Repair manual
Wiring diagrams
Volkswagen Jetta IV Repair Manual
Step-by-step repair and maintenance instructions for the Volkswagen Jetta IV (1998–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
90sections
2073articles
ENManual language
- Engine data
- Notes on removing
- Notes on installing
- Engine and transmission mountings, aligning
- Part I
- Ribbed belt, removing and installing
- Sealing flanges and flywheel/drive plate
- Drive plate, removing and installing
- Crankshaft
- Crankshaft dimensions
- Piston and cylinder dimensions, engine code AWD
- Checking piston ring gap
- Checking ring to groove clearance
- Checking piston
- Checking cylinder bores
- Piston and cylinder dimensions, engine codes AWP, AWW
- Cylinder head
- Removing
- Installing
- A - Toothed belt completely removed
- B - Toothed belt only removed from camshaft gear
- Toothed belt, tensioning
- Valvetrain
- Valve seats, refacing
- The maximum permissible refacing dimension is calculated as follows
- Refacing exhaust valve seat
- Oil seal at camshaft gear, removing and installing
- Hydraulic valve lifters, checking
- Camshafts, removing and installing
- Activation, checking
- Camshaft adjuster, checking function
- Valve guides, checking
- Valve stem seals, replacing
- Engine oil
- Oil pan, removing and installing
- Cooling system components
- Vehicles with engine code AWD
- Filling
- Coolant pump, removing and installing
- Coolant thermostat, removing and installing
- After-Run Coolant Pump V51 , checking
- Fuel supply system components
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Fuel delivery unit, removing and installing
- Fuel Level Sensor G , removing and installing
- Fuel tank, removing and installing
- Function
- Function and voltage supply, checking
- Checking delivery rate
- Fuel Pump (FP) check-valve, checking
- EPC system, function
- Electronic Power Control (EPC) Warning Lamp in instrument cluster, meaning
- Evaporative emissions (EVAP) system
- Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 , checking
- EVAP system, checking for leaks
- Checking for leaks
- Checking voltage supply
- Checking Leak Detection Pump (LDP) V144 for internal leaks
- Conditions
- Charge air system with turbocharger
- Part II
- Safety precautions
- Boost pressure regulation, checking
- Wastegate Bypass Regulator Valve N75 , checking
- Charge Air Pressure Sensor G31 , checking
- Checking function
- Turbocharger Recirculating Valve N249 , checking
- Vacuum diaphragm for boost pressure regulator valve, checking
- Deceleration shut-off valve, checking
- Charge air system, checking for leaks
- Exhaust system components
- Three Way Catalytic Converter (TWC), checking
- Secondary air injection (AIR) system
- Combi-valve, checking
- Secondary Air Injection (AIR) Pump Motor V101 , checking
- Secondary Air Injection (AIR) Solenoid Valve N112 , checking
- Accelerator linkage, servicing
- Throttle Position (TP) sensor, checking
- Function
- Charge air system with turbocharger
- Turbocharger with attachments, removing and installing
- Charge air cooler components (vehicles with engine code ALH), removing and installing
- Charge air cooler components (vehicles with engine code BEW), removing and installing
- Rules of cleanliness
- Safety precautions
- Wastegate bypass regulator valve, checking
- General notes for Diesel-Direct Fuel Injection System
- Injection pump, servicing
- Pump-Injector unit, servicing
- Intake manifold flap, servicing
- Intake manifold change-over, servicing
- Injectors, removing and installing
- Injectors, checking
- Pump-Injector Unit, removing and installing
- Removing
- Installing
- Pump-Injector Unit, checking
- Check wires to control module
- Sender for fuel gauge, checking
- Manifold Absolute Pressure (MAP) sensor and Barometric Pressure (BARO) sensor, checking
- Requirements
- Engine Coolant Temperature (ECT) sensor, checking
- Fuel Temperature Sensor, checking
- Vehicles with engine code ALH
- Modulating Piston Displacement Sensor and quantity adjuster, checking
- Modulating Piston Displacement Sensor -G149-, checking
- Checking Quantity Adjuster -N146
- Needle lift sensor, checking
- Cold Start Injector, checking
- Mass Air Flow (MAF) sensor, checking
- Checking signal and Ground wires of Mass Air Flow (MAF) Sensor
- Change-over valve for intake manifold flap, checking
- Checking function
- Oxygen sensor heating, checking
- Intake Air Temperature (IAT) sensor, checking
- Charge air pressure sensor, checking
- Exhaust Gas Recirculation (EGR) Cooler Switch-over Valve, checking
- Motor for intake flap, checking
- Checking voltage supply
- Oxygen sensor and oxygen sensor control, checking
- Checking primary voltage
- Checking oxygen sensor wires
- Voltage supply for Diesel-Direct Fuel Injection System, checking
- Control module for Diesel-Direct Fuel Injection System, replacing
- Engine speed signal, checking
- Terminal resistance for CAN-bus, checking
- Vehicles with 80-pin control module and manual transmission
- Vehicles with 80-pin control module and autom. transmission
- Continuation at 115 to 135 ohms
- Checking CAN-Bus wires
- Exhaust system components, removing and installing
- Exhaust Gas Recirculation (EGR) system
- Basic setting of EGR Vacuum Regulator Solenoid Valve (vehicles with engine code BEW)
- EGR Vacuum Regulator Solenoid Valve, checking (vehicles with engine code ALH)
- EGR Vacuum Regulator Solenoid Valve, checking
- Potentiometer for EGR, checking (vehicles with engine code BEW)
- Only vehicles with engine code BEW and vehicles with engine code ALH, model year >2001
- Vehicles with engine code ALH, model year 2002 >
- Glow plugs, checking
- Multi-Function Transmission Range (TR) Switch, replacing
- Vehicles with 01M transmission
- Vehicles with 09A transmission
- Multi-Function Transmission Range (TR) Switch, checking
- Checking wires to Transmission Control Module (TCM)
- Transmission Vehicle Speed Sensor (VSS), checking (vehicles with 01M transmission)
- Sensor for transmission RPM, checking (vehicles with 09A transmission)
- Check sensor resistance.
