1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
DESCRIPTION:
1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual – replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
TABLE OF CONTENTS:
1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
Cover.pdf (p.1)......................................................................................................................................................................................................... 1
Contents.pdf (p.2)...................................................................................................................................................................................................... 2
00-Maintenance & General Info.pdf (p.3-782)............................................................................................................................................................................. 3
00-01 VW Maintenance Chart Rev. 2008............................................................................................................................................................................... 3
00-02 VW Maintenance Chart Rev. 2009................................................................................................................................................................................ 26
00-03 Maintenance Intervals All..................................................................................................................................................................................... 32
03 – Maintenance, Diagnosis..................................................................................................................................................................................... 36
1 MY 2015 Maintenance Intervals ............................................................................................................................................................................ 36
1.1 MY 2015 Maintenance Intervals - USA................................................................................................................................................................. 36
1.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 36
1.1.2 Service at 20,000€miles....................................................................................................................................................................... 37
1.1.3 Service at 30,000€miles....................................................................................................................................................................... 37
1.1.4 Service at 40,000€miles....................................................................................................................................................................... 38
1.1.5 Service at 50,000€miles....................................................................................................................................................................... 39
1.1.6 Service at 60,000€miles....................................................................................................................................................................... 39
1.1.7 Service at 70,000€miles....................................................................................................................................................................... 40
1.1.8 Service at 80,000€miles....................................................................................................................................................................... 41
1.1.9 Service at 90,000€miles....................................................................................................................................................................... 42
1.1.10 Service at 100,000€miles..................................................................................................................................................................... 42
1.1.11 Service at 110,000€miles..................................................................................................................................................................... 43
1.1.12 Service at 120,000€miles..................................................................................................................................................................... 43
1.1.13 Service at 130,000€miles..................................................................................................................................................................... 45
1.1.14 Service at 140,000€miles..................................................................................................................................................................... 45
1.1.15 Service at 150,000€miles..................................................................................................................................................................... 46
1.1.16 Time-Dependent Maintenance Items............................................................................................................................................................. 46
1.1.17 Brake Fluid Replacement...................................................................................................................................................................... 47
1.2 MY 2015 Maintenance Intervals - Canada.............................................................................................................................................................. 47
1.2.1 Service at 15.000€kilometres.................................................................................................................................................................. 48
1.2.2 Service at 30.000€kilometres.................................................................................................................................................................. 48
1.2.3 Service at 45.000€kilometres.................................................................................................................................................................. 49
1.2.4 Service at 60.000€kilometres.................................................................................................................................................................. 50
1.2.5 Service at 75.000€kilometres.................................................................................................................................................................. 51
1.2.6 Service at 90.000€kilometres.................................................................................................................................................................. 52
1.2.7 Service at 105.000€kilometres................................................................................................................................................................. 52
1.2.8 Service at 120.000€kilometres................................................................................................................................................................. 53
1.2.9 Service at 135.000€kilometres................................................................................................................................................................. 54
1.2.10 Service at 150.000€kilometres................................................................................................................................................................ 55
1.2.11 Service at 165.000€kilometres................................................................................................................................................................ 56
1.2.12 Service at 180.000€kilometres................................................................................................................................................................ 57
1.2.13 Service at 195.000€kilometres................................................................................................................................................................ 58
1.2.14 Service at 210.000€kilometres................................................................................................................................................................ 59
1.2.15 Service at 225.000€kilometres................................................................................................................................................................ 59
1.2.16 Time-Dependent Maintenance Items............................................................................................................................................................. 60
1.2.17 Brake Fluid Replacement...................................................................................................................................................................... 61
1.3 MY 2015 Maintenance Intervals - e-Golf.............................................................................................................................................................. 61
1.3.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 61
1.3.2 Service at 20,000€miles....................................................................................................................................................................... 62
1.3.3 Service at 30,000€miles....................................................................................................................................................................... 62
1.3.4 Service at 40,000€miles....................................................................................................................................................................... 63
1.3.5 Service at 50,000€miles....................................................................................................................................................................... 64
1.3.6 Service at 60,000€miles....................................................................................................................................................................... 64
1.3.7 Service at 70,000€miles....................................................................................................................................................................... 65
1.3.8 Service at 80,000€miles....................................................................................................................................................................... 66
1.3.9 Service at 90,000€miles....................................................................................................................................................................... 67
1.3.10 Service at 100,000€miles..................................................................................................................................................................... 67
1.3.11 Service at 110,000€miles..................................................................................................................................................................... 68
1.3.12 Service at 120,000€miles..................................................................................................................................................................... 68
1.3.13 Time-Dependent Maintenance Items............................................................................................................................................................. 69
1.3.14 Brake Fluid Replacement...................................................................................................................................................................... 70
2 MY 2014 Maintenance Intervals ............................................................................................................................................................................ 71
2.1 MY 2014 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 71
2.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 71
2.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 72
2.1.3 Service at 30,000€miles....................................................................................................................................................................... 72
2.1.4 Service at 40,000€miles....................................................................................................................................................................... 73
2.1.5 Service at 50,000€miles....................................................................................................................................................................... 74
2.1.6 Service at 60,000€miles....................................................................................................................................................................... 74
2.1.7 Service at 70,000€miles....................................................................................................................................................................... 75
2.1.8 Service at 80,000€miles....................................................................................................................................................................... 76
2.1.9 Service at 90,000€miles....................................................................................................................................................................... 77
2.1.10 Service at 100,000€miles..................................................................................................................................................................... 77
2.1.11 Service at 110,000€miles..................................................................................................................................................................... 78
2.1.12 Service at 120,000€miles..................................................................................................................................................................... 78
2.1.13 Service at 130,000€miles..................................................................................................................................................................... 80
2.1.14 Service at 140,000€miles..................................................................................................................................................................... 80
2.1.15 Service at 150,000€miles..................................................................................................................................................................... 81
2.1.16 Time-Dependent Maintenance Items............................................................................................................................................................. 81
2.1.17 Brake Fluid Replacement...................................................................................................................................................................... 82
2.2 MY 2014 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 83
2.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 83
2.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 83
2.2.3 Service at 30,000€miles....................................................................................................................................................................... 84
2.2.4 Service at 40,000€miles....................................................................................................................................................................... 84
2.2.5 Service at 50,000€miles....................................................................................................................................................................... 86
2.2.6 Service at 60,000€miles....................................................................................................................................................................... 86
2.2.7 Service at 70,000€miles....................................................................................................................................................................... 87
2.2.8 Service at 80,000€miles....................................................................................................................................................................... 87
2.2.9 Service at 90,000€miles....................................................................................................................................................................... 88
2.2.10 Service at 100,000€miles..................................................................................................................................................................... 89
2.2.11 Service at 110,000€miles..................................................................................................................................................................... 89
2.2.12 Service at 120,000€miles..................................................................................................................................................................... 90
2.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 91
2.2.14 Brake Fluid Replacement...................................................................................................................................................................... 91
2.3 MY 2014 Maintenance Intervals (Only Jetta, Jetta GLI, Jetta Hybrid, The Beetle, The Beetle Convertible, and Golf Wagon) - Canada.................................................................... 92
2.3.1 Service at 15.000€kilometres.................................................................................................................................................................. 92
2.3.2 Service at 30.000€kilometres.................................................................................................................................................................. 93
2.3.3 Service at 45.000€kilometres.................................................................................................................................................................. 94
2.3.4 Service at 60.000€kilometres.................................................................................................................................................................. 94
2.3.5 Service at 75.000€kilometres.................................................................................................................................................................. 96
2.3.6 Service at 90.000€kilometres.................................................................................................................................................................. 96
2.3.7 Service at 105.000€kilometres................................................................................................................................................................. 97
2.3.8 Service at 120.000€kilometres................................................................................................................................................................. 98
2.3.9 Service at 135.000€kilometres................................................................................................................................................................. 99
2.3.10 Service at 150.000€kilometres................................................................................................................................................................ 100
2.3.11 Service at 165.000€kilometres................................................................................................................................................................ 101
2.3.12 Service at 180.000€kilometres................................................................................................................................................................ 101
2.3.13 Service at 195.000€kilometres................................................................................................................................................................ 103
2.3.14 Service at 210.000€kilometres................................................................................................................................................................ 104
2.3.15 Service at 225.000€kilometres................................................................................................................................................................ 104
2.3.16 Time-Dependent Maintenance Items............................................................................................................................................................. 105
2.3.17 Brake Fluid Replacement...................................................................................................................................................................... 106
3 MY 2013 Maintenance Intervals ............................................................................................................................................................................ 107
3.1 MY 2013 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 107
3.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 107
3.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 108
3.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 108
3.1.4 Service at 40,000€miles....................................................................................................................................................................... 109
3.1.5 Service at 50,000€miles....................................................................................................................................................................... 110
3.1.6 Service at 60,000€miles....................................................................................................................................................................... 110
3.1.7 Service at 70,000€miles....................................................................................................................................................................... 111
3.1.8 Service at 80,000€miles....................................................................................................................................................................... 111
3.1.9 Service at 90,000€miles....................................................................................................................................................................... 112
3.1.10 Service at 100,000€miles..................................................................................................................................................................... 113
3.1.11 Service at 110,000€miles..................................................................................................................................................................... 113
3.1.12 Service at 120,000€miles..................................................................................................................................................................... 114
3.1.13 Service at 130,000€miles..................................................................................................................................................................... 115
3.1.14 Time-Dependent Maintenance Items............................................................................................................................................................. 115
3.1.15 Brake Fluid Replacement...................................................................................................................................................................... 116
3.2 MY 2013 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 117
3.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 117
3.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 117
3.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 118
3.2.4 Service at 40,000€miles....................................................................................................................................................................... 119
3.2.5 Service at 50,000€miles....................................................................................................................................................................... 120
3.2.6 Service at 60,000€miles....................................................................................................................................................................... 120
3.2.7 Service at 70,000€miles....................................................................................................................................................................... 121
3.2.8 Service at 80,000€miles....................................................................................................................................................................... 121
3.2.9 Service at 90,000€miles....................................................................................................................................................................... 122
3.2.10 Service at 100,000€miles..................................................................................................................................................................... 123
3.2.11 Service at 110,000€miles..................................................................................................................................................................... 123
3.2.12 Service at 120,000€miles..................................................................................................................................................................... 124
3.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 125
3.2.14 Brake Fluid Replacement...................................................................................................................................................................... 125
3.3 MY 2013 Maintenance Intervals (All Vehicles) - Canada............................................................................................................................................... 126
3.3.1 Service at 15.000€km.......................................................................................................................................................................... 126
3.3.2 Service at 30.000€km.......................................................................................................................................................................... 127
3.3.3 Service at 60.000€km.......................................................................................................................................................................... 128
3.3.4 Service at 75.000€km.......................................................................................................................................................................... 129
3.3.5 Service at 90.000€km.......................................................................................................................................................................... 129
3.3.6 Service at 105.000€km......................................................................................................................................................................... 130
3.3.7 Service at 120.000€km......................................................................................................................................................................... 131
3.3.8 Service at 135.000€km......................................................................................................................................................................... 132
3.3.9 Service at 150.000€km......................................................................................................................................................................... 133
3.3.10 Service at 165.000€km........................................................................................................................................................................ 134
3.3.11 Service at 180.000€km........................................................................................................................................................................ 134
3.3.12 Service at 195.000€km........................................................................................................................................................................ 136
3.3.13 Time-Dependent Maintenance Items............................................................................................................................................................. 136
3.3.14 Brake Fluid Replacement...................................................................................................................................................................... 137
4 MY 2012 Maintenance Intervals ............................................................................................................................................................................ 138
4.1 MY 2012 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 138
4.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 138
4.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 139
4.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 139
4.1.4 Service at 40,000€miles....................................................................................................................................................................... 140
4.1.5 Service at 50,000€miles....................................................................................................................................................................... 141
4.1.6 Service at 60,000€miles....................................................................................................................................................................... 141
4.1.7 Service at 70,000€miles....................................................................................................................................................................... 142
4.1.8 Service at 80,000€miles....................................................................................................................................................................... 142
4.1.9 Service at 90,000€miles....................................................................................................................................................................... 143
4.1.10 Service at 100,000€miles..................................................................................................................................................................... 144
4.1.11 Service at 110,000€miles..................................................................................................................................................................... 144
4.1.12 Service at 120,000€miles..................................................................................................................................................................... 145
4.1.13 Service at 130,000€miles..................................................................................................................................................................... 146
4.1.14 Time-Dependent Maintenance Items............................................................................................................................................................. 146
4.1.15 Brake Fluid Replacement...................................................................................................................................................................... 147
4.2 MY 2012 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 148
4.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 148
4.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 148
4.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 149
4.2.4 Service at 40,000€miles....................................................................................................................................................................... 150
4.2.5 Service at 50,000€miles....................................................................................................................................................................... 151
4.2.6 Service at 60,000€miles....................................................................................................................................................................... 151
4.2.7 Service at 70,000€miles....................................................................................................................................................................... 152
