Repair manual
Volkswagen New Beetle A4 Repair Manual
Step-by-step repair and maintenance instructions for the Volkswagen New Beetle A4 (1997–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- General information
- VALVETRAIN ASSEMBLY OVERVIEW
- VALVE SEATS, REWORKING
- The maximum permissible reworking dimension is calculated as follows
- Reworking Exhaust Valve Seat
- COMPRESSION, CHECKING
- HYDRAULIC VALVE LIFTER, CHECKING
- VALVE GUIDES, CHECKING
- TOOTHED BELT
- B - Toothed Belt Only Removed From Camshaft Gear
- Toothed Belt, Tensioning
- Notes Regarding Sealing Rings
- INTAKE CAMSHAFT SEAL
- EXHAUST CAMSHAFT SEAL
- CAMSHAFTS
- VALVE STEM SEALS
- SAFETY PRECAUTIONS
- A/C REFRIGERANT R-134A, PROPERTIES
- A/C REFRIGERANT SYSTEM, IDENTIFICATION
- A/C REFRIGERANT SYSTEM
- A/C REFRIGERANT SYSTEM, DISCHARGING
- A/C REFRIGERANT SYSTEM, FLUSHING WITH COMPRESSED AIR AND NITROGEN
- A/C REFRIGERANT SYSTEM, EVACUATING AND RECHARGING
- HEATING AND A/C PASSENGER COMPARTMENT COMPONENT OVERVIEW
- HEATING AND A/C CABLES COMPONENT OVERVIEW
- HEATING AND A/C ENGINE COMPARTMENT COMPONENT OVERVIEW
- SIGHT GLASS
- A/C SYSTEM HOSES AND LINES
- A/C REFRIGERANT SYSTEM CONTROLS COMPONENT OVERVIEW
- A/C REFRIGERANT SYSTEM COMPONENT OVERVIEW
- A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW
- Ribbed Belt, Routing
- A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW
- A/C REFRIGERANT SYSTEM COMPONENTS
- A/C COMPRESSORS
- REFRIGERANT R-134A, CAPACITY
- REFRIGERANT OIL R134A, CAPACITIES
- REFRIGERANT OIL R134A, DISTRIBUTION
- REFRIGERANT OIL R134A, IDENTIFICATION
- A/C PRESSURE SWITCH, CHECKING
- HIGH PRESSURE SENSOR, FUNCTION
- HIGH PRESSURE SENSOR, ELECTRICAL TESTING
- A/C REFRIGERANT SYSTEM PRESSURES AND TEMPERATURES, CHECKING
- Pressure and Temperature Specifications
- A/C REFRIGERANT SYSTEM, TESTING WITH PRESSURE GAUGES
- REQUIREMENTS
- COMPRESSOR NOISE
- INSTRUMENT PANEL VENTS SPRAYING WATER
- A/C REFRIGERANT SYSTEM PRESSURES, CHECKING
- SPECIFIED RESULT
- A/C REFRIGERANT SYSTEM, CHECKING COOLING PERFORMANCE
- A/C PRESSURE SWITCH AND HIGH PRESSURE SENSOR
- CONDENSER
- HEATING AND A/C CONTROLS
- TEMPERATURE DOOR CABLE
- FOOTWELL/DEFROST DOOR CABLE
- CENTRAL DOOR CABLE
- A/C CLUTCH
- HEATER/EVAPORATOR UNIT
- SPECIAL TOOLS
- GENERAL INFORMATION
- SAFETY PRECAUTIONS
- DISTINGUISHING FEATURES
- REPAIR INFORMATION
- DESCRIPTION AND OPERATION
- VAS 5051, CONNECTING AND SELECTING FUNCTIONS
- ABS AND BRAKE SYSTEM WARNING LAMP MALFUNCTION DISPLAYS
- ABS AND ASR/ESP WARNING LAMP MALFUNCTION DISPLAYS
- HYDRAULIC UNIT, BRAKE BOOSTER AND MASTER CYLINDER ASSEMBLY OVERVIEW
- ABS, BRAKE AND ASR/ESP WARNING LAMP MALFUNCTION DISPLAYS, THROUGH MY 2005
- ABS, BRAKE AND ASR/ESP WARNING LAMP MALFUNCTION DISPLAYS, FROM MY 2006
- ABS COMPONENT OVERVIEW, FRONT AXLE
- FASTENER TIGHTENING SPECIFICATIONS
- DIAGNOSIS AND TESTING
- ROTOR, CHECKING - FRONT AXLE
- ROTOR, CHECKING LATERAL RUN OUT
- ROTOR, CHECKING - REAR AXLE
- REMOVAL AND INSTALLATION
- ABS CONTROL MODULE AND HYDRAULIC UNIT
- ABS WHEEL SPEED SENSOR
- WHEEL SPEED SENSOR WIRING
- WHEEL SPEED SENSOR WIRES
- ROTATION RATE SENSOR AND TRANSVERSE ACCELERATION SENSOR, THROUGH 11.01
- ESP SENSOR UNIT, FROM 12.01
- STEERING ANGLE SENSOR
- SPECIAL TOOLS