- Vehicle Speed Sensor (VSS), checking (vehicles with 01M transmission)
- Vehicle Speed Sensor (VSS), checking
- Intermediate Shaft Speed Sensor, checking (vehicles with 09A transmission)
- Solenoid valves in valve body, checking
- Checking resistance of solenoid valves
- Checking Ground (GND) refeed of valve body
- Transmission Control Module (TCM), replacing
- Equipment of control module for Diesel-Direct fuel injection system
- Equipment of Transmission Control Module (TCM)
- Requirement
- Work sequence for control module for Diesel-Direct Fuel Injection System
- Work procedure for Transmission Control Module (TCM)
- Malfunction Indicator Lamp (MIL) in instrument cluster
- Engine data
- Engine, removing and installing
- Engine, removing
- Engine and transmission mounts, aligning
- Work procedure
- Ribbed belt routing
- Sealing flanges and pressure plate/flywheel/drive plate, removing and installing
- Removing
- Installing
- Installing PTFE-version sealing ring
- Crankshaft dimensions
- Piston position at TDC, checking
- Piston and cylinder dimensions
- Cylinder head, removing and installing
- Compression pressures, checking
- Work sequence
- Valve seats, reworking
- Valve guides, checking
- Valve guides, replacing
- Valve stem seals, replacing
- Camshaft, removing and installing
- Hydraulic valve lifters, checking
- Engine oil
- Part I
- Oil pan, removing and installing
- Oil pressure and oil pressure switch, checking
- Cooling system components, removing and installing
- Engine code ALH
- Radiator, removing and installing
- Coolant pump, removing and installing
- Coolant thermostat, removing and installing
- Fuel supply system components, removing and installing
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Vehicles with all wheel drive (AWD)
- Checking breather valve
- Fuel tank, removing and installing
- Fuel Pump (FP), removing and installing
- Fuel pump, checking
- Function and voltage supply, checking
- Suction jet pump, removing and installing
- Vehicles with adjustable throttle position sensor
- Vehicles with non-adjustable throttle position sensor
- Adjusting Throttle Position (TP) sensor
- Safety precautions
- Turbocharger with attachments
- Hose connections with connection couplings
- Charge pressure regulation, checking
- Wastegate Bypass Regulator Valve N75 , checking
- Exhaust system components, removing and installing
- Front exhaust pipe and catalytic converter with attachments
- Muffler with mountings
- Exhaust Gas Recirculation (EGR) valve, checking
- Exhaust Gas Recirculation (EGR), checking
- Engine data
- Engine, removing
- Engine, installing
- Engine and transmission mountings, aligning
- Poly V-belt, removing and installing
- Sealing flanges and flywheel/drive plate, removing and installing
- Identifying Intermediate Plate, Sealing Flange And Dowel Sleeves
- Drive plate, removing and installing
- Crankshaft, removing and installing
- Color markings
- Crankshaft dimensions
- Piston and cylinder dimensions
- Cylinder head, removing and installing
- Engine codes AEG, AVH, AZG, BEV
- Semi-automatic toothed belt tensioning roller, checking
- Engine code BBW
- Valve gear, servicing
- Valve seats, reworking
- The maximum permissible reworking dimension is calculated as follows
- Reworking intake valve seat
- Reworking exhaust valve seat
- Camshaft, removing and installing
- Hydraulic lifters, checking
- Valve guides, checking
- Valve guides, replacing
- Oil pump, removing and installing
- Cooling system components, removing and installing
- Cooling system components, engine side
- Engine codes AEG, AVH and AZG (from model year 1999)
- Engine codes BBW, BEV
- Coolant hose connection diagram
- Filling
- Removing
- Coolant pump, removing and installing
- Thermostat, removing and installing
- Radiator coolant fan (vehicles with engine codes AEG, AVH and AZG), checking
- Fuel supply system components, removing and installing
- Fuel tank with attachments and fuel filter, removing and installing
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Installing
- Fuel filter, removing and installing
- Crash fuel shut-off
- Fuel Pump, Checking
- Fuel system, bleeding
- Accelerator mechanism, servicing
- Throttle cable, adjusting
- Vehicles with manual transmission
- Function of EPC system
- Function of EVAP system
- EVAP system, checking using KLI 9210 tester
- Engines: BBW, BEV
- Position of relays in protective housing (on left in engine compartment)
- General notes on injection
- Safety precautions
- Intake manifold upper part, removing and installing
- Technical data
- Engine code AEG
- Engine codes AVH, AZG
- Checking fuel pressure regulator
- Engine control module, replacing
- Adapting components and functions
- Exhaust system components, removing and installing
- Exhaust manifold, front exhaust pipe and catalytic converter with attachments
- Exhaust manifold, removing and installing
- Secondary air injection system
- Function
- Secondary air injection system components, removing and installing
- Combination valve, removing and installing
- Combination valve, checking
- Secondary air injection pump motor, checking
- Secondary air injection solenoid valve, checking
- Ignition Coil N152, Checking
- Requirements
- Checking voltage supply
- Checking activation
- Final Procedures
- General notes on ignition system
- Ignition system components, removing and installing
- Vehicles up to model year 1999
- Engine data
- Engine, removing
- Engine, attaching to engine stand
- Engine, installing
- Engine and transmission supports, aligning
- Valve timing, checking
- Work sequence
- With engine installed, cylinder head removed
- Marking roller chains
- Ribbed V-belt, removing and installing
- Removing "V" ribbed belt
- Installing "V" ribbed belt
- Sealing flange and flywheel/drive plate, removing and installing
- Removing
- Installing
- Crankshaft, removing and installing
- Piston and cylinder measurements
- Requirements
- Conditions
- Valve gear, repairing
- Valve seats, reworking
- Calculating the maximum allowable reworking dimension
- Reworking exhaust valve seat
- Camshafts, removing and installing
- Hydraulic lifters, checking
- Valve guides, checking
- Valve guides, replacing
- Valve stem seals, replacing
- Oil pan, removing and installing
- Function of the Dynamic Oil Pressure Warning System
- Warning criteria
- Oil pressure, checking
- Cooling system components, removing and installing
- Main radiator
- Auxiliary radiator
- After-Run Coolant pump V51 , checking
- Coolant Fan V7 and Right coolant fan V35 , checking
- Fuel supply system components, removing and installing
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Fuel delivery unit, removing and installing
- Fuel tank, removing and installing
- Checking function and voltage supply
- Checking delivery rate
- Checking pump non-return valve
- Function of the Electronic Power Control (EPC) system
- Electronic Power Control (EPC) warning lamp, checking
- If EPC warning lamp illuminates continuously
- Function
- Evaporative emission (EVAP) canister purge regulator valve N80 , checking
- Checking sealing quality of system
- Checking voltage supply
- Checking resistances
- EVAP system, checking using KLI 9210 tester
- Checking Leak Detection Pump (LDP) V144 for internal leaks
- Exhaust system components, removing and installing
- Muffler with hangers
- Catalytic converter, checking
- Secondary air system, function
- Secondary air system components, removing and installing
- Combination valve, checking
- Condition
- Secondary Air Injection (AIR) Solenoid Valve N112 , checking
- Combination valve, removing and installing
- Planetary transmission
- Final drive
- Repair instructions
- Definitions
- Sleeve bearing, removing from turbine shaft
- Removing control module
- Installing control module
- Gear change mechanism, servicing
- Gear change mechanism, checking
- Selector lever cable, checking and adjusting
- Removing
- Installing
- Selector lever, removing and installing
- Locking cable, adjusting
- Transmission, checking
- Main pressure, checking
- Transmission, removing and installing
- Transporting the automatic transmission
- ATF level, checking and topping up
- ATF level, checking
- ATF level, topping up
- ATF, replacing
- Position of selector elements
- Pressing clutch -K1- off -K3
- Table of shims
- Planet carrier check measurement
- Reverse gear brake -B1-, adjusting
- Reverse gear brake -B1- check measurement
- Clutch play between -K1- and -K2-, adjusting
- Check measurement (clutch play)
- 2nd and 4th gear brake -B2-, adjusting
- Determining shim(s)
- Calculating dimension "a"
- Calculating dimension "b"
- Solenoid Valves in Valve Body, Checking
- Requirements
- Checking resistance
- Final Procedures
- Checking voltage
- Transmission Control Module J217, Replacing
- Procedure
- Fitting and hooking ends of piston ring together
- Installing O-ring
- Valve body, removing and installing
- Replacing plug seal