4.2.8 Service at 80,000€miles....................................................................................................................................................................... 152
4.2.9 Service at 90,000€miles....................................................................................................................................................................... 153
4.2.10 Service at 100,000€miles..................................................................................................................................................................... 154
4.2.11 Service at 110,000€miles..................................................................................................................................................................... 154
4.2.12 Service at 120,000€miles..................................................................................................................................................................... 155
4.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 156
4.2.14 Brake Fluid Replacement...................................................................................................................................................................... 156
4.3 MY 2012 Maintenance Intervals - Canada.............................................................................................................................................................. 157
4.3.1 Service at 15.000€km.......................................................................................................................................................................... 157
4.3.2 Service at 30.000€km.......................................................................................................................................................................... 158
4.3.3 Service at 45.000€km.......................................................................................................................................................................... 159
4.3.4 Service at 60.000€km.......................................................................................................................................................................... 159
4.3.5 Service at 75.000€km.......................................................................................................................................................................... 160
4.3.6 Service at 90.000€km.......................................................................................................................................................................... 161
4.3.7 Service at 105.000€km......................................................................................................................................................................... 162
4.3.8 Service at 120.000€km......................................................................................................................................................................... 162
4.3.9 Service at 135.000€km......................................................................................................................................................................... 164
4.3.10 Service at 150.000€km........................................................................................................................................................................ 164
4.3.11 Service at 165.000€km........................................................................................................................................................................ 165
4.3.12 Service at 180.000€km........................................................................................................................................................................ 166
4.3.13 Service at 195.000€km........................................................................................................................................................................ 167
4.3.14 Time-Dependent Maintenance Items............................................................................................................................................................. 168
4.3.15 Brake Fluid Replacement...................................................................................................................................................................... 168
4.4 MY 2012 Maintenance Intervals - Routan - USA........................................................................................................................................................ 169
4.4.1 Service at 8,000 Miles........................................................................................................................................................................ 169
4.4.2 Service at 16,000 Miles....................................................................................................................................................................... 169
4.4.3 Service at 24,000 Miles....................................................................................................................................................................... 170
4.4.4 Service at 32,000 Miles....................................................................................................................................................................... 170
4.4.5 Service at 40,000 Miles....................................................................................................................................................................... 170
4.4.6 Service at 48,000 Miles....................................................................................................................................................................... 170
4.4.7 Service at 56,000 Miles....................................................................................................................................................................... 170
4.4.8 Service at 64,000 Miles....................................................................................................................................................................... 171
4.4.9 Service at 72,000 Miles....................................................................................................................................................................... 171
4.4.10 Service at 80,000 Miles...................................................................................................................................................................... 171
4.4.11 Service at 88,000 Miles...................................................................................................................................................................... 171
4.4.12 Service at 96,000 Miles...................................................................................................................................................................... 172
4.4.13 Service at 104,000 Miles..................................................................................................................................................................... 172
4.4.14 Service at 112,000 Miles..................................................................................................................................................................... 172
4.4.15 Service at 120,000 Miles..................................................................................................................................................................... 172
4.4.16 Service at 128,000 miles..................................................................................................................................................................... 173
4.4.17 Service at 136,000 Miles..................................................................................................................................................................... 173
4.4.18 Service at 144,000 Miles..................................................................................................................................................................... 173
4.4.19 Service at 152,000 Miles..................................................................................................................................................................... 173
4.5 MY 2012 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 174
4.5.1 Service at 13,000 Kilometers.................................................................................................................................................................. 174
4.5.2 Service at 26,000 Kilometers.................................................................................................................................................................. 174
4.5.3 Service at 39,000 Kilometers.................................................................................................................................................................. 174
4.5.4 Service at 52,000 Kilometers.................................................................................................................................................................. 175
4.5.5 Service at 65,000Kilometers................................................................................................................................................................... 175
4.5.6 Service at 78,000 Kilometers.................................................................................................................................................................. 175
4.5.7 Service at 91,000 Kilometers.................................................................................................................................................................. 175
4.5.8 Service at 104,000 Kilometers................................................................................................................................................................. 175
4.5.9 Service at 117,000 Kilometers................................................................................................................................................................. 176
4.5.10 Service at 130,000 Kilometers................................................................................................................................................................ 176
4.5.11 Service at 143,000 Kilometers................................................................................................................................................................ 176
4.5.12 Service at 156,000 Kilometers................................................................................................................................................................ 176
4.5.13 Service at 169,000 Kilometers................................................................................................................................................................ 177
4.5.14 Service at 182,000 Kilometers................................................................................................................................................................ 177
4.5.15 Service at 195,000 Kilometers................................................................................................................................................................ 177
4.5.16 Service at 208,000 Kilometers................................................................................................................................................................ 177
4.5.17 Service at 221,000 Kilometers................................................................................................................................................................ 177
4.5.18 Service at 234,000 Kilometers................................................................................................................................................................ 177
4.5.19 Service at 247,000 Kilometers................................................................................................................................................................ 178
5 MY 2011 Maintenance Intervals............................................................................................................................................................................. 179
5.1 MY 2011 Maintenance Intervals (Except Routan) - USA................................................................................................................................................. 179
5.1.1 Time Dependent Service........................................................................................................................................................................ 179
5.1.2 Service at 10,000€miles....................................................................................................................................................................... 180
5.1.3 Service at 20,000€miles....................................................................................................................................................................... 180
5.1.4 Service at 30,000€miles....................................................................................................................................................................... 181
5.1.5 Service at 40,000 miles....................................................................................................................................................................... 182
5.1.6 Service at 50,000 miles....................................................................................................................................................................... 183
5.1.7 Service at 60,000 miles....................................................................................................................................................................... 183
5.1.8 Service at 70,000 miles....................................................................................................................................................................... 184
5.1.9 Service at 80,000 miles....................................................................................................................................................................... 185
5.1.10 Service at 90,000 miles...................................................................................................................................................................... 186
5.1.11 Service at 100,000 miles..................................................................................................................................................................... 187
5.1.12 Service at 110,000 miles..................................................................................................................................................................... 187
5.1.13 Service at 120,000 miles..................................................................................................................................................................... 188
5.1.14 Service at 130,000 miles..................................................................................................................................................................... 189
5.2 MY 2011 Maintenance Intervals (Except Routan) - Canada.............................................................................................................................................. 190
5.2.1 Time Dependent Service........................................................................................................................................................................ 190
5.2.2 Service at 15,000€kilometers.................................................................................................................................................................. 191
5.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 192
5.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 192
5.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 193
5.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 194
5.2.7 Service at 90,000€kilometers.................................................................................................................................................................. 195
5.2.8 Service at 105,000€kilometers................................................................................................................................................................. 196
5.2.9 Service at 120,000€kilometers................................................................................................................................................................. 196
5.2.10 Service at 135,000€kilometers................................................................................................................................................................ 198
5.2.11 Service at 150,000€kilometers................................................................................................................................................................ 198
5.2.12 Service at 165,000€kilometers................................................................................................................................................................ 199
5.2.13 Service at 180,000€kilometers................................................................................................................................................................ 200
5.2.14 Service at 195,000€kilometers................................................................................................................................................................ 201
5.3 MY 2011 Maintenance Intervals - Routan - USA........................................................................................................................................................ 203
5.3.1 Service at 8,000 miles........................................................................................................................................................................ 203
5.3.2 Service at 16,000 miles....................................................................................................................................................................... 203
5.3.3 Service at 24,000 miles....................................................................................................................................................................... 203
5.3.4 Service at 32,000 miles....................................................................................................................................................................... 204
5.3.5 Service at 40,000 miles....................................................................................................................................................................... 204
5.3.6 Service at 48,000 miles....................................................................................................................................................................... 204
5.3.7 Service at 56,000 miles....................................................................................................................................................................... 204
5.3.8 Service at 64,000 miles....................................................................................................................................................................... 204
5.3.9 Service at 72,000 miles....................................................................................................................................................................... 205
5.3.10 Service at 80,000 miles...................................................................................................................................................................... 205
5.3.11 Service at 88,000 miles...................................................................................................................................................................... 205
5.3.12 Service at 96,000 miles...................................................................................................................................................................... 205
5.3.13 Service at 104,000 miles..................................................................................................................................................................... 206
5.3.14 Service at 112,000 miles..................................................................................................................................................................... 206
5.3.15 Service at 120,000 miles..................................................................................................................................................................... 206
5.3.16 Service at 128,000 miles..................................................................................................................................................................... 206
5.3.17 Service at 136,000 miles..................................................................................................................................................................... 206
5.3.18 Service at 144,000 miles..................................................................................................................................................................... 206
5.3.19 Service at 152,000 miles..................................................................................................................................................................... 207
5.4 MY 2011 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 207
5.4.1 Service at 13,000 kilometers.................................................................................................................................................................. 207
5.4.2 Service at 26,000 kilometers.................................................................................................................................................................. 208
5.4.3 Service at 39,000 kilometers.................................................................................................................................................................. 208
5.4.4 Service at 52,000 kilometers.................................................................................................................................................................. 208
5.4.5 Service at 65,000 kilometers.................................................................................................................................................................. 208
5.4.6 Service at 78,000 kilometers.................................................................................................................................................................. 208
5.4.7 Service at 91,000 kilometers.................................................................................................................................................................. 209
5.4.8 Service at 104,000 kilometers................................................................................................................................................................. 209
5.4.9 Service at 117,000 kilometers................................................................................................................................................................. 209
5.4.10 Service at 130,000 kilometers................................................................................................................................................................ 209
5.4.11 Service at 143,000 kilometers................................................................................................................................................................ 210
5.4.12 Service at 156,000 kilometers................................................................................................................................................................ 210
5.4.13 Service at 169,000 kilometers................................................................................................................................................................ 210
5.4.14 Service at 182,000 kilometers................................................................................................................................................................ 210
5.4.15 Service at 195,000 kilometers................................................................................................................................................................ 210
5.4.16 Service at 208,000 kilometers................................................................................................................................................................ 211
5.4.17 Service at 221,000 kilometers................................................................................................................................................................ 211
5.4.18 Service at 234,000 kilometers................................................................................................................................................................ 211
5.4.19 Service at 247,000 kilometers................................................................................................................................................................ 211
6 MY 2010 Maintenance Intervals............................................................................................................................................................................. 212
6.1 MY 2010 Maintenance Intervals - USA................................................................................................................................................................. 212
6.1.1 Time Dependent Service........................................................................................................................................................................ 212
6.1.2 Service at Each 5,000 miles through 35,000 miles.............................................................................................................................................. 213
6.1.3 Service at 10,000€miles....................................................................................................................................................................... 213
6.1.4 Service at 20,000€miles....................................................................................................................................................................... 213
6.1.5 Service at 30,000€miles....................................................................................................................................................................... 214
6.1.6 Service at 40,000€miles and each 5,000 miles After............................................................................................................................................ 214
6.1.7 Service at 40,000 miles....................................................................................................................................................................... 214
6.1.8 Service at 50,000 miles....................................................................................................................................................................... 216
6.1.9 Service at 60,000 miles....................................................................................................................................................................... 216
6.1.10 Service at 70,000 miles...................................................................................................................................................................... 217
6.1.11 Service at 80,000 miles...................................................................................................................................................................... 217
6.1.12 Service at 90,000 miles...................................................................................................................................................................... 218
6.1.13 Service at 100,000 miles..................................................................................................................................................................... 219
6.1.14 Service at 110,000 miles..................................................................................................................................................................... 219
6.1.15 Service at 120,000 miles..................................................................................................................................................................... 220
6.2 MY 2010 Maintenance Intervals - Canada.............................................................................................................................................................. 221
6.2.1 Time Dependent Service........................................................................................................................................................................ 221
6.2.2 Service at 15,000€kilometers or one year from vehicle in-service date......................................................................................................................... 222
6.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 222
6.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 223
6.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 223
6.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 225
6.2.7 Service at 90.000€kilometers.................................................................................................................................................................. 225
6.2.8 Service at 105,000€kilometers................................................................................................................................................................. 226
6.2.9 Service at 120,000€kilometers................................................................................................................................................................. 226
6.2.10 Service at 135,000€kilometers................................................................................................................................................................ 227
6.2.11 Service at 150,000€kilometers................................................................................................................................................................ 228
6.2.12 Service at 165,000€kilometers................................................................................................................................................................ 228
6.2.13 Service at 180,000€kilometers................................................................................................................................................................ 229
6.3 MY 2010 Maintenance Intervals - Routan - USA........................................................................................................................................................ 230
6.3.1 Service at 6,000 miles........................................................................................................................................................................ 231
6.3.2 Service at 12,000 miles....................................................................................................................................................................... 231
6.3.3 Service at 18,000 miles....................................................................................................................................................................... 231
6.3.4 Service at 24,000 miles....................................................................................................................................................................... 232
6.3.5 Service at 30,000 miles....................................................................................................................................................................... 232
6.3.6 Service at 36,000 miles....................................................................................................................................................................... 232
6.3.7 Service at 42,000 miles....................................................................................................................................................................... 232