- General information
- BATTERY TYPES
- BATTERY WARNINGS AND SAFETY PRECAUTIONS
- BATTERY POST/TERMINAL, HANDLING INSTRUCTIONS
- BATTERY CHARGER VAS 5095 A
- BATTERY CHARGER DESCRIPTION
- BATTERY, CHARGING
- SEVERELY DISCHARGED BATTERY, CHARGING
- SUPPORT MODE
- MAINTENANCE CHARGING
- BATTERY CHARGER VAS 5900
- SERVICE CHARGE
- BATTERY CHARGER VAS 5903
- REFRESH CHARGING
- BATTERY CHARGER VAS 5906
- BATTERY CHARGER UNIT DESCRIPTION
- SOLAR PANEL VAS 6102 A
- SEVERELY DISCHARGED BATTERIES
- FASTENER TIGHTENING SPECIFICATIONS
- STARTER TIGHTENING SPECIFICATION
- BATTERY, CHECKING
- INSPECTING
- VISUAL INDICATOR, CHECKING COLOR
- LOW-MAINTENANCE BATTERY, CHECKING
- ELECTROLYTE LEVEL, CHECKING
- TOPPING OFF WITH DISTILLED WATER
- BATTERY, VEHICLES IN STORAGE, CHECKING RESTING VOLTAGE
- BATTERY LOAD TEST WITH BATTERY TESTER WITH PRINTER VAS 5097 A
- LOAD TEST
- COLD CRANKING OUTPUT TABLE
- BATTERY LOAD TEST RESULTS
- TEST RESULT EVALUATION
- BATTERY LOAD TEST WITH BATTERY TESTER WITH PRINTER VAS 6161
- BATTERY TEST
- MAINTENANCE TEST
- SERVICE TEST
- WARRANTY TEST
- CURRENT DRAW TEST
- CARBON BRUSHES, CHECKING
- CRUISE CONTROL, ACTIVATING AND DEACTIVATING
- CRUISE CONTROL SWITCH, CHECKING
- BATTERY, DISCONNECTING AND CONNECTING
- DISCONNECTING
- CONNECTING
- WORK STEPS REQUIRED AFTER RECONNECTING THE BATTERY
- BATTERY [for engine(s) AEG, AVH, AZG, APH, AWV, BKF, BNU, BGD, AWP, BDC, BEV, ALH, BEW]
- BATTERY [for engine(s) BPS, BPR]
- STARTER [for engine(s) AEG, AVH, AZG, APH, AWV, BKF, BNU, BGD, AWP, BDC, BEV, ALH, BEW]
- STARTER [for engine(s) BPS, BPR]
- GENERATOR - ENGINE CODE(S): AEH, ALH, APH, AWP, AWV, AVH, AZG, BEW, BEV, BDC, BGD, BKF, BNU
- GENERATOR - ENGINE CODE(S): BPR & BPS
- B+ WIRE MOUNT ON GENERATOR
- GENERATOR, VEHICLES WITH A/C SYSTEM
- VOLTAGE REGULATOR, THROUGH 04.1999
- VOLTAGE REGULATOR, FROM 05.1999
- RIBBED BELT PULLEY WITHOUT FREEWHEEL
- RIBBED BELT PULLEY WITH FREEWHEEL
- SPECIAL TOOLS
- RADIO SYSTEMS
- AMPLIFIER -R12
- CD CHANGER -R41
- CELLULAR PHONE AND TWO-WAY RADIO OPERATION
- EXTERNAL AUDIO SOURCE CONNECTION -R199
- INTERFERENCE SUPPRESSION
- ONSTAR BUTTON
- RADIO ANTI-THEFT
- SATELLITE RADIO -R146
- SPEAKERS
- TELEMATICS
- TELEPHONE SYSTEM
- SUPPORTED MUSIC DATA FORMATS
- SUPPORTED STORAGE MEDIA
- NOTES ON OPERATION
- PREMIUM 5.5 OVERVIEW
- PREMIUM 5.5 - MONSOON OVERVIEW
- PREMIUM 5.5 MULTI-PIN CONNECTORS
- PREMIUM 5.5 - MONSOON MULTI-PIN CONNECTORS
- RADIO/GPS/TELEMATICS ANTENNA OVERVIEW
- TELEMATICS INDICATOR LAMP -K186
- FASTENER TIGHTENING SPECIFICATIONS
- AMPLIFIER -R12- ON BOARD DIAGNOSTIC (OBD)
- ANTI-THEFT CODING, ACTIVATING
- PREMIUM 5.5 ON BOARD DIAGNOSTIC (OBD)
- PREMIUM 5.5 - MONSOON ON BOARD DIAGNOSTIC (OBD)
- RADIO COMPONENTS, ADAPTING
- TELEMATICS CONTROL MODULE -J499-, CODING
- TELEMATICS CONTROL MODULE -J499-, CONFIGURING
- Continuation For All
- TELEMATICS INDICATOR LAMP -K186- MALFUNCTION RECOGNITION
- DEACTIVATING TRANSPORT MODE
- TELEMATICS TROUBLESHOOTING
- USB CONNECTION BASEPLATE -R193
- AMPLIFIER -R12- BRACKET
- MODEL YEAR 1998, INSTALLING
- MY 1999 THROUGH FEB. 2007, INSTALLING
- FROM MAY 2007, INSTALLING
- CD CHANGER -R41- IN CENTER CONSOLE
- EXTERNAL AUDIO SOURCE CONNECTION -R199-, INSIDE INSTRUMENT PANEL