- Inserting sealing plug
- Hooking operating rod onto manual selector valve
- Installing valve body
- Final drive oil, checking
- Axle flange seal, removing and installing
- Input gear, removing and installing
- Drive pinion, removing and installing
- Differential, removing and installing
- Speedometer drive
- Final drive, adjusting
- Drive pinion, adjusting
- Table of shims for drive pinion and input gear
- Input gear, adjusting
- Differential, adjusting
- Selector mechanism, disassembling and assembling
- Transmission, disassembling and assembling
- Planetary gearbox, disassembling and assembling
- Disassembling planetary gearbox
- 1st to 3rd gear clutch -K1-, disassembling and assembling
- Reverse gear clutch -K2-, disassembling and assembling
- 3rd and 4th gear clutch -K3- with turbine shaft, disassembling and assembling
- Parking lock, disassembling and assembling
- Differential, disassembling and assembling
- Transmission layout
- Gear ratios
- Calculating overall ratio "i"
- General repair instructions
- Gaskets, sealing rings
- Before installing
- Bolts and nuts
- Bearings
- Shims
- Synchronizer rings
- Selector gears
- Gear selector mechanisms
- Transmission, removing and installing
- Gear oil, checking
- Cover for transmission housing and 5th gear, removing and installing
- Transmission housing and selector mechanism, removing and installing
- Input shaft, output shaft (pinion shaft), differential and selector forks, removing and installing
- Transmissions up to 05.99
- Transmission housing and clutch housing, servicing
- Transmission housing and clutch housing
- Pulling sleeve in
- Revised selector cover and selector shaft
- Functional check
- Revised selector shaft and selector cover
- Identifying selector segments
- Installing circlip
- Removing bearing inner race
- Selector fork with selector segments installed
- Pressing on 4th gear
- Input shaft adjusting
- Pulling off small tapered roller bearing inner race
- Pulling off large tapered roller bearing inner race
- Pressing on large tapered roller bearing inner race
- Checking synchro-ring for wear
- Pressing on 1st and 2nd gear locking collar/synchro-hub
- Identifying 1st and 2nd gear synchro-rings
- Distinguishing 1st and 2nd gear synchro-rings
- Checking 2nd gear synchro-ring for wear
- Checking inner ring for wear
- Modified 1st gear synchronization from transmission build date 02 05 0
- Output shaft, adjusting
- Determining thickness of shim
- Transmission installed
- Removing
- Pulling off tapered roller bearing inner race
- Pulling tapered roller bearing outer race out of transmission housing
- Pressing tapered roller bearing outer race into transmission housing
- Installing
- Differential, adjusting
- Determining shim thickness
- Calculating overall ratio 'i'
- General repair instructions
- Over-center spring, removing and installing
- Removing
- Installing
- Clutch pedal, removing and installing
- Master cylinder, removing and installing
- Clutch system, bleeding
- Clutch, servicing
- Gear selector mechanism up to 05.99, adjusting
- Removing and installing circlip
- Gear selector mechanism from 05.99, adjusting
- Transmission, removing and installing
- Modifying support rails VW 457/1
- Gear oil, checking
- Transmission housing and clutch housing, servicing
- Input shaft, adjusting
- Measurement check
- Check inner ring 1st gear for wear
- Check synchro-ring 1st gear and outer ring for wear
- Output shaft, adjusting
- Flange shaft oil seals, replacing
- Differential, adjusting
- Assembly sequence
- Assembling
- Transmission selector mechanism up to 05.99, disassembling and assembling
- Transmission selector mechanism from 05.99, disassembling and assembling
- Selector forks, disassembling and assembling
- Input shaft, disassembling and assembling
- Output Shaft, disassembling and assembling
- Assembling 1st and 2nd gear locking collar/synchro-hub
- Assembling 3rd and 4th gear locking collar/synchro-hub
- Reverse shaft, disassembling and assembling
- Differential, disassembling and assembling
- Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks
- Assembling
- Transmission selector mechanism up to 05.99, disassembling and assembling
- Transmission selector mechanism from 05.99, disassembling and assembling
- Selector forks, disassembling and assembling
- Input shaft, disassembling and assembling
- Output shaft, disassembling and assembling
- Reverse shaft, disassembling and assembling
- Differential, disassembling and assembling
- Specifications & Drive Belt Routing - 2.0L (Aeg, Avh & Azg Engine) 3
- Specifications & Drive Belt Routing - 1.8L (Awd or Awv Engine) 3
- Specifications & Drive Belt Routing - 1.9L (Alh Engine) 3
- Specifications & Drive Belt Routing - 2.8L VR6 (Afp & Bdf Engine) 5
- 2.0L Engine Mechanical - Aeg, Avh, Azg, Bbw, Bev (A4 Platform) 7
- 1.9L TDI Engine Mechanical - Alh (A4 Platform) 5
- 1.8L - Engine Mechanical, Engine Code(s): Awd, Aww, Awp (A4 Platform) 5
- 2.8L VR6 2V Engine Mechanical - Afp (A4 Platform) 8
- Turbocharger, G-Charger - 1.9L 4CYL. 2V TDI - Alh (A4 Platform) 2
- Turbocharger, G-Charger - 1.8L, Awd, Awp, Aww Generic (A4 Platform) 5
- Turbocharger, G-Charger - 1.9L TDI, Alh, Bew (Generic Scan Tool) (A4 Platform) 4
- Exhaust System, Emission Controls - 1.9L TDI, Alh, Bew (Generic Scan Tool) (A4 Platform) 4
- Body foam insulation
- Reinforced body sheet metal
- Laser welding
- Galvanized body panels
- Body panel gaps/mating lines
- Body, rear (Jetta wagon)
- Straightening fixture
- Jetta wagon
- Welding in place
- Front wheel house, partial replacing
- Front inner fender, replacing
- Long member front section, replacing
- Front roof cross member, replacing
- Roof reinforcement, replacing
- Rear roof cross member, replacing (Golf)
- Rear cross member, replacing (Jetta)
- Rear roof crossmember, replacing (Jetta wagon)
- Welding in
- Foam insulation
- Inner B-pillar, replacing (2-door)
- Part section
- Rear cross panel, replacing
- Tail light mount, replacing (Golf)
- Rear center cross panel carrier, replacing (Jetta)
- Reinforcement for C-pillar, replacing (Jetta wagon)
- Rear long member, replacing (Jetta)
- Preparing new part
- Foamed area
- Connecting panel, replacing (Jetta)
- Rear wheelhousing, outer, replacing -partial section- (Jetta wagon)
- Spare wheel well, replacing (Golf)
- Spare wheel well, replacing (Jetta)
- Replacement part
- Replacement parts
- Partial replacement
- Rear long member, partial replacement (Golf)
- Long member, partial replacement (Jetta)
- Side panel, partial replacement (Jetta wagon)
- Quarter panel, partial replacement (Golf)
- Wheel house connecting panel, partial replacement (Jetta)
- Spare wheel well, partial replacement (Golf)
- Tools
- Lock carrier service position
- Fender gaps
- Hood, adjusting
- Gas-filled strut, removing
- Release lever, removing and installing
- Hood lock, removing and installing
- Rear lid, adjusting
- Installing
- Lock cylinder housing, removing and installing
- Removing
- Door, adjusting
- Door handle, removing and installing
- Door lock, removing and installing
- Locking knob for locking rod, removing and installing
- Door seals
- Materials
- Adaptation of keys with radio remote control
- Door, removing and installing
- Function
- Distinguishing features of Webasto and Rockwell (Meritor) sunroofs
- Water channel connection
- Removing glass panel for sunroof
- Glass panel for sunroof, installing
- Zero position
- Panel seal, replacing
- Wind deflector, removing
- Sliding headliner, removing
- Drive motor for sunroof, removing
- Drive motor for sunroof, adjusting (zero position)
- Parallel movement, checking
- Parallel movement, adjusting
- Slotted guide rail, removing
- Glass panel for sunroof, removing
- Automatic rotary switch for sunroof, removing
- Bumper cover, removing and installing
- Bumper cover (Golf R32), removing and installing
- Adapter part (Golf R32), removing and installing
- Rear bumper cover, removing and installing
- Trailer hitch, removing and installing
- Rear bumper cover (Golf R32), removing and installing
- Windshield, removing
- Windshield, installing
- Undamaged side window, removing
- Damaged side window, removing
- Side window, installing
- Undamaged rear window, removing
- Damaged rear window, removing
- Rear window, installing
- Side window
- Gap dimensions for side windows
- All other windows
- Minimum curing time
- Repairing paint damage
- Adhesive sealing material, cleaning off surplus
- Front door window, removing
- Door window, adjusting
- Door window at window regulator, installing
- Power window regulator for comfort system (automatic opening and closing) with excess force limitation (pinch protection)
- Function of window regulator with ignition switched on
- Function of window regulator with ignition switched off
- Setting automatic opening and closing
- Overcoming resistance with excess force limitation (Pinch protection)
- Window regulator, removing and installing