6.3.8 Service at 48,000 miles....................................................................................................................................................................... 232
6.3.9 Service at 54,000 miles....................................................................................................................................................................... 232
6.3.10 Service at 60,000 miles...................................................................................................................................................................... 233
6.3.11 Service at 66,000 miles...................................................................................................................................................................... 233
6.3.12 Service at 72,000 miles...................................................................................................................................................................... 233
6.3.13 Service at 78,000 miles...................................................................................................................................................................... 233
6.3.14 Service at 84,000 miles...................................................................................................................................................................... 233
6.3.15 Service at 90,000 miles...................................................................................................................................................................... 233
6.3.16 Service at 96,000 miles...................................................................................................................................................................... 234
6.3.17 Service at 102,000 miles..................................................................................................................................................................... 234
6.3.18 Service at 108,000 miles..................................................................................................................................................................... 234
6.3.19 Service at 114,000 miles..................................................................................................................................................................... 234
6.3.20 Service at 120,000 miles..................................................................................................................................................................... 234
6.3.21 Service at 126,000 miles..................................................................................................................................................................... 235
6.3.22 Service at 132,000 miles..................................................................................................................................................................... 235
6.3.23 Service at 138,000 miles..................................................................................................................................................................... 235
6.3.24 Service at 144,000 miles..................................................................................................................................................................... 235
6.3.25 Service at 150,000 miles..................................................................................................................................................................... 235
6.4 MY 2010 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 236
6.4.1 Service at 10,000 kilometers.................................................................................................................................................................. 236
6.4.2 Service at 20,000 kilometers.................................................................................................................................................................. 236
6.4.3 Service at 30,000 kilometers.................................................................................................................................................................. 237
6.4.4 Service at 40,000 kilometers.................................................................................................................................................................. 237
6.4.5 Service at 50,000 kilometers.................................................................................................................................................................. 237
6.4.6 Service at 60,000 kilometers.................................................................................................................................................................. 237
6.4.7 Service at 70,000 kilometers.................................................................................................................................................................. 237
6.4.8 Service at 80,000 kilometers.................................................................................................................................................................. 237
6.4.9 Service at 90,000 kilometers.................................................................................................................................................................. 237
6.4.10 Service at 100,000 kilometers................................................................................................................................................................ 238
6.4.11 Service at 110,000 kilometers................................................................................................................................................................ 238
6.4.12 Service at 120,000 kilometers................................................................................................................................................................ 238
6.4.13 Service at 130,000 kilometers................................................................................................................................................................ 238
6.4.14 Service at 140,000 kilometers................................................................................................................................................................ 238
6.4.15 Service at 150,000 kilometers................................................................................................................................................................ 238
6.4.16 Service at 160,000 kilometers................................................................................................................................................................ 239
6.4.17 Service at 170,000 kilometers................................................................................................................................................................ 239
6.4.18 Service at 180,000 kilometers................................................................................................................................................................ 239
6.4.19 Service at 190,000 kilometers................................................................................................................................................................ 239
6.4.20 Service at 200,000 kilometers................................................................................................................................................................ 239
6.4.21 Service at 210,000 kilometers................................................................................................................................................................ 240
6.4.22 Service at 220,000 kilometers................................................................................................................................................................ 240
6.4.23 Service at 230,000 kilometers................................................................................................................................................................ 240
6.4.24 Service at 240,000 kilometers................................................................................................................................................................ 240
6.4.25 Service at 250,000 kilometers................................................................................................................................................................ 240
7 MY 2009 Maintenance Intervals............................................................................................................................................................................. 241
7.1 MY 2009 Maintenance Intervals - USA................................................................................................................................................................. 241
7.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 241
7.1.2 Service every 5,000 miles..................................................................................................................................................................... 242
7.1.3 Service at 10,000 miles....................................................................................................................................................................... 242
7.1.4 Service at 20,000 miles....................................................................................................................................................................... 242
7.1.5 Service at 30,000 miles....................................................................................................................................................................... 243
7.1.6 Service at 40,000 miles....................................................................................................................................................................... 243
7.1.7 Service at 50,000 miles....................................................................................................................................................................... 244
7.1.8 Service at 60,000 miles....................................................................................................................................................................... 245
7.1.9 Service at 70,000 miles....................................................................................................................................................................... 245
7.1.10 Service at 80,000 miles...................................................................................................................................................................... 246
7.1.11 Service at 90,000 miles...................................................................................................................................................................... 247
7.1.12 Service at 100,000 miles..................................................................................................................................................................... 247
7.1.13 Service at 110,000 miles..................................................................................................................................................................... 248
7.1.14 Service at 120,000 miles..................................................................................................................................................................... 248
7.1.15 Service at 130,000 miles..................................................................................................................................................................... 249
7.2 MY 2009 Maintenance Intervals - Canada.............................................................................................................................................................. 250
7.2.1 Time Dependent Service........................................................................................................................................................................ 250
7.2.2 Service at 15,000€kilometers or one year from vehicle in-service date......................................................................................................................... 251
7.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 251
7.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 252
7.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 252
7.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 253
7.2.7 Service at 90.000€kilometers.................................................................................................................................................................. 254
7.2.8 Service at 105,000€kilometers................................................................................................................................................................. 254
7.2.9 Service at 120,000€kilometers................................................................................................................................................................. 255
7.2.10 Service at 135,000€kilometers................................................................................................................................................................ 256
7.2.11 Service at 150,000€kilometers................................................................................................................................................................ 257
7.2.12 Service at 165,000€kilometers................................................................................................................................................................ 257
7.2.13 Service at 180,000€kilometers................................................................................................................................................................ 258
7.3 MY 2009 Maintenance Intervals - Routan - USA........................................................................................................................................................ 259
7.3.1 Service at 6,000 miles........................................................................................................................................................................ 260
7.3.2 Service at 12,000 miles....................................................................................................................................................................... 260
7.3.3 Service at 18,000 miles....................................................................................................................................................................... 260
7.3.4 Service at 24,000 miles....................................................................................................................................................................... 261
7.3.5 Service at 30,000 miles....................................................................................................................................................................... 261
7.3.6 Service at 36,000 miles....................................................................................................................................................................... 261
7.3.7 Service at 42,000 miles....................................................................................................................................................................... 261
7.3.8 Service at 48,000 miles....................................................................................................................................................................... 261
7.3.9 Service at 54,000 miles....................................................................................................................................................................... 261
7.3.10 Service at 60,000 miles...................................................................................................................................................................... 261
7.3.11 Service at 66,000 miles...................................................................................................................................................................... 262
7.3.12 Service at 72,000 miles...................................................................................................................................................................... 262
7.3.13 Service at 78,000 miles...................................................................................................................................................................... 262
7.3.14 Service at 84,000 miles...................................................................................................................................................................... 262
7.3.15 Service at 90,000 miles...................................................................................................................................................................... 262
7.3.16 Service at 96,000 miles...................................................................................................................................................................... 262
7.3.17 Service at 102,000 miles..................................................................................................................................................................... 263
7.3.18 Service at 108,000 miles..................................................................................................................................................................... 263
7.3.19 Service at 114,000 miles..................................................................................................................................................................... 263
7.3.20 Service at 120,000 miles..................................................................................................................................................................... 263
7.3.21 Service at 126,000 miles..................................................................................................................................................................... 263
7.3.22 Service at 132,000 miles..................................................................................................................................................................... 263
7.3.23 Service at 138,000 miles..................................................................................................................................................................... 263
7.3.24 Service at 144,000 miles..................................................................................................................................................................... 264
7.3.25 Service at 150,000 miles..................................................................................................................................................................... 264
7.4 MY 2009 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 264
7.4.1 Service at 10,000 kilometers.................................................................................................................................................................. 264
7.4.2 Service at 20,000 kilometers.................................................................................................................................................................. 265
7.4.3 Service at 30,000 kilometers.................................................................................................................................................................. 265
7.4.4 Service at 40,000 kilometers.................................................................................................................................................................. 265
7.4.5 Service at 50,000 kilometers.................................................................................................................................................................. 265
7.4.6 Service at 60,000 kilometers.................................................................................................................................................................. 265
7.4.7 Service at 70,000 kilometers.................................................................................................................................................................. 265
7.4.8 Service at 80,000 kilometers.................................................................................................................................................................. 265
7.4.9 Service at 90,000 kilometers.................................................................................................................................................................. 266
7.4.10 Service at 100,000 kilometers................................................................................................................................................................ 266
7.4.11 Service at 110,000 kilometers................................................................................................................................................................ 266
7.4.12 Service at 120,000 kilometers................................................................................................................................................................ 266
7.4.13 Service at 130,000 kilometers................................................................................................................................................................ 266
7.4.14 Service at 140,000 kilometers................................................................................................................................................................ 266
7.4.15 Service at 150,000 kilometers................................................................................................................................................................ 266
7.4.16 Service at 160,000 kilometers................................................................................................................................................................ 267
7.4.17 Service at 170,000 kilometers................................................................................................................................................................ 267
7.4.18 Service at 180,000 kilometers................................................................................................................................................................ 267
7.4.19 Service at 190,000 kilometers................................................................................................................................................................ 267
7.4.20 Service at 200,000 kilometers................................................................................................................................................................ 267
7.4.21 Service at 210,000 kilometers................................................................................................................................................................ 268
7.4.22 Service at 220,000 kilometers................................................................................................................................................................ 268
7.4.23 Service at 230,000 kilometers................................................................................................................................................................ 268
7.4.24 Service at 240,000 kilometers................................................................................................................................................................ 268
7.4.25 Service at 250,000 kilometers................................................................................................................................................................ 268
8 MY 2008 Maintenance Intervals............................................................................................................................................................................. 269
8.1 MY 2008 Maintenance Intervals - USA................................................................................................................................................................. 269
8.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 269
8.1.2 Service at 5,000 miles........................................................................................................................................................................ 269
8.1.3 Service at 10,000 miles....................................................................................................................................................................... 270
8.1.4 Service at 20,000 miles....................................................................................................................................................................... 270
8.1.5 Service at 30,000 miles....................................................................................................................................................................... 271
8.1.6 Service at 40,000 miles....................................................................................................................................................................... 271
8.1.7 Service at 50,000 miles....................................................................................................................................................................... 273
8.1.8 Service at 60,000 miles....................................................................................................................................................................... 273
8.1.9 Service at 70,000 miles....................................................................................................................................................................... 274
8.1.10 Service at 80,000 miles...................................................................................................................................................................... 275
8.1.11 Service at 90,000 miles...................................................................................................................................................................... 276
8.1.12 Service at 100,000 miles..................................................................................................................................................................... 277
8.1.13 Service at 110,000 miles..................................................................................................................................................................... 278
8.1.14 Service at 120,000 miles..................................................................................................................................................................... 278
8.2 MY 2008 Maintenance Intervals - Canada.............................................................................................................................................................. 280
8.2.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 280
8.2.2 Service at 8,000 kilometers................................................................................................................................................................... 280
8.2.3 Service at 16,000 kilometers.................................................................................................................................................................. 280
8.2.4 Service at 32,000 kilometers.................................................................................................................................................................. 281
8.2.5 Service at 48,000 kilometers.................................................................................................................................................................. 282
8.2.6 Service at 64,000 kilometers.................................................................................................................................................................. 282
8.2.7 Service at 80,000 kilometers.................................................................................................................................................................. 284
8.2.8 Service at 96,000 kilometers.................................................................................................................................................................. 284
8.2.9 Service at 112,000 kilometers................................................................................................................................................................. 285
8.2.10 Service at 128,000 kilometers................................................................................................................................................................ 286
8.2.11 Service at 144,000 kilometers................................................................................................................................................................ 287
8.2.12 Service at 160,000 kilometers................................................................................................................................................................ 287
8.2.13 Service at 176,000 kilometers................................................................................................................................................................ 288
8.2.14 Service at 180,000 kilometers................................................................................................................................................................ 289
9 MY 2007 Maintenance Intervals............................................................................................................................................................................. 291
9.1 MY 2007 Maintenance Intervals - USA................................................................................................................................................................. 291
9.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 291
9.1.2 Service at 5,000 miles........................................................................................................................................................................ 292
9.1.3 Service at 10,000 miles....................................................................................................................................................................... 292
9.1.4 Service at 20,000 miles....................................................................................................................................................................... 292
9.1.5 Service at 30,000 miles....................................................................................................................................................................... 293
9.1.6 Service at 40,000 miles....................................................................................................................................................................... 293
9.1.7 Service at 50,000 miles....................................................................................................................................................................... 294
9.1.8 Service at 60,000 miles....................................................................................................................................................................... 295
9.1.9 Service at 70,000 miles....................................................................................................................................................................... 296
9.1.10 Service at 80,000 miles...................................................................................................................................................................... 296
9.1.11 Service at 90,000 miles...................................................................................................................................................................... 297
9.1.12 Service at 100,000 miles..................................................................................................................................................................... 298
9.1.13 Service at 110,000 miles..................................................................................................................................................................... 299