- EXTERNAL AUDIO SOURCE CONNECTION -R199-, NEXT TO GLOVE COMPARTMENT
- RADIO
- RADIO/GPS/TELEMATICS ANTENNA
- ROOF ANTENNA -R11
- FRONT TREBLE SPEAKER
- FRONT BASS SPEAKER
- REAR BASS SPEAKER
- REAR TREBLE SPEAKER
- MIDRANGE SPEAKER IN INSTRUMENT PANEL
- TREBLE SPEAKER IN INSTRUMENT PANEL
- TELEMATICS CONTROL HEAD -E264
- TELEMATICS CONTROL MODULE -J499
- TELEPHONE MICROPHONE -R38
- CELL PHONE OPERATING ELECTRONICS CONTROL MODULE -J412
- TELEPHONE BASEPLATE
- RADIO/TELEPHONE ANTENNA -R51
- SHIFT MECHANISM
- VAS 5051, CONNECTING
- TRANSMISSION, CHECKING
- ATF LEVEL, FILLING
- ATF, REPLACING
- TRANSMISSION WITH SELECTOR ELEMENTS
- SUPPORT RAILS VW 457/1, MODIFYING
- GUIDE 10-222A/21 FROM 10-222A, MODIFYING
- ATF PUMP TO SUPPORTING TUBE ASSEMBLY OVERVIEW
- REVERSE GEAR CLUTCH K2 TO LARGE SUN GEAR ASSEMBLY OVERVIEW
- FREEWHEEL AND REVERSE GEAR BRAKE B1 ASSEMBLY OVERVIEW
- PLANET CARRIER AND TRANSMISSION HOUSING WITH INPUT GEAR COVER ASSEMBLY OVERVIEW
- PLANETARY TRANSMISSION ADJUSTMENT OVERVIEW
- FASTENER TIGHTENING SPECIFICATIONS
- SELECTOR MECHANISM, CHECKING
- SELECTOR LEVER CABLE, CHECKING AND ADJUSTING
- IGNITION KEY REMOVAL LOCK, CHECKING OPERATION
- LOCKING CABLE, ADJUSTING
- CONDITIONS FOR CHECKING
- MAIN PRESSURE SPECIFICATIONS AT IDLE
- CAUSES FOR DEVIATIONS FROM SPECIFIED VALUES
- MAIN PRESSURE SPECIFICATIONS AT 2000 RPM
- ATF LEVEL, CHECKING
- TEST TEMPERATURE 35 °C TO 45 °C
- ATF DRIPPING FROM HOLE
- ONLY ATF IN OVERFLOW PIPE RUNNING FROM PLUG HOLE
- PLANET CARRIER, ADJUSTING
- SHIM TABLE
- EXAMPLE
- PLANET CARRIER, CHECKING MEASUREMENT
- REVERSE GEAR BRAKE B1, ADJUSTING
- CALCULATING I
- CALCULATING M
- DETERMINING GAP X
- REVERSE GEAR BRAKE B1, CHECKING MEASUREMENT
- CLUTCH, ADJUSTING PLAY BETWEEN K1 AND K2
- CONDITIONS
- CALCULATING A
- CALCULATING B
- CLUTCH PLAY, CHECKING
- SHIMS, DETERMINING
- CALCULATING DIMENSION A
- CALCULATING DIMENSION B
- SELECTOR LEVER LOCK SOLENOID
- SELECTOR LEVER CABLE
- LOCKING CABLE
- Tightening Specifications
- CLUTCH, REMOVING K1 FROM K3
- TRANSMISSION, DISASSEMBLING
- TRANSMISSION, ASSEMBLING
- General information
- TRANSMISSION, TRANSPORTING
- DESCRIPTION AND OPERATION
- SELECTOR CABLES ASSEMBLY OVERVIEW
- GEAR LEVER ASSEMBLY OVERVIEW
- GEAR LEVER AND HOUSING ASSEMBLY OVERVIEW
- SUPPORT RAILS VW 457/1, MODIFYING
- GUIDE 10-222A/21 FROM 10-222A, MODIFYING
- FASTENER TIGHTENING SPECIFICATIONS
- DIAGNOSIS AND TESTING
- GEAR SELECTOR MECHANISM, ADJUSTING
- FUNCTION TEST
- TRANSMISSION OIL, CHECKING
- REMOVAL AND INSTALLATION
- SELECTOR MECHANISM
- TRANSMISSION, REMOVING
- TRANSMISSION, INSTALLING
- DISASSEMBLY AND ASSEMBLY
- TRANSMISSION HOUSING COVER, HOUSING, SELECTOR MECHANISM, INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SELECTOR FORKS
- Install Selector Mechanism/Reverse Gear
- Insert Bolt -A-, Remove Stud, Insert Bolt -B- And Hand Tighten
- 5th Gear Synchro-Ring, Checking
- TRANSMISSION HOUSING AND CLUTCH HOUSING
- SELECTOR MECHANISM, TRANSMISSION SIDE (VEHICLES UP TO 05.99)
- SELECTOR MECHANISM, TRANSMISSION SIDE (VEHICLES AS OF 06.99)
- Press Circlip Into Selector Segment Groove With Socket
- HEADLAMPS WITH GAS-DISCHARGE BULBS
- HID HEADLAMPS, USAGE AND SAFETY PRECAUTIONS
- NOTES ON HAZARDOUS HIGH VOLTAGE / CURRENTS
