Repair manual
Wiring diagrams
Volkswagen Jetta III Repair Manual
Step-by-step repair and maintenance instructions for the Volkswagen Jetta III (1992–1998): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
74sections
699articles
ENManual language
- Engine code
- Safety precautions
- Rules of cleanliness
- Engine, removing
- Vehicles with A/C
- Vehicles with manual transmission
- All vehicles
- Engine, installing
- Front engine/transmission mount
- Right rear engine/transmission mount
- Right engine/transmission mount (Cabrio only)
- Left rear engine/transmission mount
- 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
- Sealing flange and flywheel/driveplate, removing and installing
- Crankshaft, removing and installing
- Crankshaft dimensions
- 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
- Reconditioned cylinder heads with camshaft bearing shells
- Valve dimensions
- Valve seats, refacing
- Hydraulic valve lifters, checking
- Valve guide wear, checking
- Valve guides, removing and installing
- Checking Oil Pump Backlash
- Checking Oil Pump Axial Clearance
- Oil pressure and oil pressure switches, checking
- 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
- Engine Codes: Aaz, 1Z, Ahu
- Turbocharger System Components, Removing and Installing (Engine Code Aaz)
- Turbocharger System Components, Removing and Installing (Engine Codes 1Z, Ahu)
- Turbocharger Cooling System Components, Removing and Installing (Engine Codes 1Z, Ahu)
- Rules of Cleanliness
- Engine Code Aaz
- Engine Codes 1Z, Ahu
- Turbocharger, Removing and Installing (Engine Code Aaz)
- Special Tools, Testers and Auxiliary Items
- Removing
- Installing
- Turbocharger, Removing and Installing (Engine Codes 1Z, Ahu)
- Checking Conditions
- Check Conditions
- 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
- 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
- Fuel injection system, servicing
- Motronic Engine Control Module (ECM), Heated Oxygen Sensor (HO2S), Engine Coolant Temperature (ECT) sensor and engine speed (RPM) sensor, removing and installing
- Air cleaner (ACL), Mass Air Flow (MAF) sensor and Positive Crankcase Ventilation (PCV) heating element, removing and installing
- Fuel rail and intake manifold, removing and installing
- Throttle valve control module, removing and installing
- Engine Coolant Temperature Resistance Graph
- 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
- Evaluating display group 037
- Evaluating display group 036
- Evaluating display group 003
- Basic setting, initiating
- Evaluating display group 001
- Evaluating display group 002
- Check conditions
- Checking activation
- Checking spray pattern and for leaks
- Fuel pressure regulator and residual pressure, checking
- 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
- Function
- Malfunction Indicator Lamp (MIL)
- Functional check
- 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: 4
- Work step: 12
- Procedure
- Work step: 19
- Selectable functions for address word "33 CARB / OBDII"
- Current data, mode 1
- PID Status
- Freeze frame data, mode 2
- Oxygen sensor signal (B1-S1), mode 5
- Test conditions
- Code Control Module (scan tool function 07)
- Diagnostic Trouble Code (DTC) table
- Road test procedure
- Test sequence
- Work step: 3 Diagnostic test: Engine warm -up
- Work step: 5 Diagnostic test: Oxygen Sensor (O2S) aging (regulating frequency extended)
- Work step: 6 Diagnostic test: Fuel adaptation under partial throttle
- Work step: 8 Diagnostic test: Secondary Air Injection (AIR) system
- Work step: 9 Diagnostic test: Oxygen Sensor (O2S) aging (regulating frequency extended)
- Work step: 10 Diagnostic test: Three Way Catalytic Converter (TWC)
- Work step: 11 Diagnostic test: Fuel tank vent system (EVAP canister purge regulator valve)
- Work step: 13 Diagnostic test: Vehicle Speed Sensor (VSS)
- Work step: 15, Diagnostic test: Heated Oxygen Sensor (HO2S) before three way catalytic converter
- Work step: 16, Diagnostic test: Heated Oxygen Sensor (HO2S) after three way catalytic converter
- Work step: 17, Diagnostic test: Oxygen Sensor (O2S) heating (before three way catalytic converter)
- Work step: 18, Diagnostic: Throttle valve control module
- Output Diagnostic Test Mode (DTM) (scan tool function 03)
- Read measuring value block (scan tool function 08)
- Diagnostic data
- DTC memory, mode 3
- Clear DTC memory, mode 4
- 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
- On Board Diagnostic (OBD) - 1.9L TDI, 1Z & Ahu (A3 Platform) 5
- On Board Diagnostic (OBD) - 2.0L, Aba (A3 Platform) 3
- Multiport Fuel Injection (Mfi) - 2.0L, Aba (A3 Platform) 4
- Ignition-Glow Plug System - 2.0L, Aba (A3 Platform) (A3 Platform) 3
- On Board Diagnostic (OBD) - 2.8L VR6, Aaa (A3 Platform) 2
- Glow Plug System Troubleshooting - 1.9L - Aaz (Canada Only) 2