9.1.14 Service at 120,000 miles..................................................................................................................................................................... 299
9.2 MY 2007 Maintenance Intervals - Canada.............................................................................................................................................................. 301
9.2.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 301
9.2.2 Service at 8,000 kilometers................................................................................................................................................................... 301
9.2.3 Service at 16,000 kilometers.................................................................................................................................................................. 302
9.2.4 Service at 32,000 kilometers.................................................................................................................................................................. 302
9.2.5 Service at 48,000 kilometers.................................................................................................................................................................. 303
9.2.6 Service at 64,000 kilometers.................................................................................................................................................................. 303
9.2.7 Service at 80,000 kilometers.................................................................................................................................................................. 304
9.2.8 Service at 96,000 kilometers.................................................................................................................................................................. 305
9.2.9 Service at 112,000 kilometers................................................................................................................................................................. 306
9.2.10 Service at 128,000 kilometers................................................................................................................................................................ 306
9.2.11 Service at 144,000 kilometers................................................................................................................................................................ 307
9.2.12 Service at 160,000 kilometers................................................................................................................................................................ 307
9.2.13 Service at 176,000 kilometers................................................................................................................................................................ 308
9.2.14 Service at 180,000 kilometers................................................................................................................................................................ 309
10 MY 2006 Maintenance Intervals............................................................................................................................................................................ 311
10.1 MY 2006 Maintenance Intervals - USA................................................................................................................................................................ 311
10.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 311
10.1.2 Service at 5,000 miles....................................................................................................................................................................... 312
10.1.3 Service at 10,000 miles...................................................................................................................................................................... 312
10.1.4 Service at 15,000 miles...................................................................................................................................................................... 312
10.1.5 Service at 20,000 miles...................................................................................................................................................................... 312
10.1.6 Service at 25,000 miles...................................................................................................................................................................... 313
10.1.7 Service at 30,000 miles...................................................................................................................................................................... 313
10.1.8 Service at 35,000 miles...................................................................................................................................................................... 314
10.1.9 Service at 40,000 miles...................................................................................................................................................................... 314
10.1.10 Service at 45,000 miles..................................................................................................................................................................... 315
10.1.11 Service at 50,000 miles..................................................................................................................................................................... 315
10.1.12 Service at 55,000 miles..................................................................................................................................................................... 316
10.1.13 Service at 60,000 miles..................................................................................................................................................................... 316
10.1.14 Service at 65,000 miles..................................................................................................................................................................... 317
10.1.15 Service at 70,000 miles..................................................................................................................................................................... 317
10.1.16 Service at 75,000 miles..................................................................................................................................................................... 317
10.1.17 Service at 80,000 miles..................................................................................................................................................................... 317
10.1.18 Service at 85,000 miles..................................................................................................................................................................... 319
10.1.19 Service at 90,000 miles..................................................................................................................................................................... 319
10.1.20 Service at 95,000 miles..................................................................................................................................................................... 319
10.1.21 Service at 100,000 miles.................................................................................................................................................................... 319
10.1.22 Service at 105,000 miles.................................................................................................................................................................... 320
10.2 MY 2006 Maintenance Intervals - Canada............................................................................................................................................................. 321
10.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 321
10.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 322
10.2.3 Service at 16,000 kilometers................................................................................................................................................................. 322
10.2.4 Service at 24,000 kilometers................................................................................................................................................................. 322
10.2.5 Service at 32,000 kilometers................................................................................................................................................................. 322
10.2.6 Service at 40,000 kilometers................................................................................................................................................................. 323
10.2.7 Service at 48,000 kilometers................................................................................................................................................................. 323
10.2.8 Service at 56,000 kilometers................................................................................................................................................................. 324
10.2.9 Service at 64,000 kilometers................................................................................................................................................................. 324
10.2.10 Service at 72,000 kilometers................................................................................................................................................................ 325
10.2.11 Service at 80,000 kilometers................................................................................................................................................................ 325
10.2.12 Service at 88,000 kilometers................................................................................................................................................................ 326
10.2.13 Service at 96,000 kilometers................................................................................................................................................................ 326
10.2.14 Service at 104,000 kilometers............................................................................................................................................................... 327
10.2.15 Service at 112,000 kilometers............................................................................................................................................................... 327
10.2.16 Service at 120,000 kilometers............................................................................................................................................................... 327
10.2.17 Service at 128,000 kilometers............................................................................................................................................................... 327
10.2.18 Service at 136,000 kilometers............................................................................................................................................................... 329
10.2.19 Service at 144,000 kilometers............................................................................................................................................................... 329
10.2.20 Service at 152,000 kilometers............................................................................................................................................................... 329
10.2.21 Service at 160,000 kilometers............................................................................................................................................................... 329
10.2.22 Service at 168,000 kilometers............................................................................................................................................................... 330
11 MY 2005 Maintenance Intervals............................................................................................................................................................................ 331
11.1 MY 2005 Maintenance Intervals - USA................................................................................................................................................................ 331
11.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 331
11.1.2 Service at 5,000 miles....................................................................................................................................................................... 332
11.1.3 Service at 10,000 miles...................................................................................................................................................................... 332
11.1.4 Service at 15,000 miles...................................................................................................................................................................... 332
11.1.5 Service at 20,000 miles...................................................................................................................................................................... 332
11.1.6 Service at 25,000 miles...................................................................................................................................................................... 333
11.1.7 Service at 30,000 miles...................................................................................................................................................................... 333
11.1.8 Service at 35,000 miles...................................................................................................................................................................... 334
11.1.9 Service at 40,000 miles...................................................................................................................................................................... 334
11.1.10 Service at 45,000 miles..................................................................................................................................................................... 335
11.1.11 Service at 50,000 miles..................................................................................................................................................................... 335
11.1.12 Service at 55,000 miles..................................................................................................................................................................... 335
11.1.13 Service at 60,000 miles..................................................................................................................................................................... 336
11.1.14 Service at 65,000 miles..................................................................................................................................................................... 337
11.1.15 Service at 70,000 miles..................................................................................................................................................................... 337
11.1.16 Service at 75,000 miles..................................................................................................................................................................... 337
11.1.17 Service at 80,000 miles..................................................................................................................................................................... 337
11.1.18 Service at 85,000 miles..................................................................................................................................................................... 338
11.1.19 Service at 90,000 miles..................................................................................................................................................................... 338
11.1.20 Service at 95,000 miles..................................................................................................................................................................... 339
11.1.21 Service at 100,000 miles.................................................................................................................................................................... 339
11.1.22 Service at 105,000 miles.................................................................................................................................................................... 340
11.2 MY 2005 Maintenance Intervals - Canada............................................................................................................................................................. 341
11.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 341
11.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 342
11.2.3 Service at 16,000 kilometers................................................................................................................................................................. 342
11.2.4 Service at 24,000 kilometers................................................................................................................................................................. 342
11.2.5 Service at 32,000 kilometers................................................................................................................................................................. 342
11.2.6 Service at 40,000 kilometers................................................................................................................................................................. 343
11.2.7 Service at 48,000 kilometers................................................................................................................................................................. 343
11.2.8 Service at 56,000 kilometers................................................................................................................................................................. 343
11.2.9 Service at 64,000 kilometers................................................................................................................................................................. 344
11.2.10 Service at 72,000 kilometers................................................................................................................................................................ 345
11.2.11 Service at 80,000 kilometers................................................................................................................................................................ 345
11.2.12 Service at 88,000 kilometers................................................................................................................................................................ 345
11.2.13 Service at 96,000 kilometers................................................................................................................................................................ 345
11.2.14 Service at 104,000 kilometers............................................................................................................................................................... 346
11.2.15 Service at 112,000 kilometers............................................................................................................................................................... 346
11.2.16 Service at 120,000 kilometers............................................................................................................................................................... 347
11.2.17 Service at 128,000 kilometers............................................................................................................................................................... 347
11.2.18 Service at 136,000 kilometers............................................................................................................................................................... 348
11.2.19 Service at 144,000 kilometers............................................................................................................................................................... 348
11.2.20 Service at 152,000 kilometers............................................................................................................................................................... 348
11.2.21 Service at 160,000 kilometers............................................................................................................................................................... 349
11.2.22 Service at 168,000 kilometers............................................................................................................................................................... 350
12 MY 2004 Maintenance Intervals............................................................................................................................................................................ 351
12.1 MY 2004 Maintenance Intervals - USA................................................................................................................................................................ 351
12.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 351
12.1.2 Service at 5,000 miles....................................................................................................................................................................... 352
12.1.3 Service at 10,000 miles...................................................................................................................................................................... 352
12.1.4 Service at 15,000 miles...................................................................................................................................................................... 352
12.1.5 Service at 20,000 miles...................................................................................................................................................................... 352
12.1.6 Service at 25,000 miles...................................................................................................................................................................... 353
12.1.7 Service at 30,000 miles...................................................................................................................................................................... 353
12.1.8 Service at 35,000 miles...................................................................................................................................................................... 353
12.1.9 Service at 40,000 miles...................................................................................................................................................................... 353
12.1.10 Service at 45,000 miles..................................................................................................................................................................... 354
12.1.11 Service at 50,000 miles..................................................................................................................................................................... 354
12.1.12 Service at 55,000 miles..................................................................................................................................................................... 355
12.1.13 Service at 60,000 miles..................................................................................................................................................................... 355
12.1.14 Service at 65,000 miles..................................................................................................................................................................... 356
12.1.15 Service at 70,000 miles..................................................................................................................................................................... 356
12.1.16 Service at 75,000 miles..................................................................................................................................................................... 356
12.1.17 Service at 80,000 miles..................................................................................................................................................................... 356
12.1.18 Service at 85,000 miles..................................................................................................................................................................... 357
12.1.19 Service at 90,000 miles..................................................................................................................................................................... 357
12.1.20 Service at 95,000 miles..................................................................................................................................................................... 358
12.1.21 Service at 100,000 miles.................................................................................................................................................................... 358
12.1.22 Service at 105,000 miles.................................................................................................................................................................... 358
12.2 MY 2004 Maintenance Intervals - Canada............................................................................................................................................................. 359
12.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 359
12.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 360
12.2.3 Service at 16,000 kilometers................................................................................................................................................................. 360
12.2.4 Service at 24,000 kilometers................................................................................................................................................................. 360
12.2.5 Service at 32,000 kilometers................................................................................................................................................................. 360
12.2.6 Service at 40,000 kilometers................................................................................................................................................................. 361
12.2.7 Service at 48,000 kilometers................................................................................................................................................................. 361
12.2.8 Service at 56,000 kilometers................................................................................................................................................................. 361
12.2.9 Service at 64,000 kilometers................................................................................................................................................................. 361
12.2.10 Service at 72,000 kilometers................................................................................................................................................................ 362
12.2.11 Service at 80,000 kilometers................................................................................................................................................................ 362
12.2.12 Service at 88,000 kilometers................................................................................................................................................................ 363
12.2.13 Service at 96,000 kilometers................................................................................................................................................................ 363
12.2.14 Service at 104,000 kilometers............................................................................................................................................................... 363
12.2.15 Service at 112,000 kilometers............................................................................................................................................................... 363
12.2.16 Service at 120,000 kilometers............................................................................................................................................................... 364
12.2.17 Service at 128,000 kilometers............................................................................................................................................................... 364
12.2.18 Service at 136,000 kilometers............................................................................................................................................................... 365
12.2.19 Service at 144,000 kilometers............................................................................................................................................................... 365
12.2.20 Service at 152,000 kilometers............................................................................................................................................................... 365
12.2.21 Service at 160,000 kilometers............................................................................................................................................................... 365
12.2.22 Service at 168,000 kilometers............................................................................................................................................................... 366
13 MY 2003 Maintenance Intervals............................................................................................................................................................................ 367
13.1 MY 2003 Maintenance Intervals - USA................................................................................................................................................................ 367
13.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 367
13.1.2 Service at 5,000 miles....................................................................................................................................................................... 367
13.1.3 Service at 10,000 miles...................................................................................................................................................................... 368
13.1.4 Service at 15,000 miles...................................................................................................................................................................... 368
13.1.5 Service at 20,000 miles...................................................................................................................................................................... 368
13.1.6 Service at 25,000 miles...................................................................................................................................................................... 369
13.1.7 Service at 30,000 miles...................................................................................................................................................................... 369
13.1.8 Service at 35,000 miles...................................................................................................................................................................... 369
13.1.9 Service at 40,000 miles...................................................................................................................................................................... 369
13.1.10 Service at 45,000 miles..................................................................................................................................................................... 370
13.1.11 Service at 50,000 miles..................................................................................................................................................................... 370
13.1.12 Service at 55,000 miles..................................................................................................................................................................... 370
13.1.13 Service at 60,000 miles..................................................................................................................................................................... 370
13.1.14 Service at 65,000 miles..................................................................................................................................................................... 371
13.1.15 Service at 70,000 miles..................................................................................................................................................................... 371