- Mirror housing, removing
- Radiator grill, removing and installing
- Protective side moldings, replacing
- Rear spoiler, general notes
- Rear lid preparation
- Safety precautions
- Additional bolts at front valance spoiler, installing
- Sill panel extension, removing
- Roof edge spoiler, removing
- Installing roof edge spoiler
- Preparing bodywork for adhesive
- Cleaning when soiled by adhesive sealing material
- Automatically dimming interior rearview mirror
- Retaining plate for interior mirror, installing
- Removing
- Installing
- Mirror base for interior mirror with rain sensor, bonding
- Preparing windshield
- Preparing detached and new mirror base
- Bonding mirror base
- Cleaning and removing excess adhesive
- Rain sensor and mirror, installing
- Center console, removing and installing
- Center console extension, removing and installing
- Grab handles (Roof), removing and installing
- Sill panel trim (Golf 4-door), removing and installing
- Sill panel trim (Golf 2-door), removing and installing
- Safety regulations for belt tensioners
- Disposing of belt tensioner units
- Front seat belts, removing and installing
- Rear outer seatbelts, removing and installing
- LATCH System "Lower Anchors and Tethers for CHildren", installing and retrofitting
- Check points
- Check belt webbing
- Check automatic retraction (locking effect)
- Visually check belt latch
- Check belt latch function
- Check belt guides and locking tongue
- Check securing components and anchorage points
- Tools
- Safety precautions for work on airbags
- Additional safety precautions for head curtain airbag
- Disposing airbag units
- Accident where airbag deployed
- Accident not involving activation of airbag
- Airbag units, deploying (disposal)
- Airbag spiral spring/return spring with slip ring -F138-, removing and installing
- Electronic Stability Program (ESP)
- Side curtain protection (driver and passenger sides) (Jetta), removing and installing
- Side curtain protection (driver and passenger sides) (Golf), removing and installing
- Side curtain protection (driver and passenger sides) (Golf wagon/Jetta wagon), removing and installing
- Driver and front passenger seat side airbags, removing and installing
- Components, adapting
- Work procedure
- Crash sensor for Driver side/Passenger side - side curtain protection, removing and installing
- Crash sensor for Driver side/Passengers side rear side curtain protection, removing and installing
- Instrument panel, removing and installing
- Driver side front door trim, removing and installing
- Rear door trim, removing and installing
- Front door window triangular trim (with speaker), removing and installing
- Upper B-pillar trim, removing and installing (Vehicles with side curtain protection 04.01)
- Upper B-pillar trim, removing and installing (Vehicles with side curtain protection 05.01 )
- Upper B-pillar trim, removing and installing (Vehicles without side curtain protection)
- Lower B-pillar trim, removing and installing
- Upper C-pillar trim, removing and installing (Golf with side curtain protection)
- Upper C-pillar trim, removing and installing (Golf without side curtain protection)
- Upper C-pillar trim, removing and installing (Jetta with side curtain protection )
- Upper C-pillar trim, removing and installing (Jetta without side curtain protection)
- Upper C-pillar trim, removing and installing (Golf wagon/Jetta wagon with side curtain protection 04.01)
- Upper C-pillar trim, removing and installing (Golf wagon/Jetta wagon with side curtain protection 05.01 )
- Upper C-pillar trim, removing and installing (Golf wagon/Jetta wagon without side curtain protection)
- Upper D-pillar trim, removing and installing (Golf wagon/Jetta wagon)
- Wheel housing trim, removing and installing (Golf)
- Wheel housing trim, removing and installing (Golf wagon/Jetta wagon)
- Side trim, removing and installing (Golf 2- door)
- Luggage compartment cover support, removing and installing (Golf)
- Right luggage compartment side trim, removing and installing (Golf wagon/Jetta wagon)
- Cargo net repair kit, installing
- Trunk escape handle, removing and installing
- Molded headliner, removing and installing (Vehicles with sunroof)
- Molded headliner, removing and installing (Vehicles without sunroof)
- Front seats, removing and installing
- Lumbar support, removing and installing
- Seat height adjusting element, removing and installing
- Headrest guides, removing and installing
- 8-way seat control module, removing and installing
- Seat cushion, removing and installing
- Seat cushion with integrated child seat, removing and installing
- Seat cushion, removing and installing (Golf wagon/Jetta wagon)
- Backrest, removing and installing
- Front seat cover and upholstery, removing and installing
- Front seat cover and upholstery, removing and installing (Golf R32)
- Front backrest cover and upholstery, removing and installing
- Front backrest cover and upholstery, removing and installing (Golf R32)
- Front seat heating element, removing and installing
- Front backrest heating element, removing and installing
- Cover and cushion for backrest, removing and installing
- Vehicle data sticker
- Technical data, brakes
- Notes for repair work on ABS, ABS/EDL
- ABS system components for front axle, removing and installing
- Removing
- Installing
- ABS wheel speed sensor rotor for front axle, checking
- ABS wheel speed sensor gap, checking
- Wheel speed sensor on rear axle, removing and installing
- Wheel speed sensor on rear axle (drum brakes), removing and installing
- Anti-lock brake system (ABS) Mark 60
- Control module and hydraulic unit Mark 60, removing and installing
- Brake pad wear indicator light -K32
- ABS warning light -K47
- ABS warning light -K47- and Warning light for brake system -K118
- ASR/ESP control lamp -K155
- ABS system components on front axle, removing and installing
- Removing and installing speed sensor on front axle
- Checking or removing and installing rotor on front axle
- Checking rotor lateral run-out
- Speed sensor on front axle, removing and installing
- Rotor on front axle, checking or removing
- Speed sensor on rear axle (front wheel drive), removing and installing
- Speed sensor on rear axle (disc brakes all-wheel drive), removing and installing
- ESP system components, removing and installing
- Sender for rotation rate -G202- and sensor for transverse acceleration -G200-, removing and installing
- ESP sensor unit -G419-, vehicles from my 02.02, removing and installing
- Steering angle sensor -G85-, removing and installing
- Front brake pads, removing and installing
- Brake pads, removing and installing
- Front brakes, 2FN brake caliper, servicing
- Rear brake pads, removing and installing
- Parking brake, adjusting
- Rear wheel brakes/disc brakes (all-wheel drive), servicing
- Parking brake cables for disc brakes - front wheel drive, removing and installing
- Parking brake cables for disc brakes - all wheel drive, removing and installing
- Brake pedal from brake booster, disconnecting and connecting
- Brake pedal, removing and installing
- Brake light switch, removing and installing/adjusting
- "Old style" brake light switch, removing and installing/adjusting
- "New style" brake light switch, removing and installing
- Front brake caliper piston, removing and installing
- FN 3 front brake calipers, servicing
- Front caliper piston, removing and installing
- Rear brake caliper, servicing
- Rear brake caliper piston, removing and installing
- Brake pressure regulator, checking and adjusting
- Brake system, bleeding
- Bleeding brake system with brake filler and bleeder unit VAS 5234, vehicles with ABS Mark 20
- Bleeding sequence
- Brake system, bleeding without pressure bleeder
- Bleeding brake system with brake filler and bleeder unit VAS 5234, vehicles with ABS Mark 60
- Pre-bleeding sequence
- Bleeding brake system without brake filling and bleeding appliance
- Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 10.00
- Vacuum pump for brake booster (vehicles with Diesel engines), removing and installing
- Sender 1 for brake booster -G201- and Sensor -2- for brake pressure -G214-, removing and installing
- Check function of brake assist in brake booster, vehicles from my 02.02
- Brake system vacuum pump -V192-, removing and installing
- Brake system vacuum pump -V192-, checking
- Brake booster pressure sensor -G294-, removing and installing
- Check function of check valve -A-.
- Brake system vacuum pump -V192-, vehicles up to my 05.02, electrical check
- Multi-pin connector with contact assignment
- Brake system vacuum pump -V192-, vehicles from my 06.02, electrical check
- Brake master cylinder, removing and installing
- Brake booster, removing and installing
- Definitions
- Engine Cooling System - 1.8L 4-CYL. 5V Turbo - Awd, Aww, Awp (A4 Platform) 3
- Engine Cooling System - 1.9L 4CYL. 2V TDI - Alh (A4 Platform) 2