- NOTES ON PRESSURE/TEMPERATURE/RADIATION/ELECTRIC ARC
- ASSEMBLY NOTES ON HID LAMPS
- DISPOSAL REGULATIONS FOR HID LAMPS
- HID HEADLAMP, ADJUSTING
- PARKING AID
- HEADLAMP, ADJUSTING
- HEADLAMP ADJUSTMENT, THROUGH 06.2005
- HEADLAMP ADJUSTMENT, FROM 07.2005
- FOG LAMP, CORRECTING HEIGHT, VEHICLES THROUGH 06.05
- FOG LAMP, CORRECTING HEIGHT, VEHICLES FROM 07.2005
- PARKING AID SENSOR BRACKET IN BUMPER COVER, BONDING
- REAR PARKING AID SENSOR, PAINTING
- FASTENER TIGHTENING SPECIFICATIONS
- HID HEADLAMP, PERFORMING BASIC SETTING
- PARKING AID CONTROL MODULE, CODING
- PARKING AID CONTROL MODULE, ADAPTING
- PARKING AID SENSOR, CHECKING
- REAR PARKING AID WARNING BUZZER, CHECKING
- LEFT HEADLAMP, THROUGH 06.2005
- RIGHT HEADLAMP, THROUGH 06.2005
- HEADLAMP, FROM 07.2005
- HEADLAMP CARRIER PLATE, FROM 07.2005
- LOW BEAM BULB, THROUGH 06.2005
- HIGH BEAM BULB, THROUGH 06.2005
- PARKING LAMP BULB, THROUGH 06.2005
- LOW BEAM BULB, FROM 07.2005
- HIGH BEAM BULB, REPLACING, FROM 07.2005
- PARKING LAMP BULB, FROM 07.2005
- HEADLAMP RANGE CONTROL POSITIONING MOTOR, THROUGH 06.2005
- HEADLAMP RANGE CONTROL POSITIONING MOTOR, FROM 07.2005
- HEADLAMPS
- HID BULB
- HIGH BEAM BULB
- PARKING LAMP BULB
- HID HEADLAMP CONTROL MODULE
- LEFT FRONT LEVEL CONTROL SYSTEM SENSOR
- LEFT REAR LEVEL CONTROL SYSTEM SENSOR
- HEADLAMP RANGE CONTROL MODULE
- HEADLAMP RANGE CONTROL POSITIONING MOTOR
- FOG LAMP, THROUGH 11.1999
- FOG LAMP, FROM 12.1999
- FOG LAMP, FROM 07.2005
- FOG LAMP BULB, THROUGH 06.2005
- FOG LAMP BULB, FROM 07.2005
- TURN SIGNAL, THROUGH 06.2005
- TURN SIGNAL, FROM 07.2005
- TURN SIGNAL BULB, THROUGH 06.2005
- TURN SIGNAL BULB, FROM 07.2005
- TURN SIGNAL, SPORT EDITION
- TURN SIGNAL BULB, SPORT EDITION
- SIDE TURN SIGNAL
- SIDE TURN SIGNAL, SPORT EDITION
- SIDE TURN SIGNAL BULB, SPORT EDITION
- EXTERIOR REARVIEW MIRROR TURN SIGNAL BULBS
- TAIL LAMP, THROUGH 06.2005
- TAIL LAMP, FROM 07.2005
- TAIL LAMP BULB, THROUGH 06.2005
- TAIL LAMP BULB, FROM 07.2005
- BACKUP LAMP, THROUGH 06.2005
- BACKUP LAMP, FROM 07.2005
- BACKUP LAMP BULB, THROUGH 06.2005
- BACKUP LAMP BULB, FROM 07.2005
- FOG LAMP, THROUGH 06.2005
- LICENSE PLATE LAMP, THROUGH 06.2005
- LICENSE PLATE LAMP, THROUGH 07.2005
- LICENSE PLATE BULB, 07.2005
- HIGH-MOUNTED BRAKE LAMP, SEDAN
- STEERING COLUMN SWITCH
- LOCK CYLINDER
- IGNITION SWITCH
- PARKING AID CONTROL MODULE, SEDAN
- REAR PARKING AID SENSOR
- REAR PARKING AID WARNING BUZZER, SEDAN
- SPECIAL TOOLS
- General information
- INPUT GEAR ASSEMBLY OVERVIEW
- DRIVE PINION ASSEMBLY OVERVIEW
- DIFFERENTIAL ASSEMBLY OVERVIEW
- FINAL DRIVE, CHECKING OIL LEVEL
- ADJUSTING AFTER REPLACING COMPONENTS
- DRIVE PINION, ADJUSTING
- TABLE OF SHIMS FOR DRIVE PINION AND INPUT GEAR
- INPUT GEAR, ADJUSTING
- DIFFERENTIAL, ADJUSTING
- DRIVE FLANGE SEAL
- INPUT GEAR
- DRIVE PINION
- VEHICLE LEVEL SENSOR WITH AUTOMATIC HEADLIGHT VERTICAL AIM CONTROL
- LONGITUDINAL MEMBER THREADS, SERVICING
- LEFT FRONT LEVEL CONTROL SYSTEM SENSOR OVERVIEW
- LEFT REAR LEVEL CONTROL SYSTEM SENSOR OVERVIEW
- SUBFRAME, STABILIZER BAR AND CONTROL ARM ASSEMBLY OVERVIEW
- WHEEL BEARING AND HOUSING ASSEMBLY OVERVIEW
- SUBFRAME
- CONTROL ARM
- PENDULUM SUPPORT
- STABILIZER BAR
- WHEEL BEARING HOUSING
- STRUT
- DRIVE AXLE