13.1.16 Service at 75,000 miles..................................................................................................................................................................... 371
13.1.17 Service at 80,000 miles..................................................................................................................................................................... 371
13.1.18 Service at 85,000 miles..................................................................................................................................................................... 372
13.1.19 Service at 90,000 miles..................................................................................................................................................................... 372
13.1.20 Service at 95,000 miles..................................................................................................................................................................... 373
13.1.21 Service at 100,000 miles.................................................................................................................................................................... 373
13.1.22 Service at 105,000 miles.................................................................................................................................................................... 373
13.2 MY 2003 Maintenance Intervals - Canada............................................................................................................................................................. 374
13.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 374
13.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 374
13.2.3 Service at 16,000 kilometers................................................................................................................................................................. 374
13.2.4 Service at 24,000 kilometers................................................................................................................................................................. 375
13.2.5 Service at 32,000 kilometers................................................................................................................................................................. 375
13.2.6 Service at 40,000 kilometers................................................................................................................................................................. 375
13.2.7 Service at 48,000 kilometers................................................................................................................................................................. 375
13.2.8 Service at 56,000 kilometers................................................................................................................................................................. 376
13.2.9 Service at 64,000 kilometers................................................................................................................................................................. 376
13.2.10 Service at 72,000 kilometers................................................................................................................................................................ 377
13.2.11 Service at 80,000 kilometers................................................................................................................................................................ 377
13.2.12 Service at 88,000 kilometers................................................................................................................................................................ 377
13.2.13 Service at 96,000 kilometers................................................................................................................................................................ 377
13.2.14 Service at 104,000 kilometers............................................................................................................................................................... 378
13.2.15 Service at 112,000 kilometers............................................................................................................................................................... 378
13.2.16 Service at 120,000 kilometers............................................................................................................................................................... 378
13.2.17 Service at 128,000 kilometers............................................................................................................................................................... 378
13.2.18 Service at 136,000 kilometers............................................................................................................................................................... 379
13.2.19 Service at 144,000 kilometers............................................................................................................................................................... 379
13.2.20 Service at 152,000 kilometers............................................................................................................................................................... 379
13.2.21 Service at 160,000 kilometers............................................................................................................................................................... 379
13.2.22 Service at 168,000 kilometers............................................................................................................................................................... 380
14 MY 2002 Maintenance Intervals............................................................................................................................................................................ 381
14.1 MY 2002 Maintenance Intervals - USA................................................................................................................................................................ 381
14.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 381
14.1.2 Service at 5,000 miles....................................................................................................................................................................... 381
14.1.3 Service at 10,000 miles...................................................................................................................................................................... 382
14.1.4 Service at 15,000 miles...................................................................................................................................................................... 382
14.1.5 Service at 20,000 miles...................................................................................................................................................................... 382
14.1.6 Service at 25,000 miles...................................................................................................................................................................... 383
14.1.7 Service at 30,000 miles...................................................................................................................................................................... 383
14.1.8 Service at 35,000 miles...................................................................................................................................................................... 383
14.1.9 Service at 40,000 miles...................................................................................................................................................................... 383
14.1.10 Service at 45,000 miles..................................................................................................................................................................... 384
14.1.11 Service at 50,000 miles..................................................................................................................................................................... 384
14.1.12 Service at 55,000 miles..................................................................................................................................................................... 384
14.1.13 Service at 60,000 miles..................................................................................................................................................................... 384
14.1.14 Service at 65,000 miles..................................................................................................................................................................... 385
14.1.15 Service at 70,000 miles..................................................................................................................................................................... 385
14.1.16 Service at 75,000 miles..................................................................................................................................................................... 385
14.1.17 Service at 80,000 miles..................................................................................................................................................................... 385
14.1.18 Service at 85,000 miles..................................................................................................................................................................... 386
14.1.19 Service at 90,000 miles..................................................................................................................................................................... 386
14.1.20 Service at 95,000 miles..................................................................................................................................................................... 387
14.1.21 Service at 100,000 miles.................................................................................................................................................................... 387
14.1.22 Service at 105,000 miles.................................................................................................................................................................... 387
14.2 MY 2002 Maintenance Intervals - Canada............................................................................................................................................................. 388
14.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 388
14.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 388
14.2.3 Service at 16,000 kilometers................................................................................................................................................................. 388
14.2.4 Service at 24,000 kilometers................................................................................................................................................................. 389
14.2.5 Service at 32,000 kilometers................................................................................................................................................................. 389
14.2.6 Service at 40,000 kilometers................................................................................................................................................................. 389
14.2.7 Service at 48,000 kilometers................................................................................................................................................................. 389
14.2.8 Service at 56,000 kilometers................................................................................................................................................................. 390
14.2.9 Service at 64,000 kilometers................................................................................................................................................................. 390
14.2.10 Service at 72,000 kilometers................................................................................................................................................................ 391
14.2.11 Service at 80,000 kilometers................................................................................................................................................................ 391
14.2.12 Service at 88,000 kilometers................................................................................................................................................................ 391
14.2.13 Service at 96,000 kilometers................................................................................................................................................................ 391
14.2.14 Service at 104,000 kilometers............................................................................................................................................................... 392
14.2.15 Service at 112,000 kilometers............................................................................................................................................................... 392
14.2.16 Service at 120,000 kilometers............................................................................................................................................................... 392
14.2.17 Service at 128,000 kilometers............................................................................................................................................................... 392
14.2.18 Service at 136,000 kilometers............................................................................................................................................................... 393
14.2.19 Service at 144,000 kilometers............................................................................................................................................................... 393
14.2.20 Service at 152,000 kilometers............................................................................................................................................................... 393
14.2.21 Service at 160,000 kilometers............................................................................................................................................................... 393
14.2.22 Service at 168,000 kilometers............................................................................................................................................................... 394
15 MY 2001 Maintenance Intervals............................................................................................................................................................................ 395
15.1 MY 2001 Maintenance Intervals - USA................................................................................................................................................................ 395
15.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 395
15.1.2 Service at 5,000 miles....................................................................................................................................................................... 396
15.1.3 Service at 10,000 miles...................................................................................................................................................................... 396
15.1.4 Service at 15,000 miles...................................................................................................................................................................... 396
15.1.5 Service at 20,000 miles...................................................................................................................................................................... 396
15.1.6 Service at 25,000 miles...................................................................................................................................................................... 397
15.1.7 Service at 30,000 miles...................................................................................................................................................................... 397
15.1.8 Service at 35,000 miles...................................................................................................................................................................... 397
15.1.9 Service at 40,000 miles...................................................................................................................................................................... 397
15.1.10 Service at 45,000 miles..................................................................................................................................................................... 398
15.1.11 Service at 50,000 miles..................................................................................................................................................................... 398
15.1.12 Service at 55,000 miles..................................................................................................................................................................... 398
15.1.13 Service at 60,000 miles..................................................................................................................................................................... 398
15.1.14 Service at 65,000 miles..................................................................................................................................................................... 399
15.1.15 Service at 70,000 miles..................................................................................................................................................................... 399
15.1.16 Service at 75,000 miles..................................................................................................................................................................... 399
15.1.17 Service at 80,000 miles..................................................................................................................................................................... 399
15.1.18 Service at 85,000 miles..................................................................................................................................................................... 400
15.1.19 Service at 90,000 miles..................................................................................................................................................................... 400
15.1.20 Service at 95,000 miles..................................................................................................................................................................... 400
15.1.21 Service at 100,000 miles.................................................................................................................................................................... 400
15.1.22 Service at 105,000 miles.................................................................................................................................................................... 401
15.2 MY 2001 Maintenance Intervals - Canada............................................................................................................................................................. 402
15.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 402
15.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 402
15.2.3 Service at 16,000 kilometers................................................................................................................................................................. 402
15.2.4 Service at 24,000 kilometers................................................................................................................................................................. 403
15.2.5 Service at 32,000 kilometers................................................................................................................................................................. 403
15.2.6 Service at 40,000 kilometers................................................................................................................................................................. 403
15.2.7 Service at 48,000 kilometers................................................................................................................................................................. 403
15.2.8 Service at 56,000 kilometers................................................................................................................................................................. 404
15.2.9 Service at 64,000 kilometers................................................................................................................................................................. 404
15.2.10 Service at 72,000 kilometers................................................................................................................................................................ 404
15.2.11 Service at 80,000 kilometers................................................................................................................................................................ 405
15.2.12 Service at 88,000 kilometers................................................................................................................................................................ 405
15.2.13 Service at 96,000 kilometers................................................................................................................................................................ 405
15.2.14 Service at 104,000 kilometers............................................................................................................................................................... 405
15.2.15 Service at 112,000 kilometers............................................................................................................................................................... 406
15.2.16 Service at 120,000 kilometers............................................................................................................................................................... 406
15.2.17 Service at 128,000 kilometers............................................................................................................................................................... 406
15.2.18 Service at 136,000 kilometers............................................................................................................................................................... 407
15.2.19 Service at 144,000 kilometers............................................................................................................................................................... 407
15.2.20 Service at 152,000 kilometers............................................................................................................................................................... 407
15.2.21 Service at 160,000 kilometers............................................................................................................................................................... 407
15.2.22 Service at 168,000 kilometers............................................................................................................................................................... 408
16 MY 2000 Maintenance Intervals............................................................................................................................................................................ 409
16.1 MY 2000 Maintenance Intervals - USA................................................................................................................................................................ 409
16.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 409
16.1.2 Service at 5,000 miles....................................................................................................................................................................... 409
16.1.3 Service at 10,000 miles...................................................................................................................................................................... 410
16.1.4 Service at 15,000 miles...................................................................................................................................................................... 410
16.1.5 Service at 20,000 miles...................................................................................................................................................................... 410
16.1.6 Service at 25,000 miles...................................................................................................................................................................... 411
16.1.7 Service at 30,000 miles...................................................................................................................................................................... 411
16.1.8 Service at 35,000 miles...................................................................................................................................................................... 411
16.1.9 Service at 40,000 miles...................................................................................................................................................................... 411
16.1.10 Service at 45,000 miles..................................................................................................................................................................... 412
16.1.11 Service at 50,000 miles..................................................................................................................................................................... 412
16.1.12 Service at 55,000 miles..................................................................................................................................................................... 412
16.1.13 Service at 60,000 miles..................................................................................................................................................................... 412
16.1.14 Service at 65,000 miles..................................................................................................................................................................... 413
16.1.15 Service at 70,000 miles..................................................................................................................................................................... 413
16.1.16 Service at 75,000 miles..................................................................................................................................................................... 413
16.1.17 Service at 80,000 miles..................................................................................................................................................................... 413
16.1.18 Service at 85,000 miles..................................................................................................................................................................... 414
16.1.19 Service at 90,000 miles..................................................................................................................................................................... 414
16.1.20 Service at 95,000 miles..................................................................................................................................................................... 414
16.1.21 Service at 100,000 miles.................................................................................................................................................................... 414
16.1.22 Service at 105,000 miles.................................................................................................................................................................... 415
16.2 MY 2000 Maintenance Intervals - Canada............................................................................................................................................................. 416
16.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 416
16.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 416
16.2.3 Service at 16,000 kilometers................................................................................................................................................................. 416
16.2.4 Service at 24,000 kilometers................................................................................................................................................................. 417
16.2.5 Service at 32,000 kilometers................................................................................................................................................................. 417
16.2.6 Service at 40,000 kilometers................................................................................................................................................................. 417
16.2.7 Service at 48,000 kilometers................................................................................................................................................................. 417
16.2.8 Service at 56,000 kilometers................................................................................................................................................................. 418
16.2.9 Service at 64,000 kilometers................................................................................................................................................................. 418
16.2.10 Service at 72,000 kilometers................................................................................................................................................................ 418
16.2.11 Service at 80,000 kilometers................................................................................................................................................................ 419
16.2.12 Service at 88,000 kilometers................................................................................................................................................................ 419
16.2.13 Service at 96,000 kilometers................................................................................................................................................................ 419
16.2.14 Service at 104,000 kilometers............................................................................................................................................................... 419
16.2.15 Service at 112,000 kilometers............................................................................................................................................................... 420
16.2.16 Service at 120,000 kilometers............................................................................................................................................................... 420
16.2.17 Service at 128,000 kilometers............................................................................................................................................................... 420
16.2.18 Service at 136,000 kilometers............................................................................................................................................................... 421
16.2.19 Service at 144,000 kilometers............................................................................................................................................................... 421
16.2.20 Service at 152,000 kilometers............................................................................................................................................................... 421
16.2.21 Service at 160,000 kilometers............................................................................................................................................................... 421
16.2.22 Service at 168,000 kilometers............................................................................................................................................................... 422
00-04 Maintenance Procedures General................................................................................................................................................................................ 426
03 – Maintenance, Diagnosis..................................................................................................................................................................................... 430
1 General Information....................................................................................................................................................................................... 430