- Cooling System - 2.0L (Aeg, Avh, Azg, Bbw, Bev) (A4 Platform) 5
- Cooling System - 2.8L (Afp) (A4 Platform) 5
- 1.8L - Fuel Injection & Ignition, Engine Code(s): Awd 4
- 1.8L - Fuel Injection Ignition, Engine Code(s): Aww, Awp (A4 Platform) 5
- 1.8L - Generic Scan Tool, Engine Code(s): Awp, Aww, Awd (A4 Platform) 6
- Safety precautions
- Rules for cleanliness
- Injection pump, servicing
- Intake manifold flap, servicing
- Removing
- Vehicles with manual transmission
- Vehicles with automatic transmission
- Start of injection, dynamically checking and adjusting
- Injectors, removing and installing
- Installing
- Injectors, checking
- Checking injection pressure
- Checking for leaks
- Injection timing device cover gasket, replacing
- Engine speed sensor, checking
- Manifold Absolute Pressure (MAP) sensor and Barometric Pressure (BARO) sensor, checking
- Engine Coolant Temperature (ECT) sensor, checking
- Brake light switch and brake pedal switch, checking
- Checking conditions
- Clutch vacuum vent valve switch, checking
- Intake Air Temperature (IAT) sensor, checking
- Fuel temperature sensor, checking
- Modulating piston displacement sensor- G419- and quantity adjuster, checking
- Needle lift sensor, checking
- Diesel injection timing control range, checking
- Mass Air Flow (MAF) sensor, checking
- Requirements
- Checking function
- Engine Control Module (ECM) -J248-, coding
- Work sequence
- Automatic transmission shift change signal, checking
- Compressor shut-off, checking
- A/C signal and engine speed adaptation, checking
- Cruise Control System (CCS), checking
- Check conditions
- CAN-Bus, checking (through MY 1999)
- Function
- If resistance is outside specified range
- Continuation for 115...135 ohms
- Further information
- Battery
- Battery types
- Warnings and Safety Measures for lead-acid batteries
- Battery post/terminal, handling instructions
- Battery, checking
- Battery, checking procedure
- Visual check
- Charge indicator, readings
- Electrolyte level, checking
- Electrolyte level too low
- Electrolyte level too high
- Batteries without charge indicator (magic eye), checking
- Electrolyte level, checking (batteries without charge indicator)
- Specific gravity, checking
- No load voltage, checking
- Battery, charging
- Battery charger, connecting
- Charging totally discharged batteries
- Battery with fastened fuse holder, disconnecting and reconnecting
- Battery, disconnecting
- Battery, reconnecting
- Battery with clipped fuse holder, disconnecting and reconnecting
- Work steps required after reconnecting battery
- Battery with fastened fuse holder, removing and installing
- Battery, removing
- Battery, installing
- Battery with clipped fuse holder, removing and installing
- Batteries with central gas venting
- Starter, removing and installing
- Starter - vehicles with manual transmission or automatic transmission 01M, removing
- Installing
- Starter - vehicles with automatic transmission 09A, removing
- Generator (GEN) B+ & D+ connections, securing
- Generator (GEN) carbon brushes, checking
- Ribbed belt, checking
- Ribbed belt, removing and installing
- Removing
- Ribbed belt, routing
- Generator (GEN) ribbed belt pulley, replacing
- Ribbed belt pulley with freewheel, installing
- Cruise Control System (CCS) through m.y. 2001, servicing
- 1.8L Turbo and 2.8L VR6 & 2.0L (codes AVH & AZG)
- 2.0L (code AEG)
- 1.9L TDI
- Cruise control system - 1.9L TDI, activating
- Cruise control system - 1.8L Turbo, 2.0L (codes AVH & AZG) and 2.8L VR6, activating
- Notes on replacing instrument cluster
- Additional information
- Additional information, instrument clusters from m.y. 2000
- Instrument cluster from m.y. 2000, replacing
- VAS 5051/5052, connecting
- Instrument cluster multi-pin connector assignments from m.y. 2000
- 32 pin multi-connector -T32a-, green
- Windshield wiper system
- Cowl panel, removing
- Wiper motor, installing in frame
- Wiper blade park position, adjusting
- "Aero-wiper" blades, removing and installing
- Wiper blade contact angle, checking and adjusting
- Window & headlight washer system reservoir, removing and installing
- Windshield Washer Pump -V5-, removing and installing
- Windshield washer jets, removing and installing
- Windshield washer jets, checking and adjusting
- Rear window wiper & washer system
- Wiper arm, removing
- Rear window wiper motor -V12-, removing
- Wiper arm, installing
- Rear window wiper rest position, adjusting
- Rear window washer jet, replacing
- Rear window washer jets, adjusting
- Wiper rubber, removing and installing
- Washer hoses, repairing
- Smooth hoses, repairing
- Corrugated hoses, repairing
- Headlights, removing and installing
- Headlight securing lugs, servicing
- Headlight beam adjusting motor, removing and installing
- Headlights, adjusting
- Headlight Bulb (dual filament low/high beam) -L1- / -L2-, replacing
- Parking Light/Turn Signal (dual filament) bulb, replacing
- Fog Light bulb -L22- / -L23-, replacing
- Side mounted turn signals, removing and installing
- Rear light housing - Golf, removing and installing
- Rear light housing - Jetta, removing and installing
- Rear light housing - Jetta Wagon, removing and installing
- Rear light bulb holder - Golf/Jetta, removing and installing
- Rear light bulb holder - Jetta Wagon, removing and installing
- License plate light, removing and installing
- High-mount brake light - Golf, removing and installing
- High-mount brake light - Jetta, removing and installing
- High-mount brake light - Jetta Wagon, removing and installing
- Steering column switches, removing and installing
- Horn contact plate, removing and installing
- Steering column switches, multi-pin connector assignments
- Lock cylinder, removing and installing
- Ignition/starter switch, removing and installing
- Ignition/starter switch, connector assignments
- Light Switch -E1-, removing and installing
- Instrument Panel Light Dimmer/Switch -E20-, removing and installing
- Sunroof Regulator -E139-, removing and installing
- Front Interior Light -W1-, removing and installing
- Power Window Regulator Switches in driver's door, removing and installing
- Power Window Regulator Switches in front passenger's door/rear doors, removing and installing
- Switches in instrument panel, removing and installing
- Door Warning Lights -M27- & -M28-, removing and installing
- Door contact switches, removing and installing
- Luggage Compartment Light Switch -F5-, removing and installing
- Glove Box Light -W6-, removing and installing
- Rear Reading Lights -W11- & -W12-, removing and installing
- Luggage Compartment Light -W3- - Golf/Jetta, removing and installing
- Luggage Compartment Light -W3- - Jetta Wagon, removing and installing
- Remote Fuel Filler Flap Release Switch -E204-, removing and installing
- Rear Lid Handle Unlock Switch -E234- - Jetta, removing and installing
- Rear Lid Handle Unlock Switch -E234- - Jetta Wagon, removing and installing
- Anti-theft Immobilizer control module, replacing
- VAS 5051, connecting
- Anti-theft Immobilizer control module, removing and installing
- Induction Coil of Anti-theft Immobilizer -D2-, removing and installing
- Transponder (key)
- Fuse holder and relay carriers
- Fuse holder, removing and installing
- Relay plate and 13 position relay carrier, removing and installing
- A-pillar coupling station
- Fuse holder on battery, removing and installing
- Protective housing for relays in engine compartment, removing and installing
- Protective housing in plenum chamber, removing and installing
- Safety measures
- Electrical system, general repair measures
- Antenna cables, replacing
- Antenna connector cable, replacing
- Battery
- Battery types
- Battery with "Magic Eye" charge indicator
- Absorbent Glass Mat (AGM) battery
- Safe interaction with vehicle batteries
- Battery post/terminal, handling instructions
- Battery, checking
- Battery with "Magic Eye" charge indicator, checking
- "Magic Eye" charge indicator, checking color display
- Battery no load voltage - vehicles in storage, checking
- Battery, charging
- Battery charger, connecting
- Totally discharged batteries, charging
- Cruise Control System (CCS)
- Cruise Control System, activating and deactivating
- Instruments
- Washer Hose Couplings
- Washer hoses, repairing
- Smooth hoses, repairing
- Corrugated hoses, repairing
- High Intensity Gas Discharge (HID) lamps, usage and safety information
- Information on dangerous high voltage/currents
- Information on pressure, temperature and radiation/glare
- Disposal regulations for HID lamps
- Lights, Lamps, Switches - Interior
- Safety measures
- Vehicle electrical system, general repair notes
- Airbag and seat belt tensioner wires, repairing
- Fiber optic cables
- Repairing CAN-Bus wires
- Antenna wires, replacing
- Wires with a cross-section up to 0.35 mm 2 , repairing
- Repairing terminals in terminal housing
- Secondary lock
- Primary lock
- Round connector systems
- Flat connector systems
