque of wiper arms: 15 N.m (11 ft lb).

Radio anti-theft coding, activating

See Radio Owner's Manual.

Service Reminder Indicator (SRI), programming

If the instrument cluster is replaced, the Service Reminder Indicator (SRI) (F27) must be programmed so that the correct displays will appear at the appropriate mileage and time intervals.

Note. Examples based on an odometer displaying miles appear throughout the following procedure to illustrate the programming steps. The procedure is the same for vehicles with odometers displaying kilometers.

To program SRI displays

Scheme 44

Scheme 45

1. Switch ignition ON.
2. Press and hold the odometer reset button -arrow- located below speedometer.
3. While holding the odometer reset button, press the lower digital clock reset button -1- or the analog clock reset button -2-, and release both buttons. The programming mode will be activated and OEL1.S (distance counter) will be displayed NOTE: The ".S" at the end of the display means the system is in the setting/programming mode.

Service Reminder Indicator (SRI) display/function

SERVICE REMINDER INDICATOR (SRI) DISPLAY/FUNCTION

1. With OEL1.S indicated on display, press the lower digital clock reset button or the analog clock reset button. 7500 (miles) or 12,000 (km) indicated on display Distance can now be set for next oil change.

Example

The instrument cluster is replaced on a 4 month old vehicle with 5000 miles. The 5000 accumulated miles must be subtracted from the displayed mileage setting of 7500. The new mileage setting should read 2500 (7500 - 5000 = 2500).

1. Press the lower digital clock reset button or the analog clock reset button to decrease mileage setting in intervals of 500 until the correct setting is displayed.

After OEL1.S distance counter is set correctly

1. Press odometer reset button. OEL2.S (time counter) indicated on display
2. Press the lower digital clock reset button or the analog clock reset button. 6 (months) indicated on display Time can now be set for next oil change.

Example

In the previous example, the instrument cluster was replaced on a 4 month old vehicle. The accumulated time of 4 months must be subtracted from the displayed setting of 6. The new time setting should read 2 (6 - 4 = 2).

1. Press the lower digital clock reset button or the analog clock reset button to decrease the time setting until the correct setting is displayed.

After OEL2.S time counter is set correctly

1. Press odometer reset button. IN01.S (time counter) indicated on display
2. Press the lower digital clock reset button or the analog clock reset button. 12 (months) indicated on display Time can now be set for the next maintenance interval.

Example

In the previous example, the instrument cluster was replaced on a 4 month old vehicle. The accumulated time of 4 months must be subtracted from the above displayed setting of 12. The new time setting should read 8 (12 - 4 = 8).

1. Press the lower digital clock reset button or the analog clock reset button to decrease the time setting until the correct setting is displayed. NOTE: The IN01.S display (usually associated with the 15,000 mile/24,000 km maintenance) is programmed by months only (not distance) and uses the distance counter from the OEL1.S (7500 mile/12,000 km oil change) which was set previously. After IN01.S time counter is set correctly
2. Press odometer reset button. IN02.S (distance counter) indicated on display
3. Press the lower digital clock reset button or the analog clock reset button. 30,000 (miles) or 48,000 (km) indicated on display Distance can now be set for next 30,000 mile (48,000 km) maintenance interval.

Example

In the previous example, the 5000 accumulated miles must be subtracted from the above displayed mileage setting of 30,000. The new mileage setting should read 25,000 (30,000 - 5000 = 25,000).

1. Press the lower digital clock reset button or the analog clock reset button to decrease mileage setting in intervals of 500 until correct setting is displayed.

Note. The IN02.S display is programmed by distance only (not time) and uses the time counter from the IN01.S (12 month maintenance) which was set previously.

After IN02.S time counter is set correctly

1. Switch ignition OFF. SRI programming is stored

Clock, setting

Digital clock

Two buttons -1- are located on the right below the speedometer for setting the clock. The upper button sets the hours and the lower button sets the minutes.

Press the appropriate button to set the clock exactly to the second.

Analog clock

A button -2- is located on the right below the clock for setting the time.

The clock can be set exactly to the second by pressing the button.

Scheme 46

Service

Within 48 Hours after arrival at Dealer

RAPGARD® Disposal

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

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.

Original equipment blades are temporarily installed during the Pre-Delivery Inspection to check wiper blade park position.

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 47

Scheme 48

1. Grasp blade as shown and rotate in direction of arrow (toward windshield).
2. 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, see WIPER BLADE CONTACT ANGLE, CHECKING AND ADJUSTING .

Scheme 49

Scheme 50

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

Model year

1. N = 1992
2. P = 1993
3. R = 1994

1.8 and 2.0 liter engines

On front of engine block below the separation point between engine block and cylinder head

Scheme 51

4-cylinder diesel engines

Between injection pump and vacuum pump on the cylinder block.

Scheme 52

6-cylinder engines

On cylinder block at vibration damper side -arrow-.

On the 6-cylinder engine the number is visible by looking through from the front right between suspension strut tower and air cleaner.

Scheme 53

Notes for all engines

1. The engine code letters can also be found on the vehicle data plate, located in the rear left side of the engine compartment.
2. The engine code letters and engine number can also be found on a sticker on the camshaft drive belt guard (4 -cyl. engines) or on the left cylinder head cover (6 -cyl. engine).