1.1 Engine Overview..................................................................................................................................................................................... 430
1.2 Oil Change Service.................................................................................................................................................................................. 434
1.3 Inspection Service through MY 99.................................................................................................................................................................... 434
1.4 Inspection Service from MY 00....................................................................................................................................................................... 434
1.5 Lifting Vehicle..................................................................................................................................................................................... 434
1.5.1 General Information........................................................................................................................................................................... 434
1.5.2 Vehicle Hoist Lifting Points.................................................................................................................................................................. 435
1.5.3 Golf R32, Lifting............................................................................................................................................................................. 435
1.5.4 Floor Jack Lifting Points..................................................................................................................................................................... 435
1.6 Labels.............................................................................................................................................................................................. 436
1.6.1 Attaching Data Label in the Luggage Compartment............................................................................................................................................... 436
1.7 Diagnostic Tool, Connecting......................................................................................................................................................................... 437
1.8 Severe Operating Conditions......................................................................................................................................................................... 439
1.9 Vehicle Identification Number....................................................................................................................................................................... 440
1.10 Vehicle Data Label................................................................................................................................................................................. 440
1.11 Hot Climate Countries.............................................................................................................................................................................. 441
1.12 Engine Code and Engine Identification.............................................................................................................................................................. 442
1.13 RME biodiesel...................................................................................................................................................................................... 442
1.14 Type Plate......................................................................................................................................................................................... 443
1.15 Glossary........................................................................................................................................................................................... 443
2 Maintenance Procedures.................................................................................................................................................................................... 446
2.1 Exhaust System, Inspect Visually For Leaks, Fasteners And Damage.................................................................................................................................... 448
2.2 Ball Joints, Checking............................................................................................................................................................................... 448
2.3 Automatic Transmission 01M, Changing ATF............................................................................................................................................................ 448
2.4 Automatic Transmission 01M, Replacing ATF Strainer.................................................................................................................................................. 448
2.5 Automatic Transmission 01M, Checking Final Drive Gear Oil........................................................................................................................................... 449
2.6 Automatic Transmission 01M, Checking ATF Level and Filling.......................................................................................................................................... 449
2.7 Automatic Transmission 09A, Checking ATF Level and Filling.......................................................................................................................................... 449
2.8 Battery Terminals, Checking for Secure Fit.......................................................................................................................................................... 449
2.9 Battery, Checking................................................................................................................................................................................... 450
2.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure and Tread Depth............................................................................................................................ 451
2.10.1 General Information.......................................................................................................................................................................... 451
2.10.2 Checking..................................................................................................................................................................................... 451
2.10.3 Tires, Checking Wear Pattern................................................................................................................................................................. 452
2.10.5 Tires, Including Spare, Checking Pressure and Correcting..................................................................................................................................... 452
2.11 Brake System, Check for Leaks and Damage........................................................................................................................................................... 453
2.12 Front and Rear Brake Pads, Checking Thickness...................................................................................................................................................... 453
2.12.1 Front Disc Brake Pads........................................................................................................................................................................ 453
2.12.2 Rear Disc Brake Pads......................................................................................................................................................................... 454
2.12.3 Drum Brake Pads, Checking, Rear.............................................................................................................................................................. 455
2.13 Brake and Clutch System, Changing Brake Fluid...................................................................................................................................................... 457
2.13.1 Application Information and Safety Precautions............................................................................................................................................... 457
2.13.2 Brake Fluid Specifications................................................................................................................................................................... 457
2.13.3 Brake Fluid, Changing........................................................................................................................................................................ 457
2.14 Brake Fluid Level, Checking........................................................................................................................................................................ 460
2.15 DSG transmission 02E, Fluid and Filter Change, 6-Speed, AWD........................................................................................................................................ 461
2.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization............................................................................................................................. 461
2.16.1 Power Window Regulators, Performing Initialization........................................................................................................................................... 461
2.16.2 8-Way Memory Seat, Performing Initialization................................................................................................................................................. 462
2.17 Performing Vehicle System Test..................................................................................................................................................................... 462
2.18 Protective Joint Boots, Inspecting................................................................................................................................................................. 463
2.19 Noise Insulation, Installing, Golf R32............................................................................................................................................................. 463
2.20 Haldex Clutch Oil Filter, Removing and Installing, AWD............................................................................................................................................. 465
2.21 Haldex Clutch, AWD, Changing Oil................................................................................................................................................................... 465
2.22 First Aid Kit Expiration Date, Checking............................................................................................................................................................ 465
2.23 Fuel Filter, Diesel, Removing and Installing....................................................................................................................................................... 465
2.24 Fuel Filter, Diesel, Draining Water................................................................................................................................................................ 466
2.25 Ribbed Belt, Checking Condition.................................................................................................................................................................... 467
2.26 Cooling System, Checking Freeze Protection and Coolant Level....................................................................................................................................... 468
2.27 Air Filter, Cleaning Housing and Removing and Installing Air Filter................................................................................................................................ 471
2.27.1 Air Filter, Cleaning Housing, Replacing Filter, Cleaning Snow Screen If Equipped............................................................................................................. 471
2.28 Upper Engine Cover, Removing and Installing........................................................................................................................................................ 473
2.28.1 Engine Cover, Removing and Installing, 1.4L with Ignition Coil............................................................................................................................... 473
2.28.3 Engine Cover, 1.8L, Removing and Installing.................................................................................................................................................. 474
2.28.6 Engine Cover, Removing and Installing, 2.8L Fuel Injection Engines........................................................................................................................... 476
2.28.7 Engine Cover, Removing and Installing, 3.2L Fuel Injection Engines........................................................................................................................... 476
2.28.9 Engine Cover, Removing and Installing, 4-Cylinder TDI PD Engines............................................................................................................................. 477
2.29 Lower Engine Compartment Cover, Removing and Installing............................................................................................................................................ 478
2.30 Engine Oil Level, Checking......................................................................................................................................................................... 480
2.31 Engine Oil, Draining or Extracting and Filling; Replacing Oil Filter............................................................................................................................... 480
2.31.1 Engine Oil, Draining or Extracting and Filling............................................................................................................................................... 480
2.31.2 Oil Filter, Replacing........................................................................................................................................................................ 482
2.31.3 Engine Oil, Filling.......................................................................................................................................................................... 485
2.32 Engine and Engine Compartment Components, Checking for Leaks and Damage............................................................................................................................ 486
2.33 Perform a Road Test................................................................................................................................................................................ 486
2.34 Radio/Radio Navigation System, Attaching Serial Number and Code Number to Unit Card................................................................................................................ 487
2.35 Radio/Radio Navigation System, Activating Anti-Theft Coding........................................................................................................................................ 487
2.35.1 General Information.......................................................................................................................................................................... 487
2.35.2 ALPHA Radio Units, Activating Security Code.................................................................................................................................................. 487
2.35.4 On the Radio Navigation System activate the security code as follows:........................................................................................................................ 488
2.36 Wheel Bolts, Tightening Specifications............................................................................................................................................................. 489
2.37 Attaching Wheel Housing Liner to Front Apron (Anniversary Golf GTI with 132 kW only)............................................................................................................... 491
2.38 Tire Repair Kit, Checking.......................................................................................................................................................................... 492
2.39 Power Steering, Checking Fluid Level............................................................................................................................................................... 493
2.40 Sunroof, Checking Function, Cleaning and Lubricating Guide Rails................................................................................................................................... 494
2.41 Sunroof Water Drains, Checking and Cleaning........................................................................................................................................................ 495
2.42 Windshield and Headlamp Washer System, Checking for Damage, Function and Spray Nozzle Adjustment................................................................................................... 496
2.42.1 Windshield Wiper/Washer System Freeze Protection, Checking and Filling....................................................................................................................... 496
2.42.2 Windshield Washer System, Checking and Adjusting Spray Nozzle Position....................................................................................................................... 498
2.42.3 Headlamp Washer System, Checking Spray Nozzles............................................................................................................................................... 500
2.43 Windshield Wiper Blades, Checking for Damage, End Position and Adjustment Angle.................................................................................................................... 500
2.43.1 Windshield Wiper Blades Parked Position, Adjusting........................................................................................................................................... 500
2.43.2 Windshield Wiper Blades, Checking Angle and Adjusting........................................................................................................................................ 501
2.44 Manual Transmission/Final Drive, Checking Oil Level................................................................................................................................................ 502
2.45 Headlamps, Checking and Adjusting.................................................................................................................................................................. 502
2.45.1 General Information.......................................................................................................................................................................... 502
2.45.2 Headlamps, Checking Adjustment with New Test Screen without 15° Adjustment Line.............................................................................................................. 503
2.45.3 Adjusting Headlamps for the Golf............................................................................................................................................................. 504
2.45.4 Headlamps, Adjusting, Jetta.................................................................................................................................................................. 504
2.45.5 Headlamps, Checking Headlamp with Gas Discharge Lamps........................................................................................................................................ 505
2.46 Service Interval Display, Resetting................................................................................................................................................................ 506
2.47 Service Interval Display, Coding................................................................................................................................................................... 508
2.48 Tie Rod Ends, Checking Play, Security and Joint Boots.............................................................................................................................................. 509
2.49 Language, Selecting................................................................................................................................................................................ 509
2.50 Dust and Pollen Filter, Cleaning Housing and Removing and Installing Filter Element................................................................................................................ 510
2.51 Transport Protection, Removing Locking Pieces from Front Axle Struts............................................................................................................................... 510
2.52 Door Arrester, Lubricating......................................................................................................................................................................... 511
2.53 Clock, Setting..................................................................................................................................................................................... 512
2.54 Underbody Components, Checking for Damage.......................................................................................................................................................... 512
2.55 Toothed Belt and Camshaft Drive Tensioner, Replacing............................................................................................................................................... 513
2.55.1 Toothed Belt and Camshaft Drive Tensioning Roller, Removing and Installing, Diesel, Engine Codes ALH and BEW................................................................................. 513
2.55.2 Camshaft Drive Toothed Belt, Removing and Installing, 4-Cylinder, 5-Valve Gasoline, Engine Code AWP.......................................................................................... 513
2.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gasoline Engine.................................................................................................................................. 513
2.57 Toothed Belt, Diesel, Checking for Wear............................................................................................................................................................ 514
2.58 Camshaft Drive Toothed Belt, Checking Condition and Tension, Diesel, Engine Codes ALH with Automatic Transmission.................................................................................. 514
2.58.1 Checking Toothed Belt Condition.............................................................................................................................................................. 514
2.58.2 Toothed Belt, Checking Tension............................................................................................................................................................... 515
2.58.3 Toothed Belt, Tensioning..................................................................................................................................................................... 515
2.59 Spark Plugs, Removing and Installing............................................................................................................................................................... 515
2.59.1 Spark Plugs, Removing and Installing, 1.4L Engines with Ignition Coil........................................................................................................................ 515
2.59.2 Spark Plugs, Removing and Installing, 2.8L Engines, 4-Valve, with Ignition Coil.............................................................................................................. 516
2.59.3 Spark Plugs, Replacing, 2.8L and 3.2L Engines, 4-Valve with Ignition Coil with Power Output Stage............................................................................................ 517
2.59.4 Spark Plugs, 1.8L with Ignition Transformer, Replacing....................................................................................................................................... 518
2.59.5 Spark Plugs, Replacing, 1.8L Engines with Threaded Ignition Coils with Power Output Stages................................................................................................... 519
2.59.6 Spark Plugs, Replacing, 1.8L Engines with Connected Ignition Coils with Power Output Stages.................................................................................................. 520
2.59.7 Spark Plugs, 2.0L Engines, Replacing......................................................................................................................................................... 522
2.60 Rear Lid, Lubricating Multi-Joint Hinges........................................................................................................................................................... 523
3 Special Tools............................................................................................................................................................................................. 526
4 Revision History.......................................................................................................................................................................................... 527
00-05 Maintenance Procedures Variant................................................................................................................................................................................ 531
1 Engine Overview............................................................................................................................................................................................... 535
2 Service Work.................................................................................................................................................................................................. 539
2.1 Oil Change Service...................................................................................................................................................................................... 539
2.2 Inspection Service through MY 99........................................................................................................................................................................ 539
2.3 Inspection Service from MY 00........................................................................................................................................................................... 539
3 General Information........................................................................................................................................................................................... 540
3.1 Lifting Vehicle......................................................................................................................................................................................... 540
3.1.1 General Information............................................................................................................................................................................... 540
3.1.2 Vehicle Hoist Lifting Points...................................................................................................................................................................... 541
3.1.3 Golf R32, Lifting................................................................................................................................................................................. 541
3.1.4 Floor Jack Lifting Points......................................................................................................................................................................... 541
3.2 Labels.................................................................................................................................................................................................. 542
3.2.1 Attaching Data Label in the Luggage Compartment................................................................................................................................................... 542
3.3 Diagnostic Tool, Connecting............................................................................................................................................................................. 543
3.4 Severe Operating Conditions............................................................................................................................................................................. 545
3.5 Vehicle Identification Number........................................................................................................................................................................... 545
3.6 Vehicle Data Label...................................................................................................................................................................................... 546
3.7 Hot Climate Countries................................................................................................................................................................................... 547
3.8 Engine Code and Engine Identification................................................................................................................................................................... 548
3.9 RME Biodiesel........................................................................................................................................................................................... 548
3.10 Type Plate............................................................................................................................................................................................. 549
4 Work Descriptions............................................................................................................................................................................................. 551
4.1 Exhaust System, Inspect Visually For Leaks, Fasteners And Damage........................................................................................................................................ 553
4.2 Ball Joints, Checking................................................................................................................................................................................... 553
4.3 Automatic Transmission 01M, Changing ATF................................................................................................................................................................ 553
4.4 Automatic Transmission 01M, Replacing ATF Strainer...................................................................................................................................................... 553
4.5 Automatic Transmission 01M, Checking Final Drive Gear Oil............................................................................................................................................... 554
4.6 Automatic Transmission 01M, Checking ATF Level and Filling.............................................................................................................................................. 554
4.7 Automatic Transmission 09A, Checking ATF Level and Filling.............................................................................................................................................. 554
4.8 Battery Terminals, Checking for Secure Fit.............................................................................................................................................................. 554
4.9 Battery, Checking....................................................................................................................................................................................... 555
4.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure and Tread Depth................................................................................................................................ 556
4.10.1 General Information.............................................................................................................................................................................. 556
