Maintenance (A4 Platform): Maintenance Volkswagen Jetta IV

Maintenance service

Refer to Additional Information. Maintenance Schedule for appropriate model year

Additional Information about 4 spd. automatic transmission 01M

Every 40,000 miles (64.000 km)

Additional Information about GTI 337 Edition

Door check strap, lubricating

Perform the following work sequence

Scheme 123

1. Lube the door arrester at the areas indicated by the - arrows -.
2. Use lubrication paste G 000 150 or lock cylinder grease spray G052778A2 .

Sunroof, checking function, cleaning and lubricating guide rails

Perform the following work sequence

1. Check function of sunroof.

Scheme 124

1. Clean guide rails - arrows - and lubricate with special grease. G 000 450 02

Checking windshield wash/wipe system freeze protection concentration, add fluid if necessary

Checking freeze protection concentration

Special tools, testers and auxiliary items required

Scheme 125

1. Refractometer T10007

Note. Read bright/dark boundary to obtain an accurate reading for following tests. Place a drop of water on glass to improve readability of bright/dark boundary. Bright/dark boundary can be clearly recognized on "WATERLINE".

1. Check concentration of anti-freeze additive using Refractometer T10007 (operating instructions).

Scale - 1 - of the Refractometer T10007 is designed specifically for genuine Volkswagen windshield cleaner "G 052 164".

Scheme 126

Scale - 2 - is designed for commercially available windshield cleaner as well as a mixture of commercially available windshield cleaner and "G 052 164".

Engine oil, draining or extracting and filling; replacing oil filter

Special tools, testers and auxiliary items required

Scheme 127

1. Oil extractor V.A.G 1307 A

or

Scheme 128

1. Oil extractor V.A.G 1358 A

1. Torque wrench V.A.G 1331/ (5 - 50 Nm)

Note. If oil is drained and not extracted with oil extractor, replace seal for oil drain plug. This helps prevent possible leaks. Observe waste disposal regulations!

Turbo-engines

1. After engine oil and oil filter have been replaced, observe following when first starting engine

As long as oil pressure warning light in instrument panel insert flashes, engine is only to run at idle. Do not touch accelerator pedal! Bumping accelerator pedal can damage turbocharger or destroy it completely.

Only when warning light turns off, is full oil pressure achieved, and engine can be accelerated.

Capacities with filter change: Additional Information. Fluid Capacity Charts for appropriate model year

Scheme 129

Tightening torque for oil drain plug (Replace if leaking) - arrow

Note. Remember that following torque specifications must not be exceeded. A higher torque can lead to leaks in area of drain plug or even to damage. 4-cylinder engine 30 Nm 6-cylinder engine 30 Nm

Oil specification for gasoline engines

For oil specification for gasoline engines, please refer to

Refer to Additional Information. Fluid Capacity Charts for appropriate model year

Oil specification for diesel engines

For oil specification for gasoline engines, please refer to

Refer to Additional Information. Fluid Capacity Charts for appropriate model year

Due to individual characteristics of oils. Refer to Oil characteristics under Oil characteristics use only following released engine oils

Fuel filter, draining (diesel engine)

Note. Make sure that no diesel fuel gets onto the coolant hoses. If necessary, clean hoses immediately! Observe waste disposal regulations!

Perform the following work sequence

1. Remove the retaining clip - 1 - and remove regulator valve - 2 - with attached fuel lines.

Scheme 130

1. Place a hose onto the hose connection of the drain screw - arrow - , open the screw, and drain approx. 0.1 L of fluid.
2. Tighten the drain screw - arrow - and remove the hose.
3. Install a new O-ring for the sealing of the regulating valve.

1. Install regulator valve - 2 - and the retaining clip - 1 -.
2. Start the engine and perform a visual inspection of the fuel system for leaks.
3. Rev the engine several times. Thereafter, the fuel must flow through the see-through line - C - without any bubbles while at idle.