- Special connector systems
- Faston terminals
- Repair Set VAS 6410 , using
- Threaded connections, servicing
- Battery terminal clamp and battery terminal, cleaning
- Protecting
- Engine number
- Engine data
- Engine mount
- Transmission mount
- Part I
- Part II
- Installing ribbed belt
- Ribbed belt routing
- Sealing flanges and drive plate, removing and installing
- Installing
- Removing
- Crankshaft, removing and installing
- Color markings
- Vehicles with engine code: AWD
- Checking Piston Ring End Gap
- Checking Piston Ring To Groove Clearance
- Checking Piston
- Checking Cylinder Bores
- Piston and cylinder dimensions
- Engine codes: AWP, AWW
- Checking Ring To Groove Clearance
- Cylinder head, removing and installing
- Checking Cylinder Head For Distortion
- Toothed belts, removing, installing and tensioning
- Requirements
- Compression pressure, checking
- Work sequence
- Vehicles with engine codes AWP, AWW
- Continued for all vehicles
- Valve train, servicing
- Valve seats, refacing
- Refacing exhaust valve seat
- Removing and installing camshaft sprocket oil seal
- Removing oil seal on Camshaft Position sensor
- Hydraulic valve lifters, checking
- Camshafts, removing and installing
- Only vehicles with engine codes: AWP, AWW
- Engine code AWW
- Engine code AWP
- Continuation for all vehicles
- Valve guides, checking
- Valve stem seals, replacing
- Oil Dipstick
- Oil pan, removing and installing
- Oil pressure and oil pressure switch, checking
- Vehicles with A/C
- Vehicles with manual transmission
- Vehicles with automatic transmission
- All vehicles
- Engine and transmission mounts, aligning
- Part I
- Idler pulley, removing and installing
- Installing
- Part II
- Ribbed belt, removing and installing
- Toothed belt, removing, installing, tensioning
- Continued for all vehicles
- Sealing flange and flywheel/drive plate, removing and installing
- Crankshaft, removing and installing
- Crankshaft dowel pin projection, checking
- Piston ring gap, checking
- Ring to groove clearance, checking
- Cylinder bores, checking
- Checking
- Piston and cylinder dimensions
- Cylinder head distortion, checking
- Requirements
- Removing
- Compression pressure
- Valve train, servicing
- Camshaft axial clearance, checking
- Camshaft bearing caps, installed position
- Valve dimensions
- Valve timing at 1 mm valve lift
- Valve seats, reworking
- Intake valve seat, reworking
- Exhaust valve seat, reworking
- Valve guides, checking
- Oil pressure warning system, function
- Oil pressure warning light, checking
- Warning conditions
- Oil pressure,checking
- 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
- Emission Control Description & Operation - Diesel 2
- State Emission Standards - Diesel
- Multiport Fuel Injection (Mfi) - 1.8L, Aww, Awp (A4 Platform) 5
- Fuel Supply - 1.8L, Awd, Awp, Aww (A4 Platform) 6
- Multiport Fuel Injection (Mfi) - 1.8L, Awd, Awp, Aww Generic (A4 Platform) 6
- Diesel Fuel Injection - 1.9L Alh, 2V TDI (A4 Platform) 6
- Fuel Supply - 1.9L TDI, Alh, Bew (Generic Scan Tool) (A4 Platform) 4
- Diesel Fuel Injection - 1.9L TDI, Alh, Bew (Generic Scan Tool) (A4 Platform) 5
- Fuel Supply - 2.0L Aeg, Avh, Azg 6
- Multiport Fuel Injection (Mfi) - 2.0L Aeg, Avh, Azg 6
- Multiport Fuel Injection (Mfi) - 2.8L Afp (A4 Platform) 5
- Fuel Supply - 2.8L Afp, Bdf (A4 Platform) 6
- Multiport Fuel Injection (Mfi) - 2.8L Afp, Bdf (Generic Scan Tool) (A4 Platform) 6
- 2.8L & 3.2L VR6 Generic Scan Tool, Engine Code(s): Afp, Bdf, Bjs (A4 Platform)
- 1.9L TDI and TDI Pd Generic Scan Tool, Engine Code(s): Alh, Bew (A4 Platform) 4
- 2.0L Generic Scan Tool, Engine Code(s): Aeg (A4 Platform) 5
- 2.8L VR6 2V Fuel Injection Ignition, Engine Code(s): Afp (A4 Platform) 4
- VAS 5051 or VAG 1551 , connecting
- VAS 5051 , connecting and selecting functions
- VAG 1551 , connecting and selecting functions
- List of available functions
- Basic Setting (function 04)
- End Output (function 06)
- Climatronic Control Module J255 , coding (function 07)
- Read Measuring Value Block (function 08)
- Table of selectable display group numbers
- Heating and ventilation system, servicing
- Rear footwell air duct, removing
- Center air outlet - Golf/GTI, removing
- Center air outlet - Jetta, removing
- Drivers air outlet - Golf/GTI and Jetta, removing
- Heating and ventilation controls, removing and installing
- Heating and ventilation cables, installing and adjusting
- Temperature flap cable, adjusting
- Footwell/defroster flap cable, adjusting
- Central flap cable, adjusting
- Ventilation system, checking
- Heating and ventilation unit, removing and installing
- Fresh/Recirculating Air Door Motor V154 , removing and installing
- Manual A/C system components in passenger compartment, servicing
- Heating and A/C controls, removing and installing
- Heating and A/C cables, installing and adjusting
- Manual A/C system components in engine compartment, servicing
- Climatronic components, checking and adjusting with VAS 5051
- Climatronic components in passenger compartment, servicing
- Footwell Outlet Temperature Sensor G192 , removing and installing
- Fresh Air Blower Control Module J126 , removing and installing
- Fresh Air Blower V2 , removing and installing
- A/C Display Control Head E87 with Climatronic Control Module J255 , removing and installing
- Air flap motors (for climate control regulation), replacing
- Air Flow Flap Motor V71 , removing and installing
- Temperature Regulator Flap Motor V68 , removing and installing
- Central Air Flap Motor V70 , removing and installing
- Footwell/defrost flap motor V85 , removing and installing
- Climatronic components in engine compartment, servicing
- Safety measures
- Commercial designation
- Color
- Temperature/pressure relationship
- Refrigerant oil
- Airborne properties
- Affects on plastic
- Affects on metal
- Water solubility
- Flammability
- Refrigerant containers
- Leak detection
- R-134a refrigerant oil
- A/C refrigerant circuit with expansion valve and receiver drier
- A/C system hoses and lines
- A/C refrigerant system, replacing components
- A/C Refrigerant System - Servicing
- Low pressure service valve, removing
- High pressure service valve, removing
- A/C Pressure Switch F129 , electrical checking
- A/C Pressure Switch F129 , functional checks
- High Pressure Sensor G65 , checking
- Checking
- Expansion valve, removing and installing
- Condenser, removing and installing
- Heating and A/C unit, removing and installing
- Evaporator inlet/outlet seal, installing
- A/C refrigerant system pressures and temperatures, checking
- Measuring pressure and temperature in a "switched-on" refrigerant system
- Measuring pressure and temperature in a closed container or "switched-off" refrigerant system
- A/C refrigerant system, discharging
- A/C refrigerant system, evacuating and recharging
- Requirements
- Compressor noisy
- A/C compressor noisy immediately after switching A/C ON and/or when driving around corners or braking (refrigerant shock), system overcharged
- With an otherwise properly operating A/C system, water sprays out of instrument panel vents
- A/C refrigerant system pressures, checking
- A/C refrigerant system cooling performance, checking
- Refrigerant (PAG) oil R-134a, distribution
- A/C Compressor and Bracket
- 4-cylinder TDI engine
- 4-cylinder TDI-PD engine
- Ribbed belt, routing
- A/C Clutch N25 - Sanden, servicing
- A/C Clutch N25 - Sanden, removing and installing
- A/C Clutch N25 - Zexel, removing and installing
- Ignition/glow Plug System - 1.8L, Awd (A4 Platform) 4
- Ignition/glow Plug System - 1.8L, Aww, Awp (A4 Platform) 4
- Ignition/glow Plug System - 1.8L, Awd, Awp, Aww Generic (A4 Platform) 5
- Ignition/glow Plug System - 1.9L Alh, 2V TDI (A4 Paltform) 3
- Ignition/glow Plug System - 2.8L Afp (A4 Platform) 4
- Ignition/glow Plug System - 2.8L Afp, Bdf (Generic Scan Tool) (A4 Platform) 4
- 1.9L TDI Fuel Injection Glow Plug, Engine Code: Alh, MY 1999-2001 (A4 Platform) 5
- Service work
- Oil change service
- General
- Equipment which has been packed inside vehicle, installing
- Engine compartment trim (sound insulation), removing and installing
- Apply sticker "Next service"
- Apply data sticker in service schedule (for customers)
- Vehicle data sticker
- Engine code and engine number
- Vehicle, lifting
- Lifting points for vehicle hoist
- Golf "R32" , lifting
- Tow starting/towing
- Rear towing eye
- For vehicles with all wheel drive
- Instrument panel cluster, adapting language
- Transport Mode, deactivating
- Power windows, perform initialization
- 8-way memory seat, perform initialization
- Clock, setting
- Climatronic, setting temperature to 72 F (22 C)
- Radio and radio/navigation system, activating anti-theft coding
- Wheel cover caps
- Wheelhousing liner, bolting to front apron (only anniversary Golf GTI with 132 kW engine)
- Transportation device, blocking pieces on front axle springs, removing