4.10.2 Checking......................................................................................................................................................................................... 556
4.10.3 Tires, Checking Wear Pattern..................................................................................................................................................................... 557
4.10.5 Tires, Including Spare, Checking Pressure and Correcting......................................................................................................................................... 557
4.11 Brake System, Check for Leaks and Damage............................................................................................................................................................... 558
4.12 Front and Rear Brake Pads, Checking Thickness.......................................................................................................................................................... 558
4.12.1 Front Disc Brake Pads............................................................................................................................................................................ 558
4.12.2 Rear Disc Brake Pads............................................................................................................................................................................. 559
4.12.3 Drum Brake Pads, Checking, Rear.................................................................................................................................................................. 560
4.13 Brake and Clutch System, Changing Brake Fluid.......................................................................................................................................................... 562
4.13.1 Application Information and Safety Precautions................................................................................................................................................... 562
4.13.2 Brake Fluid Specifications....................................................................................................................................................................... 562
4.13.3 Brake Fluid, Changing............................................................................................................................................................................ 562
4.14 Brake Fluid Level, Checking............................................................................................................................................................................ 565
4.15 Direct Shift Gearbox (DSG) Transmission 02E, Fluid and Filter Change, 6-Speed, AWD..................................................................................................................... 566
4.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization................................................................................................................................. 566
4.16.1 Power Window Regulators, Performing Initialization............................................................................................................................................... 566
4.16.2 8-Way Memory Seat, Performing Initialization..................................................................................................................................................... 567
4.17 Performing Vehicle System Test......................................................................................................................................................................... 567
4.18 Protective Joint Boots, Inspecting..................................................................................................................................................................... 568
4.19 Noise Insulation, Installing, Golf R32................................................................................................................................................................. 568
4.20 Haldex Clutch Oil Filter, Removing and Installing, All Wheel Drive (AWD)............................................................................................................................... 570
4.21 Haldex Clutch, All Wheel Drive (AWD), Changing Oil..................................................................................................................................................... 570
4.22 First Aid Kit Expiration Date, Checking................................................................................................................................................................ 570
4.23 Fuel Filter, Diesel, Removing and Installing........................................................................................................................................................... 570
4.24 Fuel Filter, Diesel, Draining Water.................................................................................................................................................................... 571
4.25 Ribbed Belt, Checking Condition........................................................................................................................................................................ 572
4.26 Cooling System, Checking Freeze Protection and Coolant Level........................................................................................................................................... 573
4.27 Air Filter, Cleaning Housing and Removing and Installing Air Filter.................................................................................................................................... 576
4.27.1 Air Filter, Cleaning Housing, Replacing Filter, Cleaning Snow Screen If Equipped................................................................................................................. 576
4.28 Upper Engine Cover, Removing and Installing............................................................................................................................................................ 578
4.28.1 Engine Cover, Removing and Installing, 1.4L with Ignition Coil................................................................................................................................... 578
4.28.3 Engine Cover, 1.8L, Removing and Installing...................................................................................................................................................... 579
4.28.6 Engine Cover, Removing and Installing, 2.8L Fuel Injection Engines............................................................................................................................... 581
4.28.7 Engine Cover, Removing and Installing, 3.2L Fuel Injection Engines............................................................................................................................... 581
4.28.9 Engine Cover, Removing and Installing, 4-Cylinder TDI PD Engines................................................................................................................................. 582
4.29 Lower Engine Compartment Cover, Removing and Installing................................................................................................................................................ 583
4.30 Engine Oil Level, Checking............................................................................................................................................................................. 585
4.31 Engine Oil, Draining or Extracting and Filling; Replacing Oil Filter................................................................................................................................... 585
4.31.1 Engine Oil, Draining or Extracting and Filling................................................................................................................................................... 585
4.31.2 Oil Filter, Replacing............................................................................................................................................................................ 587
4.31.3 Engine Oil, Filling.............................................................................................................................................................................. 590
4.32 Engine and Engine Compartment Components, Checking for Leaks and Damage................................................................................................................................ 591
4.33 Perform a Road Test.................................................................................................................................................................................... 591
4.34 Radio/Radio Navigation System, Attaching Serial Number and Code Number to Unit Card.................................................................................................................... 592
4.35 Radio/Radio Navigation System, Activating Anti-Theft Coding............................................................................................................................................ 592
4.35.1 General Information.............................................................................................................................................................................. 592
4.35.2 ALPHA Radio Units, Activating Security Code...................................................................................................................................................... 592
4.35.4 On the Radio Navigation System activate the security code as follows:............................................................................................................................ 593
4.36 Wheel Bolts, Tightening Specifications................................................................................................................................................................. 594
4.37 Attaching Wheel Housing Liner to Front Apron (Anniversary Golf GTI with 132 kW only)................................................................................................................... 596
4.38 Tire Repair Kit, Checking.............................................................................................................................................................................. 597
4.39 Power Steering, Checking Fluid Level................................................................................................................................................................... 598
4.40 Sunroof, Checking Function, Cleaning and Lubricating Guide Rails....................................................................................................................................... 599
4.41 Sunroof Water Drains, Checking and Cleaning............................................................................................................................................................ 600
4.42 Windshield and Headlamp Washer System, Checking for Damage, Function and Spray Nozzle Adjustment....................................................................................................... 601
4.42.1 Windshield Wiper/Washer System Freeze Protection, Checking and Filling........................................................................................................................... 601
4.42.2 Windshield Washer System, Checking and Adjusting Spray Nozzle Position........................................................................................................................... 603
4.42.3 Headlamp Washer System, Checking Spray Nozzles................................................................................................................................................... 605
4.43 Windshield Wiper Blades, Checking for Damage, End Position and Adjustment Angle........................................................................................................................ 605
4.43.1 Windshield Wiper Blades Parked Position, Adjusting............................................................................................................................................... 605
4.43.2 Windshield Wiper Blades, Checking Angle and Adjusting............................................................................................................................................ 606
4.44 Manual Transmission/Final Drive, Checking Oil Level.................................................................................................................................................... 607
4.45 Headlamps, Checking and Adjusting...................................................................................................................................................................... 607
4.45.1 General Information.............................................................................................................................................................................. 607
4.45.2 Headlamps, Checking Adjustment with New Test Screen without 15° Adjustment Line.................................................................................................................. 608
4.45.3 Adjusting Headlamps for the Golf................................................................................................................................................................. 609
4.45.4 Headlamps, Adjusting, Jetta...................................................................................................................................................................... 609
4.45.5 Headlamps, Checking Headlamp with Gas Discharge Lamps............................................................................................................................................ 610
4.46 Service Interval Display, Resetting.................................................................................................................................................................... 611
4.47 Service Interval Display, Coding....................................................................................................................................................................... 613
4.48 Tie Rod Ends, Checking Play, Security and Joint Boots.................................................................................................................................................. 614
4.49 Language, Selecting.................................................................................................................................................................................... 614
4.50 Dust and Pollen Filter, Cleaning Housing and Removing and Installing Filter Element.................................................................................................................... 615
4.51 Transport Protection, Removing Locking Pieces from Front Axle Struts................................................................................................................................... 615
4.52 Door Arrester, Lubricating............................................................................................................................................................................. 616
4.53 Clock, Setting......................................................................................................................................................................................... 617
4.54 Underbody Components, Checking for Damage.............................................................................................................................................................. 617
4.55 Toothed Belt and Camshaft Drive Tensioner, Replacing................................................................................................................................................... 618
4.55.1 Toothed Belt and Camshaft Drive Tensioning Roller, Removing and Installing, Diesel, Engine Codes ALH and BEW..................................................................................... 618
4.55.2 Camshaft Drive Toothed Belt, Removing and Installing, 4-Cylinder, 5-Valve Gasoline, Engine Code AWP.............................................................................................. 618
4.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gasoline Engine...................................................................................................................................... 618
4.57 Toothed Belt, Diesel, Checking for Wear................................................................................................................................................................ 619
4.58 Camshaft Drive Toothed Belt, Checking Condition and Tension, Diesel, Engine Codes ALH with Automatic Transmission...................................................................................... 619
4.58.1 Checking Toothed Belt Condition.................................................................................................................................................................. 619
4.58.2 Toothed Belt, Checking Tension................................................................................................................................................................... 620
4.58.3 Toothed Belt, Tensioning......................................................................................................................................................................... 620
4.59 Spark Plugs, Removing and Installing................................................................................................................................................................... 620
4.59.1 Spark Plugs, Removing and Installing, 1.4L Engines with Ignition Coil............................................................................................................................ 620
4.59.2 Spark Plugs, Removing and Installing, 2.8L Engines, 4-Valve, with Ignition Coil.................................................................................................................. 621
4.59.3 Spark Plugs, Replacing, 2.8L and 3.2L Engines, 4-Valve with Ignition Coil with Power Output Stage................................................................................................ 622
4.59.4 Spark Plugs, 1.8L with Ignition Transformer, Replacing........................................................................................................................................... 623
4.59.5 Spark Plugs, Replacing, 1.8L Engines with Threaded Ignition Coils with Power Output Stages....................................................................................................... 624
4.59.6 Spark Plugs, Replacing, 1.8L Engines with Connected Ignition Coils with Power Output Stages...................................................................................................... 625
4.59.7 Spark Plugs, 2.0L Engines, Replacing............................................................................................................................................................. 627
4.60 Rear Lid, Lubricating Multi-Joint Hinges............................................................................................................................................................... 628
5 Glossary...................................................................................................................................................................................................... 631
00-06 VW Fluid Capacity Charts...................................................................................................................................................................................... 636
00-07 Fluid Capacity Tables All..................................................................................................................................................................................... 645
03 – Maintenance, Diagnosis..................................................................................................................................................................................... 649
1 New Beetle/New Beetle Convertible......................................................................................................................................................................... 649
2 Golf/GTI/Jetta/Jetta Wagon................................................................................................................................................................................ 651
3 new Jetta................................................................................................................................................................................................. 653
4 Passat.................................................................................................................................................................................................... 654
5 Phaeton................................................................................................................................................................................................... 655
6 Touareg................................................................................................................................................................................................... 656
00-08 VW Maintenance Labor Operations Times......................................................................................................................................................................... 660
00-09 Towing Guide.................................................................................................................................................................................................. 669
01-Engine Mechanical & Systems.pdf (p.783-3293)......................................................................................................................................................................... 783
01-01A Engine Mechanical AFP........................................................................................................................................................................................ 783
01-01B Fuel Injection & Ignition AFP................................................................................................................................................................................ 949
01-02A Engine Mechanical ALH........................................................................................................................................................................................1132
01-02B Fuel Injection & Glow Plug ALH...............................................................................................................................................................................1274
01-03A Engine Mechanical AWD-AWW-AWP................................................................................................................................................................................1426
01-03B Fuel_Injection & Ignition AWP, AWW...........................................................................................................................................................................1617
01-03C Fuel Injection & Ignition AWD................................................................................................................................................................................1930
01-04A Engine Mechanical BDF........................................................................................................................................................................................2141
01-04B Fuel_Injection & Ignition BDF................................................................................................................................................................................2328
01-05 Engine Mechanical, Fuel Injection & Ignition BJS.............................................................................................................................................................2631
01-06 Engine Mechanical, Fuel Injection & Ignition 1999 AEG-AVH-AZG.................................................................................................................................................2825
01-07 Engine Mechanical Fuel Injection & Glow Plug BEW..............................................................................................................................................................3115
02-Engine Performance.pdf (p.3294-4841).................................................................................................................................................................................3294
02-00A Gasoline Quality.............................................................................................................................................................................................3294
02-00B 1.9L Pump Values TDI-BEW & BRM...............................................................................................................................................................................3300
02-01A Generic Scan Tool AFP........................................................................................................................................................................................3324
02-01B-Generic Scan Tool ALH, BEW...................................................................................................................................................................................3457
02-01C Generic Scan Tool AWP, AWW, AWD..............................................................................................................................................................................3596
02-01D Generic Scan Tool AVH, AZG, BBW, BEV.........................................................................................................................................................................3800
02-01E Generic Scan Tool BJS........................................................................................................................................................................................4046
02-02A VW Engine & Transmission Fault Codes.........................................................................................................................................................................4239
02-02B DTC List Complete 1998-2004..................................................................................................................................................................................4263
P Codes.........................................................................................................................................................................................................4263
U Codes.........................................................................................................................................................................................................4321
02-02C DTC List-Engine & Transmission...............................................................................................................................................................................4327
02-02D Simos 6 OBD System Strategy..................................................................................................................................................................................4355
1. CATALYST MONITORING .........................................................................................................................................................................................4357
1.01 Diagnostic Overview:...................................................................................................................................................................................4357
1.02 General description....................................................................................................................................................................................4357
1.03 Monitoring Structure...................................................................................................................................................................................4357
1.04 Flow Chart Catalyst Monitoring .......................................................................................................................................................................4358
2. HEATED CATALYST MONITORING...................................................................................................................................................................................4359
3. MISFIRE MONITORING...........................................................................................................................................................................................4359
3.01 General Description....................................................................................................................................................................................4359
3.02 Monitoring function description........................................................................................................................................................................4359
3.04 Chart and Flow Chart(s)................................................................................................................................................................................4362
3.05 Paths for misfire and catalyst damaging misfire rate.................................................................................................................................4363
4 EVAPORATIVE SYSTEM DIAGNOSIS.................................................................................................................................................................................4364
4.04 Leakage Check / Reed Sensor ...........................................................................................................................................................................4364
4.04.01 General description ............................................................................................................................................................................4364
4.04.02 Monitoring function description ..............................................................................................................................................................4364
4.04.03 Chart(s) and flow chart(s) ....................................................................................................................................................................4365
4.05 Purge Check ...........................................................................................................................................................................................4367
4.05.01 General description.............................................................................................................................................................................4367
4.05.02 Monitoring function description................................................................................................................................................................4368
4.05.03 Chart(s) and flow chart(s) .....................................................................................................................................................................4368
5 SECONDARY/ AIR SYSTEM MONITORING..............................................................................................................................................................................4369
6 FUEL SYSTEM MONITORING........................................................................................................................................................................................4369
6.04 General Description....................................................................................................................................................................................4369
6.05 Monitoring function description........................................................................................................................................................................4369
6.05.01 Adaptive pilot control..........................................................................................................................................................................4369
6.05.02 Fuel trim.......................................................................................................................................................................................4369