- LEFT FRONT LEVEL CONTROL SYSTEM SENSOR -G78
- BALL JOINT, CHECKING
- BALL JOINT
- CONTROL ARM BONDED RUBBER BUSHINGS
- SUBFRAME BONDED RUBBER BUSHINGS
- FRONT WHEEL BEARING, HUB AND INNER RACE, WITH WHEEL BEARING HOUSING INSTALLED
- COIL SPRING
- DRIVE AXLE WITH CV JOINT AND TRIPLE ROLLER JOINTS AAR 2000 AND AAR 2900
- TIGHTENING SPECIFICATIONS
- OUTER CV JOINT
- INNER CV JOINT
- DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I
- TIGHTEN 12 POINT NUT TO 200 Nm AND RELEASE A HALF A ROTATION
- DRIVE AXLE WITH CV JOINT
- GREASE QUANTITIES AND TYPES
- DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2000
- DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2900
- SPECIAL TOOLS
- General information
- Safety instructions
- Body foam insulation
- Galvanized body parts
- Cutting location
- Replacement part
- Welding in
- 50 52 55 50 Intermediate piece, replacing
- 50 53 55 50 Fender connecting plate, replacing
- 50 72 55 50 Long member - upper wheel house, replacing
- Foam insulation
- 50 75 55 50 Front wheel house, partial replacement
- 50 80 55 00 Long member - front section, replacing
- Replacement parts
- 51 03 55 00 Roof, replacing
- 51 07 55 50 Roof front cross member, replacing
- 51 09 55 50 Roof rear cross member, replacing
- 51 37 55 00 A pillar, replacing
- Partial repair
- 51 38 55 50 A pillar, inner, replacing
- 51 42 55 50 Inner B pillar, replacing (2-door)
- 51 45 55 00 Outer sill panel, replacing
- Part section
- 53 09 55 00 Rear lock carrier, replacing (Sedan)
- 53 13 55 00 Corner bracket, replacing (Sedan)
- 53 48 55 52 Rear long member, partial replacement
- 53 65 55 50 Side panel reinforcement, replacing
- Preparing new part
- 53 68 55 50 Rear wheel house, replacing
- 53 80 55 50 Spare wheel well, Replacing
- 53 80 55 52 Spare wheel well, partial replacement
- ENGINE OVERVIEW
- RAISING VEHICLE
- SERVICE LABEL
- DIAGNOSTIC tool, CONNECTING
- VIN
- TIME OR DISTANCE DEPENDENT SERVICE
- ENGINE CODE AND ENGINE NUMBER
- BIODIESEL FUEL
- TYPE PLATE
- VW ENGINE OIL STANDARDS
- SERVICE INTERVALS
- GLOSSARY
- REMOVABLE TRAILER HITCH, CHECKING AND CLEANING
- OUTSIDE TEMPERATURE DISPLAY, SELECTING UNITS
- AUTOMATIC TRANSMISSION, 01M, CHANGING ATF
- AUTOMATIC TRANSMISSION, 01M, CHANGING OIL STRAINER
- AUTOMATIC TRANSMISSION, 01M, CHECKING FINAL DRIVE GEAR OIL
- AUTOMATIC TRANSMISSION, 01M, CHECKING ATF LEVEL AND FILLING
- AUTOMATIC TRANSMISSION, 09G, CHECKING ATF LEVEL AND FILLING
- AUTOMATIC TRANSMISSION 09G, CHANGING ATF
- BATTERY, TESTING
- BATTERY TERMINALS, CHECKING FOR SECURE FIT
- GENERAL INFORMATION
- TIRES, CHECKING CONDITION
- TIRES, CHECKING WEAR PATTERN
- BRAKE SYSTEM, CHECK FOR LEAKS AND DAMAGE
- FRONT DISC BRAKE PADS
- REAR DISC BRAKE PADS
- REAR DRUM BRAKE PADS
- APPLICATION INFORMATION AND SAFETY PRECAUTIONS
- BRAKE FLUID SPECIFICATIONS
- BRAKE FLUID, CHANGING
- BRAKE FLUID LEVEL, CHECKING PROCEDURE
- ANTI-THEFT WHEEL BOLTS, INSTALLING
- DIGITAL CLOCK, SETTING TIME AND DISPLAY MODE
- DSG® TRANSMISSION, 02E, REPLACING OIL AND FILTER
- POWER WINDOW REGULATORS, ACTIVATING
- VEHICLE SYSTEM TEST, PERFORMING
- PROTECTIVE JOINT BOOTS, INSPECTING
- FIRST AID KIT, CHECKING EXPIRATION DATE
- RIBBED BELT, CHECKING CONDITION