- Battery, check battery terminals for secure seating
- Battery, checking
- Engine oil level, checking
- Driver side airbag
- Front passenger side airbag
- Windshield wash/wipe system and headlight wash system, check function
- Mixture ratio
- Windshield
- Rear window
- Transportation wiper blades, removing at vehicle delivery
- Tires, checking tire condition, wear pattern, inflation pressure and tread depth
- Checking condition
- Checking tire wear pattern
- Tire tread depth (including spare), checking
- Tire inflation pressure (including spare wheel), checking and correcting inflation pressures if necessary
- Tire inflation pressure table for normal tires
- Golf
- GTI and R32 with all-wheel drive (AWD)
- Jetta
- Jetta with all-wheel drive (AWD)
- Golf Wagon, Jetta Wagon
- Golf wagon with all-wheel drive (AWD), Jetta wagon with all-wheel drive (AWD)
- Released engine oil standards for vehicles
- Oil characteristics
- Oil filter, replacing
- Engine code AEG
- Engine and components in engine compartment (from above and below): Visual check for leaks and damage
- Ribbed belt, checking condition
- Manual Transmission / final drive oil level, checking
- Automatic transmission final drive oil level, checking
- Automatic transmission, check ATF level, top off if necessary (01M - transmission)
- Automatic transmission, change ATF (01M transmission)
- Haldex clutch, replacing oil filter (all wheel drive (AWD))
- Haldex clutch, changing oil (all wheel drive (AWD))
- Brake system, visual check for leaks and damage
- Brake pads (front and rear), check thickness
- Front disc brake pads
- Rear disc brake pads
- Underbody protection, perform visual check for damage
- Tie rod ends, check play and joint boots
- Engine code(s) AEG, AVH, AZG, BBW, BEV
- Engine code BJS
- Engine code AWD
- Engine code(s) AWW and AWP
- Cooling system anti-freeze protection and coolant level, checking
- Checking freeze protection and adding coolant additive if necessary
- Checking coolant level and adding coolant if necessary
- Freeze protection table
- All engines
- Toothed belt for camshaft drive, replacing (Diesel engine 2001 - Engine code ALH)
- Toothed belt and idler pulley for camshaft drive, replacing (Diesel engine 2002 - Engine code ALH)
- Toothed belt and toothed belt tensioner for camshaft drive, replacing (4-cyl. - 5 valve gasoline engine)
- Toothed belt for camshaft drive, checking (4-cyl. Gasoline Engine)
- Toothed belt, check wear (diesel engine)
- Check condition of toothed belt
- Tensioning toothed belt
- Fuel filter, replacing (diesel engine)
- Automatic transmission, check ATF level
- Power assisted steering, check oil level
- Oil, when cold
- Adjusting headlights for the Golf
- Adjusting headlights for the Jetta
- Child restraint LATCH guidance fixture, installing
- General notes on injection
- Injection system components, removing and installing
- Safety precautions
- Rules for cleanliness
- Technical data
- Check conditions
- Checking voltage supply for Mass Air Flow (MAF) sensor
- Throttle valve control module -J338-, checking
- Continuation of check when display approx. 143 °C
- Continuation of check when display reads approx. -48 °C
- Continuation of check when display reads approx. 143 °C
- Engine speed (RPM) sensor, checking
- Checking voltage supply
- Checking activation and voltage supply
- Checking for leaks
- Fuel pressure regulator and holding pressure, checking
- Idle, checking
- Idle speed, adaptation
- Work sequence
- Functional check
- Checking basic voltage
- Function
- Engine operating modes, checking
- Checking voltage supply terminal 30
- Checking voltage supply terminal 15
- Checking voltage supply via main relay
- Procedure after voltage supply open circuit
- Vehicles with automatic transmission
- Continued for all vehicles
- Engine Control Module, coding variations
- Throttle valve control module, adapting to engine control module
- Conditions
- Kick-down position, learning
- Vehicles with automatic transmission only
- Injection, general notes
- Injection system components, removing and installing
- Safety precautions
- Rules of cleanliness
- Technical data
- Oxygen sensor heating for oxygen sensor before catalyst, checking
- Check conditions
- Checking voltage supply for Mass Air Flow (MAF) sensor
- Throttle valve control module, checking
- Engine speed (RPM) sensor -G28-, checking
- Checking resistance of injectors
- Checking voltage supply
- Checking activation and voltage supply
- Checking for leaks
- Checking injected quantity
- Fuel pressure regulator and holding pressure, checking
- Idling check
- Checking idling speed
- Idling speed, adapting
- Oxygen sensor and oxygen sensor control before catalyst, checking
- Oxygen sensor and oxygen sensor control after catalyst, checking
- Checking basic voltage
- Functional check
- Engine operating mode, checking
- Checking voltage supply terminal 30
- Checking voltage supply terminal 15
- Procedure after voltage supply open circuit
- Work sequence
- Vehicles with automatic transmissions
- Engine control module, coding
- Coding variations of engine control module
- Engine control module, adapting to throttle valve control module
- Conditions
- Kick-down point, learning
- Only engine code AWP
- Only engine code AWW
- Vehicles with automatic transmission only
- Function
- Malfunction Indicator Lamp (MIL), significance
- EPC warning lamp (malfunction lamp for power accelerator activation) in instrument cluster, significance
- Work procedure
- VAS5051 tester, connecting and selecting "Engine Electronics" vehicle system 01
- Fuel and air ratios
- DTCs: P1102 to P1853, VAG 17510 to 18261
- Function
- Work step 3: Temperature check
- Generating Readiness Code, Work Steps 1-6
- Generating Readiness Code, Work Steps 7-12
- Safety precautions
- Explanation of 8 digit numeric block
- Evaluation display group 1, display field 1 - engine speed (idle speed)
- Evaluation display group 2, display field 3 - injection timing
- Evaluation display group 2, display field 4 - mass air taken in
- Evaluation display group 4, display field 2 - control module voltage supply
- Evaluation display group 4, display field 3 - coolant temperature
- Evaluation display group 4, display field 4 - intake air temperature
- Evaluation display group 10, display field 2 - engine load
- Evaluation display group 10, display field 3 - throttle valve angle
- Evaluation display group 14, display field 3 - number of ignition misfires
- Evaluation display groups 22/23, display fields 3 and 4 - ignition timing angle retarding
- Meaning of 3 digit number block in display fields 1 and 2
- Evaluation display group 32, display field 2 through 4- oxygen sensor adaptation values
- Evaluation display group 33, display field 1 - oxygen sensor control before catalytic converter
- Evaluation display group 33, display field 2 - oxygen sensor voltage before catalytic converter
- Evaluation display group 36, display field 1 - sensor voltage of oxygen sensor behind catalytic converter
- Display group 54 - RPM regulation
- Explanation of 5-digit indication
- Display group 56 - RPM regulation, adaptation EPC system
- Display group 63 - RPM regulation, kick down adaptation
- Display group 66 - cruise control system
- Explanation of 8 -digit readiness code
- Evaluation display group 113, display field 4 - atmospheric pressure
- Display group 125 - communication, databus messages
- On Board Diagnostic (OBD), characteristics
- On Board Diagnostic (OBD), technical data
- Function test
- Test requirements
- Diagnostic Trouble Code (DTC) memory
- DTC memory of Engine Control Module (ECM), checking (scan tool function 02) and erasing (scan tool function 05)
- Automatic test sequence
- Diagnostic Trouble Code (DTC) table: SAE P0-Codes
- Diagnostic Trouble Code (DTC) table: SAE P1-Codes
- Output Diagnostic Test Mode (DTM), initiating
- Work step 1: Check DTC Memory
- Work step 2: Erase DTC Memory
- Work step 4: Diagnostic of leak detection system
- Work step 5: Diagnostic of tank ventilation system
- Work step 6: Diagnostic fuel system
- Work step 7: Diagnostic of Secondary Air Injection (AIR) system
- Work step 9: Diagnostic of oxygen sensor aging before catalytic converter (monitoring period duration)
- Work step 10: Diagnostic of oxygen sensor control system
- Work step 11: Diagnostic of oxygen sensor aging behind catalytic converter
- Work step 12: Diagnostic of catalytic converter
- Read Measuring Value Block (scan tool function 08)
- Display group 34 - oxygen sensor control, diagnostic of oxygen sensor before catalytic converter (aging test)
- Display group 37 - oxygen sensor control, dwell time test
- Display group 43 - oxygen sensor control, diagnostic oxygen sensor behind catalytic converter (aging test)
- Display group 46 - oxygen sensor control, diagnostic of catalytic converter (conversion test)
- Display group 107 - oxygen sensor control, fuel system diagnostic