Hydraulic fluid at operating temperature (from approx. 122 ° F (50 ° C))

1. With engine not running, move front wheels in straight-ahead position.

1. Insert a suitable screwdriver into the recess at the cap - arrow - and unscrew caps with dipstick.
2. Clean dipstick with clean cloth.
3. Screw cap on hand-tight and remove again.

Note. Screw cap fully in to get an accurate fluid level reading.

Scheme 131

1. Check oil level: Check fluid level. It must be between MIN and MAX markings.

Note. If the fluid level is above the MAX mark, siphon fluid off. If the fluid level is below the MIN mark, check the hydraulic system for leaks (repair procedure). It is not enough to simply top off with oil. If no leaks are detected, top off with hydraulic fluid "G 002 000".

1. Screw cap on hand-tight (with screwdriver).

Brake fluid, changing

Special tools, testers and auxiliary items required

Scheme 132

1. Brake filler and bleeder unit VAS 5234

or

Scheme 133

1. Brake filler and bleeder unit V.A.G 1869/ with Rigging set V.A.G 1869/4

Scheme 134

1. Brake pedal depressor V.A.G 1869/2

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

Perform the following work sequence

Scheme 135

Follow user manual for Brake filling and bleeding tool VAS 5234 or Brake filling and bleeding tool V.A.G 1869/ !

1. Remove brake fluid reservoir cap.

Scheme 136

1. With filter inserted, extract as much brake fluid as possible using the suction hose from Brake filler and bleeder unit VAS 5234 - 1 - or Brake filler and bleeder unit V.A.G 1869/ or with a suction bottle.

Note. After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the strainer).

1. Install and extend Brake pedal depressor V.A.G 1869/2 between driver seat and brake pedal.

Scheme 137

1. Install adapter - 1 - to brake fluid reservoir.

Note. If adapter - 1 - can not be used because of space limitations, use Adapter VAS 5234/1 or Adapter V.A.G 1869/1 A.

1. Connect the filling hose from Brake filler and bleeder unit VAS 5234 or from Brake filler and bleeder unit V.A.G 1869/ to the adapter.
2. Remove caps from the bleeder screws.

Scheme 138

1. Connect collecting bottle bleeder hose - 1 - to rear bleeder screw, open bleeder screw and allow the appropriate quantity to flow out (see table on side). Close bleeder screw.

Repeat procedure on left rear.

Scheme 139

1. Connect collecting bottle bleeder hose - 1 - to front bleeder screw * See footnote , open bleeder screw and allow the appropriate quantity to flow out (see table on side). Close bleeder screw.

Repeat procedure on left front.

Table - Sequence / quantity of brake fluid

Total quantity: approx. 1.25 liter

* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.

1. Install cover caps on brake wheel cylinder and/or brake caliper bleeder screws.
2. Move filler lever on Brake filler and bleeder unit VAS 5234 or Brake filler and bleeder unit V.A.G 1869/ to position - B - (see operating instructions).
3. Remove filler hose from adapter.
4. Unscrew adapter from brake fluid reservoir.

1. Check brake fluid level and correct if necessary.
2. Install cap to brake fluid reservoir.
3. Remove brake pedal depressor.
4. Check pedal pressure and brake pedal free play. Free play: max. 1/3 of pedal travel

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

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

Note the following

Delivery inspection

Scheme 140

At time of delivery inspection, brake fluid level must be at MAX mark.

Note. To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark.

Inspection service

1. The fluid level must always be judged in conjunction with brake pad wear. When vehicle is in use, the fluid level tends to drop slightly due to brake pad wear and automatic adjustment.
2. With brake fluid at MIN mark or slightly above, topping off brake fluid is not necessary when wear limit of brake pads has been almost reached.
3. When brake pads are new or if there is still enough brake lining left, the brake fluid level must be between MIN and MAX marks.
4. If brake fluid level is below MIN mark, check brake system (repair procedure), before adding brake fluid.