- RIBBED BELT WITHOUT AUTOMATIC TENSIONER, ADJUSTING TENSION
- FUEL FILTER, FILTER SYSTEM WITHOUT REGULATOR VALVE, REPLACING
- FUEL FILTER, DIESEL, DRAINING WATER
- FREEZE PROTECTION, CHECKING AND ADDING COOLANT ADDITIVE
- COOLANT LEVEL, CHECKING AND FILLING
- AIR FILTER, CLEANING HOUSING AND REPLACING FILTER ELEMENT AND CLEANING SNOW SCREEN
- ENGINE COVER, 1.8L, REMOVING AND INSTALLING
- ENGINE COVER, REMOVING AND INSTALLING, 2.5L FUEL INJECTION ENGINES
- LOWER ENGINE COMPARTMENT COVER, REMOVING AND INSTALLING
- ENGINE OIL LEVEL, CHECKING
- ENGINE OIL, DRAINING OR EXTRACTING
- OIL FILTER, REMOVING AND INSTALLING
- OIL FILTER, 1.8L AND 2.0L, REPLACING
- OIL FILTER, SDI/TDI DIESEL, REPLACING
- OIL FILTER, 2.5L, REPLACING
- OIL FILTER, TDI PD, REPLACING
- ENGINE OIL, FILLING
- ENGINE AND ENGINE COMPARTMENT COMPONENTS, CHECKING FOR LEAKS AND DAMAGE
- ROAD TEST, PERFORMING
- WHEEL BOLTS, TIGHTENING SPECIFICATIONS
- RADIO CODE, REQUESTING WITH DIAGNOSTIC tool
- ANTI-THEFT CODING, VOLKSWAGEN RADIO SYSTEMS, ACTIVATING
- 5-SPEED MANUAL TRANSMISSION 02K
- 5-SPEED MANUAL TRANSMISSION 02J
- 5- AND 6-SPEED MANUAL TRANSMISSION 02M
- WINDSHIELD WASHER/WIPER SYSTEM, CHECKING FREEZE PROTECTION AND FILLING FLUID
- WINDSHIELD WASHER SYSTEM, CHECKING AND ADJUSTING SPRAY NOZZLES
- HEADLAMP WASHER SYSTEM, CHECKING AND ADJUSTING SPRAY NOZZLES
- WINDSHIELD WIPER BLADES, CHECKING END POSITION AND ADJUSTING
- WINDSHIELD WIPER BLADES, CHECKING ANGLE AND ADJUSTING
- WIPER BLADE PROTECTOR, TYPE 1, REMOVING
- WIPER BLADE PROTECTOR, TYPE 2, REMOVING
- WIPER BLADE PROTECTOR, TYPE 3, TRANSPORT WIPER BLADE, REMOVING AND INSTALLING
- HEADLAMPS, CHECKING ADJUSTMENT
- HALOGEN HEADLAMPS, ADJUSTING
- HID HEADLAMPS, ADJUSTING IN GUIDED FUNCTIONS
- HID HEADLAMPS, ADJUSTING IN VEHICLE OBD
- FOG LAMPS AND OTHER AUXILIARY HEADLAMPS, ADJUSTING
- SUNROOF, CHECKING FUNCTION, CLEANING AND LUBRICATING GUIDE RAILS
- SUNROOF DRAINS, CLEANING
- SERVICE INTERVAL DISPLAY THROUGH 04.99
- SERVICE INTERVAL DISPLAY, RESETTING, VEHICLES FROM MAY 99
- Reset The Service Interval Display Using A Vehicle Diagnosis Tester In "Guided Functions"
- Reset Service Reminder Indicator using Adjustment Button for Odometer and Clock at Instrument Cluster
- Reset Service Interval Display Using A Vehicle Diagnosis Tester In "OBD"
- SERVICE INTERVAL DISPLAY, CODING/ADAPTING
- POWER STEERING, CHECKING FLUID LEVEL
- DUST AND POLLEN FILTER, REPLACING FILTER ELEMENT
- TRANSPORT PROTECTION, REMOVING LOCKING PIECES FROM FRONT AXLE STRUTS
- TRANSPORT ANCHOR OPENINGS, SEALING USING CAPS
- DOOR ARRESTER, LUBRICATING
- UNDERBODY COMPONENTS, CHECKING FOR DAMAGE
- CONVERTIBLE TOP END POSITION LOCKING MECHANISM, POWER CONVERTIBLE TOP, INSPECTING WITH TOP OPEN
- POWER CONVERTIBLE TOP, OPENING
- CONVERTIBLE TOP PROTECTIVE COVER, REMOVING
- CAMSHAFT DRIVE TOOTHED BELT, CHECKING
- CAMSHAFT DRIVE TOOTHED BELT, TDI, CHECKING FOR WEAR
- CAMSHAFT DRIVE TOOTHED BELT AND IDLER PULLEY, TDI, REPLACING
- CAMSHAFT DRIVE TOOTHED BELT, PD DIESEL, REPLACING
- CAMSHAFT DRIVE TENSIONER, PD DIESEL, REPLACING
- CAMSHAFT DRIVE TOOTHED BELT AND TENSIONER, 4-CYLINDER, REPLACING
- SPARK PLUGS, 1.8L, REPLACING
- SPARK PLUGS, 2.0L, REPLACING
- SPARK PLUGS, 2.5L, REPLACING
- General information