- Display group 70 - emission reduction, EVAP canister system diagnostic (tank vent system)
- Display group 71 - emissions reduction, leak diagnostic system
- Display group 77 - emissions reduction, secondary air diagnostic system
- Equipment
- Selectable functions (modes) under address word 33, CARB / OBD II
- Exhaust gas warning lamp MIL (Malfunction Indicator Lamp), significance
- Functional check
- Electronic Power Control (EPC) warning lamp in instrument cluster, significance
- Work sequence
- Fuel, air metering and additional exhaust gas regulation
- Fuel and air metering
- Ignition system
- Additional exhaust gas regulation
- Speed and idling speed regulation
- Control module and output signals
- Gearbox
- DTCs P1102 to P1238, VAG 17510 to 18570
- Function
- Check conditions
- Work step 3: Matching the throttle valve control module to the engine control module
- Work step 4: Temperature check
- Work step 14: Read out readiness code
- Work step 15: Read readiness code
- Safety precautions
- Read Measuring Value Block (function 08)
- Significance of 8 -digit number block for readiness code
- Evaluating display group 1, display zone 1 - Engine speed (idling speed)
- Evaluating display group 2, display zone 3 - Injection period
- Evaluating display group 2, display zone 4 - Air mass drawn in
- Evaluating display group 4, display zone 2 - Control module voltage supply
- Evaluating display group 4, display zone 3 - Coolant temperature
- Evaluating display group 4, display zone 4 - Intake air temperature
- Display Group 8 - Basic Function- Vacuum Pump For Brakes
- Evaluating display group 10, display zone 2 - Engine load
- Evaluating display group 10, display zone 3 - Throttle valve angle
- Evaluating display group 14, display zone 3 - Total number of misfires
- Evaluating display groups 22/23, display zones 3 and 4 - Retardation of ignition
- Significance of 3 digit number block in display zones 1 and 2
- Evaluating display zone 32, display zones 1 and 2 - Oxygen sensor learned values
- Evaluating display group 33, display zone 1 - oxygen sensor regulator before catalyst
- Evaluating display group 36, display zone 1 - Oxygen sensor voltage, oxygen sensor after catalyst
- Significance of 5 digit number block
- Display Group 60 (Speed Regulation) Adaptation EPC System
- Display Group 63 (Speed Regulation) Kick Down Adaptation
- Display Group 66 Cruise Control System
- Significance of the numbers in the 8-digit display, display field 2, brake and cruise control switch
- Significance of the numbers in the 8-digit display, display field 4, cruise control switch
- Display Group Value Blocks 70 (Emission Reduction)
- Evaluating display group 113, display zone 4 - atmospheric pressure
- On Board Diagnostic (OBD), features
- Functions which can be selected when using the VAG1551/1552 scan tools or VAS5051
- Test conditions
- VAS5051 Vehicle Diagnostic, Testing and Information System, connecting and selecting engine control module
- Diagnostic Trouble Code (DTC) memory
- DTC memory, checking and erasing (functions 02 and 05)
- Automatic test sequence
- Diagnostic Trouble Code (DTC) table: SAE P0 codes
- Output Diagnostic Test Mode (function 03), performing
- Work step 1: Check Diagnostic Trouble Code (DTC) memory
- Work step 2: Erase DTC memory
- Work step 6: Diagnosis of oxygen sensor status
- Work step 7: Diagnosis tank venting system
- Work step 8: Oxygen sensor aging diagnosis before catalyst (cycle duration monitor)
- Work step 9: Secondary air system diagnosis
- Work step 10: Oxygen sensor control system diagnosis
- Work step 11: Diagnosis of oxygen sensor aging after catalyst
- Work step 13: Catalyst diagnosis
- Work step 1: Check DTC memory
- Work step 5: EVAP system diagnosis (tank venting system)
- Work step 6: Diagnosis of fuel system
- Work step 7: Diagnosis of tank venting system
- Work step 9: Diagnosis of oxygen sensor aging after catalyst
- Work step 10: Diagnosis of oxygen sensor status
- Work step 11: Oxygen sensor aging diagnosis (cycle duration monitor)
- Work step 12: Oxygen sensor control system diagnosis
- Work step 14: Secondary air system diagnosis
- Display Group 34 (Oxygen Sensor Control) Oxygen Sensor Diagnostic Before Catalyst (Checking Age Via Cycle Duration Monitoring)
- Display Group 37 (Oxygen Sensor Control) Oxygen Sensor - Dwell Period Test
- Display Group 43 (Oxygen Sensor Control) Oxygen Sensor Diagnostic After Catalyst (Ageing Check)
- Display Group 46 (Oxygen Sensor Control) Catalyst Diagnostic (Conversion Test)
- Display Group 107 Oxygen Sensor Control - Diagnostic Of Fuel System
- Wheels, tires
- Check list for evaluating the suspension of accident vehicles
- Evaluation of accident vehicles
- Left Front Level Control System Sensor G78 on front axle
- Left Front Level Control System Sensor G78 on front axle R32
- Left Rear Level Control System Sensor G76 on the rear axle for front wheel drive
- Left Rear Level Control System Sensor G76 on the rear axle for four wheel drive
- Modified mounting for stabilizer bar
- Ball joint, checking
- Removing
- Installing
- Control arm, removing and installing
- Subframe, removing and installing
- Threads in longitudinal member, servicing
- Pulling out wheel bearing
- Wheel bearing, pressing in
- Coil spring, installing
- Ball joint, removing and installing
- Front wheel bearing, pressing out and pressing in
- Wheel hub, pulling out
- Wheel bearing, pulling out
- Wheel hub, pressing in
- Suspension strut, removing and installing
- Front strut, servicing
- Coil spring, removing
- Outer constant velocity joint, checking
- Inner constant velocity joint, checking
- II - Front axle shaft with constant velocity joint VL 3700, servicing
- III - Axle shaft with triple roller joint AAR 2000, servicing
- IV - Axle shaft with triple roller joint AAR 2900, servicing
- V - Axle shaft with triple roller joint AAR 3300i, servicing
- Right bonded rubber bushing, removing
- Right bonded rubber bushing, installing
- Both sides, continued
- Spring, removing and installing
- Spring, installing
- Shock absorber, removing
- Wheel bearings, vehicles with front wheel drive, servicing
- Wheel bearing/wheel hub on vehicles with drum brakes, removing and installing
- Left spring, installing
- Right spring, installing
- Left spring, removing
- Right spring, removing
- Shock absorber, removing and installing
- Rear wheel bearing, pressing out and in with trailing arm installed
- Trailing arm, installing
- Upper ball joint/bonded rubber bushing, removing
- Lower ball joint/bonded rubber bushing, removing and installing
- Lower ball joint/bonded rubber bushing, removing
- Trailing arm, removing and installing
- Transverse link, removing and installing
- Rear drive shafts, removing and installing
- Rear drive shaft with constant velocity joint, servicing
- Removing outer constant velocity joint
- Pressing off inner constant velocity joint
- Pressing on inner constant velocity joint
- Wheel centering seat, protecting against corrosion
- Vehicles with wheel repair kit
- Tire sealant
- Tire, removing
- Tire sealant, disposal
- New tire, installing
- General
- Measurement preparations
- Vehicle trim height "Vehicle trim height"
- Vehicle data sticker
- Front axle camber, adjusting
- Camber on rear axle (vehicles front wheel drive), adjusting
- Camber on rear axle (vehicles with all-wheel drive), adjusting
- Toe on rear axle (vehicles front wheel drive), adjusting
- Toe on rear axle (vehicles with all-wheel drive), adjusting
- Toe on front axle, adjusting
- Left and right-hand wheel lock, checking
- Airbag
- Install steering column
- Steering column, checking for damage
- Steering column, identifying
- Locking cable for ignition with key withdrawal lock, removing and installing
- Unhooking
- Fitting
- Ignition key lock, checking
- For right-hand drive vehicles
- Modified tie rod ball joints
- Modified tie rods
- Security and boots on tie rod ends, checking play
- Center position on rack, determining
- Steering gear, adjusting
- P.A.S. power steering pump, vehicles with high mounted power steering pump, removing and installing
- Pressure line and intake hose on vehicles with 1.4 ltr., 1.6 ltr., 1.9 ltr. SDI/TDI engines without an air conditioner, securing
- Definitions
- On Board Diagnostic (OBD) - 1.8L, Awd (A4 Platform) 2
- Multiport Fuel Injection (Mfi) - 1.8L, Awd (A4 Platform) 5
- On Board Diagnostic (OBD) - 1.8L, Aww, Awp (A4 Platform) 2
- On Board Diagnostic (OBD), Generic Scan Tool - 1.8L, Awd, Awp, Aww 5
- On Board Diagnostic (OBD) - 1.9L Alh, 2V TDI 5
- Ignition/glow Plug System - 1.9L Alh, 2V TDI (A4 Platform) 2
- Ignition/glow Plug System - 1.9L TDI, Alh, Bew (Generic Scan Tool) (A4 Platform) 3
- On Board Diagnostic (OBD), Generic Scan Tool - 1.9L TDI, Alh, Bew (A4 Platform) 3
- On Board Diagnostic (OBD), Generic Scan Tool - 2.0L Aeg, Avh, Azg 5
- On Board Diagnostic (OBD) - 2.8L Afp (A4 Platform) 4
- On Board Diagnostic (OBD) , Generic Scan Tool - 2.8L Afp, Bdf (A4 Platform) 5