Floor jack

In order to prevent damage to the vehicle underbody, a suitable rubber or wood liner must be used. The vehicle must never be lifted on the engine oil pan, transmission, rear axle, front axle or bottom sill. Serious damage can occur.

Workshop hoist

Front

At the reinforcing plate welded to the floor panel.

Scheme 54

Note. Do not lift the vehicle at the front vertical reinforcing plate of the lower sill, otherwise severe damage may be caused.

Rear

At the rear vertical reinforcing plate of the lower sill in the area of the marking for the vehicle jack.

Scheme 55

To prevent damage to transmission and differential

1. Tow any vehicle with the drive wheels lifted, whenever possible.
2. Excessive towing speeds and distances may damage both manual and automatic transmissions.
3. Tow front-wheel-drive vehicles from the front whenever possible.
4. If a vehicle is to be towed on it's drive wheels, the transmission and differential MUST be operable. Place the transmission in NEUTRAL: Move the vehicle only within the manufacturer's recommended speeds and distances. If any doubt exists about the condition of the transmission or differential, tow the vehicle with the drive wheels lifted, use self-loading wheel dollies or wheel lift equipment.

Towing a vehicle from the rear (with the rear wheels lifted)

1. Before towing, always unlock the steering wheel with the ignition key.
2. Then secure the steering wheel with a steering wheel clamping device, which has been specially designed for towing service.
3. Reason: The anti-theft steering column lock is not strong enough to withstand shocks transmitted from the wheels while towing.
4. When the ignition key is not available, DO NOT tow from the rear, serious damage to vehicle systems will result.

Towing locked vehicles when keys are not available

1. The front of the car must be lifted to prevent damage to the steering column anti-theft lock.
2. Locked front-wheel-drive cars may be moved on their rear wheels, provided the parking brake is released.

Towing speed

Ground clearance

1. Towed vehicles should be raised until lifted wheels are a minimum of 6 inches from the ground and there is adequate clearance at the opposite end of the lifted vehicle.
2. Ground clearance can be increased by removing the wheels from the lifted end of the disabled vehicle; an 8 inch clearance must be maintained between brake rotors or drums and the ground.
3. Increased ground clearance may be obtained by using a self-loading dolly. Lift the end of the disabled vehicle just as if towing.
4. Care must be taken to insure adequate ground clearance when towing over rough terrain or when crossing sharp rises, such as curbs.
5. Sharp rises, such as curbs, should be crossed at a 45 ° angle to minimize the possibility of scraping the underbody of the towed vehicle.

Stopping

Always avoid "panic" or "fast" stops during towing.

1. Many vehicles tend to ride up the sling belts. When this happens, the vehicle may come in contact with rigid portions of the wrecker or sling, considerably damaging the towed vehicle and the wrecker
2. To minimize the chances for ride up, make sure the tow bar end of the sling spacer bars is lower than the wrecker end of the spacer bars.

Vehicle hook-up

1. Always inspect points of attachment to the disabled vehicle. If they appear to be damaged or deteriorated, select other attachment points at a substantial structural member of the frame.
2. Never allow the fuel tank to support any of the vehicle's weight during towing. Before moving the vehicle, carefully secure or remove any loose or protruding parts of damaged vehicles; such as, hoods, fenders, trim, etc.
3. Always use a safety chain system which is completely independent of the primary lifting and towing attachments.
4. During installation of safety chains, be careful not to damage lights, bumpers, or painted surfaces.
5. To avoid serious vehicle damage, never lift or tow any vehicle by attaching towing chains or hooks to shock absorbers, stabilizer bars, or front strut rods.
6. To prevent damage to brake lines and front drive shaft boots, always position hooks and chains cautiously to prevent damage to brake lines and front drive shaft dust boots.
7. When making a towing attachment using the grab hook ends of the chains (commonly called "short-chaining"), pass the hook over then back under the chassis member before attaching the hook in the chain. This method will cause the hook to remain engaged in the chain in the event the chain becomes slack.
8. Prior to towing the vehicle, ensure that all attachment points are firmly secured.

All towing equipment is not the same

1. Always be thoroughly familiar with specific towing equipment being used.
2. Always follow the manufacturer's recommendations for such equipment.

Know all applicable legal towing requirements

1. All state and local laws regarding such items as warning signals, night illumination, speed, etc., must be followed.

ABOVE ALL, SAFETY FIRST

Front towing (Golf III , GTI)

Scheme 56

1. Attach wheel lift equipment to wheels
2. Attach safety straps to wheels
3. Attach safety chains to lower control arms
4. Towing clearance: 6-12 inches between tires and ground

Rear towing (Golf III , GTI)

Scheme 57

1. Attach wheel lift equipment to wheels
2. Attach safety straps to wheels
3. Attach safety chains to axle beam
4. Towing clearance: 6-12 inches between tires and ground

Front towing (Jetta III )

Scheme 58

1. Attach wheel lift equipment to wheels
2. Attach safety straps to wheels
3. Attach safety chains to lower control arms
4. Towing clearance: 6-12 inches between tires and ground

Rear towing (Jetta III )

Scheme 59

1. Attach wheel lift equipment to wheels
2. Attach safety straps to wheels
3. Attach safety chains to axle beam
4. Towing clearance:6 - 12 inches between tires and ground