- DOOR PANEL TRIM ASSEMBLY OVERVIEW
- LOWER REAR LID TRIM ASSEMBLY OVERVIEW FROM 12.2004
- LOWER REAR LID TRIM ASSEMBLY OVERVIEW THROUGH 11.2004
- INSTRUMENT PANEL
- FRONT DOOR TRIM
- DOOR PANEL TRIM UPPER PART
- UPPER A-PILLAR TRIM
- LOWER A-PILLAR TRIM
- B-PILLAR TRIM
- C-PILLAR TRIM
- SIDE TRIM
- LEFT/RIGHT LUGGAGE COMPARTMENT SIDE TRIM
- LOADING EDGE COVER
- UPPER REAR LID TRIM
- LOWER REAR LID TRIM THROUGH 11.04
- LOWER REAR LID TRIM FROM 12.04
- HEADLINER
- SPECIAL TOOLS
- On Board Diagnostic II
- Malfunction Indicator Lamp, significance
- Special tools and equipment
- Test conditions
- Functional check
- Control Module identification
- Technical data
- Prerequisites
- Work sequence
- Scan Tool VAS 5051, connecting
- Automatic test sequence
- DTC table: VAG codes
- Diagnostic Trouble Code (DTC) table: SAE P codes
- Performing Output Diagnostic Test Mode
- Prerequisites (with air conditioning)
- Activating Cold Start Injector -N108
- Function
- Work step: 1
- Work step: 2
- Work step: 3
- Work step: 4
- Work step: 5
- Safety precautions
- Evaluation: Injected quantity display
- Evaluation: Modulating piston displacement sensor -G419- voltage display
- Evaluation: "Throttle position" display
- Evaluation: "Operating condition" display
- Evaluation: Air mass drawn in (specified) display
- Evaluation: Air mass drawn in (actual) display
- Evaluation: Start of injection (specified) display
- Evaluation: Start of injection display (actual)
- Display group 005
- Evaluation: Brake pedal monitor display
- Evaluation: Cruise control system display
- Evaluation: Fuel temperature display
- Evaluation: Intake Air Temperature display
- Evaluation: Coolant temperature display
- Display group 009
- Display group 012
- Evaluation: idle speed smooth running control display
- Display group 015
- Evaluation: Additional heater display
- Evaluation: Heater element activation display
- Evaluation: Modulating piston displacement sensor -G419- voltage display (start/stop)
- Display group 000 at Wide Open Throttle (WOT), test drive in 3rd gear, Engine Coolant Temperature 80 °C (176 °F) minimum
- Display group 004 at Wide Open throttle (WOT), test drive in 3rd gear, Engine Coolant Temperature 80 °C (176 °F) minimum
- Evaluation: Start of injection (actual) display
- Evaluation: Cold start valve duty cycle display
- Display group 008 at Wide Open Throttle (WOT), test drive in 3rd gear, Engine Coolant Temperature 80 °C (176 °F)
- Evaluation: Injected quantity (driver's requirement) display
- Evaluation: Injected quantity limitation via RPM (torque limitation) display
- Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
- Display group 010 at WOT, test drive in 3rd gear, Engine Coolant Temperature 80 °C (176 ° F) minimum
- Evaluation: Air mass drawn in display
- Evaluation: Intake manifold pressure (charge pressure) display
- Evaluation: Accelerator pedal position display
- Display group 011 at Wide Open Throttle (WOT), test drive in 3rd gear, Engine Coolant Temperature 80 °C (176 °F) minimum
- Evaluation: Manifold Absolute Pressure display (actual)
- STEERING RACK, DETERMINING CENTER POSITION
- STEERING SYSTEM, BLEEDING
- POWER STEERING FLUID LEVEL, CHECKING
- DESCRIPTION AND OPERATION
- VAS 5501, CONNECTING AND SELECTING FUNCTIONS
- STEERING COLUMNS, DISTINGUISHING CHARACTERISTICS
- IGNITION KEY REMOVAL LOCK CABLE, DISENGAGING AND ENGAGING
- Disengaging
- Engaging
- POWER STEERING GEAR ASSEMBLY OVERVIEW
- POWER STEERING SYSTEM OVERVIEW
- PRESSURIZED LINE OVERVIEW (1.8L, 2.0L ENGINES)
- Steering Column
- Crossmember for Steering Column, Sedan
- Crossmember for Steering Column, Convertible
- Steering Gear
- Power Steering Pump
- Pressurized Line/Intake Hose TDI Engines
- Pressurized Line/Intake Hose 1.8L Engines
- Pressurized Line/Intake Hose 2.0L Engines
- Pressurized Line/Intake Hose 2.5L Engines
- Pressurized Line to Manual Transmission 02J
- Pressurized Line to Manual Transmission 0A4
- Pressurized Line to Manual Transmission 02M
- Pressurized Line to Automatic Transmission 01M
- Pressurized Line to Automatic Transmission 09G
- Pressurized Line to DSG Transmission 02E
- TIE ROD ENDS, MODIFIED VERSION
- TIE RODS, MODIFIED VERSION
- DIAGNOSIS AND TESTING
- STEERING COLUMN, CHECKING FOR DAMAGE
- IGNITION KEY REMOVAL LOCK, CHECKING
- SECURING BOOTS AND CHECKING TIE ROD END PLAY
- STEERING GEAR, ADJUSTING
- STEERING SYSTEM, CHECKING FOR LEAKS
- LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE
- HIGH MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE - ENGINE CODE(S): ALH & BEW
- HIGH MOUNT POWER STEERING PUMP, CHECKING DELIVERY PRESSURE - ENGINE CODE(S): BPR & BPS
- REMOVAL AND INSTALLATION
- Removing
- Remove Trim for Steering Column Switch
- Securing Steering Column before Removing
- Installing
- Basic Setting of the Steering Angle Sensor Must be Checked After the Following Repair Work
- STEERING LOCK HOUSING
- POWER STEERING GEAR
- TIE ROD
- TIE ROD BOOT, INSTALLING
- LOW MOUNTED POWER STEERING PUMP
- HIGH MOUNTED POWER STEERING PUMP - ENGINE CODE(S): ALH & BEW
- HIGH MOUNT POWER STEERING PUMP - ENGINE CODE(S): BPR & BPS
- SPECIAL TOOLS
- VEHICLE DIAGNOSTIC, TESTING AND INFORMATION SYSTEM
- TIRE PRESSURE MONITORING CONTROL MODULE
- COMFORT SYSTEM CENTRAL CONTROL MODULE
- ANTENNA WIRES
- WIRING HARNESSES AND CONNECTORS SAFETY PRECAUTIONS
- VEHICLE ELECTRICAL SYSTEM GENERAL REPAIR INFORMATION
- GENERAL NOTES FOR REPAIRING WIRING HARNESSES AND CONNECTORS
- FIBER OPTIC CABLES
- VEHICLE DIAGNOSIS, TESTING AND INFORMATION SYSTEM, CONNECTING
- ANTENNA WIRING ASSEMBLY OVERVIEW
- CRIMP CONNECTOR
- AIRBAG AND BELT TENSIONER WIRES, REPAIRING
- WIRING HARNESS REPAIR SET VAS 1978 B
- RELEASE TOOL SET VAS 1978/35
- SECONDARY CONNECTOR LOCKS
- PRIMARY CONNECTOR LOCKS
- SPECIAL CONNECTOR SYSTEMS
- Crimping Pliers V.A.S 1978/9A
- CONTACT SURFACES, CLEANING USING CONTACT SURFACE CLEANING SET
- WIRING EYELETS, SERVICING
- THREADED CONNECTIONS, SERVICING
- BATTERY CLAMPS AND BATTERY TERMINALS, CLEANING
- PROTECTING
- FASTENER TIGHTENING SPECIFICATIONS
- TIRE PRESSURE MONITORING SYSTEM CONTROL MODULE, CODING
- COMFORT SYSTEM CENTRAL CONTROL MODULE COMPONENTS, ADAPTING
- COMFORT SYSTEM CENTRAL CONTROL MODULE, CODING
- LEFT INSTRUMENT PANEL FUSE HOLDER
- RELAY PANEL AND 13-PIN RELAY CARRIER
- CONNECTOR STATION, A-PILLAR
- FUSE PANEL ON BATTERY
- PROTECTIVE HOUSING FOR RELAYS IN ENGINE COMPARTMENT
- CABLE GUIDE INSIDE ENGINE COMPARTMENT
- NEW ANTENNA WIRE, INSTALLING
- SPECIAL TOOLS