6.06 Chart(s) and flowchart(s)..............................................................................................................................................................................4370
7 OXYGEN SENSOR AND HEATER MONITORING..........................................................................................................................................................................4373
7.04.01 Open circuit (UN)...................................................................................................................................................................................4373
7.04.02 Open circuit (VM)...............................................................................................................................................................................4373
7.04.03 Open circuit (IP)...............................................................................................................................................................................4373
7.04.04 Open circuit (IA)...............................................................................................................................................................................4373
8. EGR MONITORING...........................................................................................................................................................................................4384
9. PCV MONITORING............................................................................................................................................................................................4384
10. ENGINE COOLANT SYSTEM MONITORING ..........................................................................................................................................................................4384
7.15 General description ..................................................................................................................................................................................4384
7.16 Monitor Functional Description........................................................................................................................................................................4385
7.16.01 Cooling System Performance (P2081)..............................................................................................................................................................4386
7.16.02 Engine Coolant Temperature Sensor Rationality (P3081)..........................................................................................................................................4388
7.16.03 Engine Coolant Temperature Sensor Stuck Low (P0116)............................................................................................................................................4390
7.16.04 Engine Coolant Temperature Sensor Stuck High (P0116)............................................................................................................................................4392
7.16.05 Engine Coolant Temperature Sensor Out of Range Check (P0118 / P0117)............................................................................................................................4394
10. COLD START EMISSION REDUCTION STRATEGY MONITORING ........................................................................................................................................................4395
11. AIR CONDITIONING (A/C) SYSTEM COMPONENT MONITORING ........................................................................................................................................................4395
12. VARIABLE VALVE TIMING AND/OR CONTROL (VVT) SYSTEM MONITORING .............................................................................................................................................4395
13. DIRECT OZON REDUCTION (DOR) SYSTEM MONITORING..............................................................................................................................................................4395
14. PARTICULATE MATER (PM) TRAP MONITORING ...................................................................................................................................................................4395
15. COMPREHENSIVE COMPONENTS MONITORING........................................................................................................................................................................4395
15.01 Electrical checks for Sensor signals...........................................................................................................................................................4396
15.02 Electrical checks for Actuators.......................................................................................................................................................................4396
15.03 Camshaft position sensor and variable valve actuator ..................................................................................................................................4397
15.03.01 Signal activity and rationality check..........................................................................................................................................................4397
15.04 Variable valve actuator functional check.............................................................................................................................................4398
15.05 Engine speed sensor ...............................................................................................................................................................4399
15.05.01 Electrical check..............................................................................................................................................................................4399
15.05.02 Signal activity and rationality check.........................................................................................................................................................4400
15.06 Knock sensor.....................................................................................................................................................................4401
15.06.01 Signal activity check..........................................................................................................................................................................4401
15.07 Vehicle speed sensor..............................................................................................................................................................4402
15.07.01 Rationality check..............................................................................................................................................................................4402
15.08 MAP and altitude sensor..........................................................................................................................................................4403
15.08.01 Rationality check..............................................................................................................................................................................4403
15.2.1 Rationality check................................................................................................................................................................................4405
15.3 Idle controller ......................................................................................................................................................................................4406
15.3.1 Out of range check...............................................................................................................................................................................4406
15.4 Accelerator pedal position sensor ....................................................................................................................................................................4407
15.4.1 Out of Range / Rationality check.................................................................................................................................................................4407
15.5 Injection valve check .................................................................................................................................................................................4408
15.19 Automatic Transmission Monitor.........................................................................................................................................................4408
16 OTHER EMISSION CONTROL OR SOURCE SYSTEM MONITORING..........................................................................................................................................................4409
.17.01.01 Intake manifold runner flap ..........................................................................................................................................................4409
.17.01.02 Out of range low / high......................................................................................................................................................................4409
.17.01.03 Stuck open / close.....................................................................................................................................................................4410
18. PARAMETERS AND CONDITIONS TO BEGIN CLOSED LOOP OPERATION.................................................................................................................................................4411
02-02E DTC & Mode 6 Summary Tables 2004-2005 1.9L TDI BEW...........................................................................................................................................................4416
.01.00.00 – MODE 06 REQUEST ON - BOARD MONITORING TEST RESULTS..................................................................................................................................................4417
Mode 06 - TID 01 Oxygen Sensor Monitoring...................................................................................................................................................................4417
Mode 06 - TID 09 Dynamic plausibility of coolant temperature sensor.........................................................................................................................................4417
Mode 06 - TID 10 Start-Stop positions test of quantity adjuster.............................................................................................................................................4418
Mode 06 - TID 11 Dynamic plausibility of fuel temperature sensor............................................................................................................................................4418
Mode 06 - TID 12 Plausibility of boost pressure sensor with atmospheric pressure sensor.....................................................................................................................4418
Mode 06 - TID 31 Exhaust Gas Recirculation (EGR)............................................................................................................................................................4419
.............................................................................................................................................................................................................4419
.02.00.00 ( OBD DTC SUMMARY TABLE ..............................................................................................................................................................................4420
02-03A Glow Plug Fault Diagnosis for Engines BEW....................................................................................................................................................................4435
02-03B How to Set Readiness Code 2005 All Models with 2.0L AVH......................................................................................................................................................4440
02-03C How to Set Readiness Code 2002-2005 Golf & Jetta 2.8L BDF & AFP..............................................................................................................................................4444
02-03D How to Set Readiness Code 2002-2006 All Models with 1.8L engine-except BKF...................................................................................................................................4448
02-03E How to Set Readiness Code 2004-2005 All Models with Diesel BHW BEW BKW.......................................................................................................................................4452
02-03F How to Set Readiness Code 2005 All Models with 2.0L BEV......................................................................................................................................................4456
02-03G VW New OBD II Drive Cycle Procedure..........................................................................................................................................................................4460
02-04A Immobilizer Self Study Program...............................................................................................................................................................................4463
02-04B Immobilizer Theory...........................................................................................................................................................................................4518
02-04C Immobilizer Service Requirements - Vehicle Keys..............................................................................................................................................................4535
02-04D Immobilizer Service Requirements - Guided Fault Finding......................................................................................................................................................4546
02-05A Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy................................................................................................................................................4566
...............................................................................................................................................................................................................4568
.01.00.00 CATALYST MONITORING ..................................................................................................................................................................................4569
.01.01.00 Passive measurement of amplitude ratio............................................................................................................................................................4569
.01.01.01 General description...........................................................................................................................................................................4569
.......................................................................................................................................................................................................4570
.01.01.02 Monitoring Structure..........................................................................................................................................................................4570
.01.01.03 Flow Chart Catalyst Monitoring ...............................................................................................................................................................4570
...........................................................................................................................................................................................................4571
.01.02.00 Active measurement of OSC.........................................................................................................................................................................4571
.01.02.01 General description...........................................................................................................................................................................4571
.01.02.02 Monitoring Structure..........................................................................................................................................................................4572
Main-catalyst.......................................................................................................................................................................................4573
Catalyst-system.................................................................................................................................................................................4573
.......................................................................................................................................................................................................4575
.01.02.03 Flow Chart Catalyst Monitoring................................................................................................................................................................4575
.02.00.00 HEATED CATALYST MONITORING............................................................................................................................................................................4576
.03.00.00 MISFIRE MONITORING....................................................................................................................................................................................4576
.03.00.01 General Description...............................................................................................................................................................................4576
.......................................................................................................................................................................................................4577
.03.01.02 Monitoring function description...............................................................................................................................................................4577
...........................................................................................................................................................................................................4578
...........................................................................................................................................................................................................4579
.03.00.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4580
...............................................................................................................................................................................................................4582
.04.00.00 EVAPORATIVE SYSTEM DIAGNOSIS..........................................................................................................................................................................4582
.04.01.00 Leakage Check ....................................................................................................................................................................................4582
.04.01.01 General description ..........................................................................................................................................................................4582
.04.01.02 Monitoring function description ............................................................................................................................................................4582
.......................................................................................................................................................................................................4583
.04.01.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4583
.04.02.00 Purge Check ......................................................................................................................................................................................4585
.04.02.01 General description...........................................................................................................................................................................4585
.......................................................................................................................................................................................................4586
.04.02,02 Monitoring function description...............................................................................................................................................................4586
.04.02.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4586
...............................................................................................................................................................................................................4587
.05.00.00 SECONDARY AIR SYSTEM MONITORING.......................................................................................................................................................................4587
.05.01.00 Via lambda deviation .............................................................................................................................................................................4587
.05.01.01 General Description...........................................................................................................................................................................4587
.......................................................................................................................................................................................................4588
.05.01.02 Monitoring Structure..........................................................................................................................................................................4588
.05.01.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4590
.05.02.00 Via exhaust temperature sensor ...................................................................................................................................................................4592
.05.02.01 General Description...........................................................................................................................................................................4592
.05.02.02 Monitor function description .................................................................................................................................................................4592
.......................................................................................................................................................................................................4593
.05.02.03 Chart(s) and flow chart(s)....................................................................................................................................................................4593
...............................................................................................................................................................................................................4594
.06.00.00 Fuel System Monitoring................................................................................................................................................................................4594
.06.00.01 General Description...............................................................................................................................................................................4594
.06.00.02 Monitoring function description...............................................................................................................................................................4594
...........................................................................................................................................................................................................4595
.06.00.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4595
.07.00.00 OXYGEN SENSOR MONITORING............................................................................................................................................................................4598
.07.01.00 Calibrations with ASIC CJ 110.....................................................................................................................................................................4598
.07.01.01 General Description...........................................................................................................................................................................4598
.07.01.02 Monitoring function description...............................................................................................................................................................4598
.07.01.03 Chart(s) and flow chart(s)....................................................................................................................................................................4600
.07.02.00 Oxygen Sensor Heater Monitoring .................................................................................................................................................................4605
.07.03.01 General description (ASIC CJ 110).............................................................................................................................................................4605
.07.02.02 Monitor function description .................................................................................................................................................................4605
.......................................................................................................................................................................................................4606
07.02.03 Chart(s) and Flow Chart(s) ...................................................................................................................................................................4606
.07.03.01 General Description...........................................................................................................................................................................4608
.07.03.02 Monitor function description..................................................................................................................................................................4608
.......................................................................................................................................................................................................4610
.07.03.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4610
.07.04.00 Oxygen Sensor Heater Monitoring (ASIC CJ 125/120)................................................................................................................................................4612
.07.04.01 General description ..........................................................................................................................................................................4612
.07.04.02 Monitor function description..................................................................................................................................................................4612
.07.04.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4613
.07.05.00 SULEV applications................................................................................................................................................................................4614
.07.05.01 General description...........................................................................................................................................................................4614
.07.05.02 Monitor function description..................................................................................................................................................................4614
.07.05.03 Chart(s) and flow chart(s)....................................................................................................................................................................4616
.07.06.00 Oxygen Sensor Heater Monitoring (SULEV).........................................................................................................................................................4621
.07.06.01 General description ..........................................................................................................................................................................4621
.07.06.02 Monitor function description).................................................................................................................................................................4621
.......................................................................................................................................................................................................4623
.07.06.03 Chart(s) and Flow Chart(s)...................................................................................................................................................................4623
...............................................................................................................................................................................................................4625
.08.00.00 EGR Monitoring........................................................................................................................................................................................4625
.09.00.00 PCV MONITORING........................................................................................................................................................................................4625
.10.00.00 ENGINE COOLANT SYSTEM MONITORING .....................................................................................................................................................................4625
.10.01.00 General description .............................................................................................................................................................................4625
.......................................................................................................................................................................................................4626
.10.01.02 Monitor Functional Description...............................................................................................................................................................4626
.10.03.00 Charts and Flow Charts........................................................................................................................................................................4627
.11.00.00 COLD START EMISSION REDUCTION STRATEGY MONITORING ...................................................................................................................................................4638
.12.00.00 AIR CONDITIONING (A/C) SYSTEM COMPONENT MONITORING ...................................................................................................................................................4638
.13.00.00 VARIABLE VALVE TIMING AND/OR CONTROL (VVT) SYSTEM MONITORING ........................................................................................................................................4638
.14.00.00 DIRECT OZON REDUCTION (DOR) SYSTEM MONITORING.........................................................................................................................................................4638
.15.00.00 PARTICULATE MATER (PM) TRAP MONITORING ..............................................................................................................................................................4638
.16.00.00 COMPREHENSIVE COMPONENTS MONITORING...................................................................................................................................................................4638
.16.01.00 Injection Valve...................................................................................................................................................................................4638
.16.02.00 Fuel Pump Relay...................................................................................................................................................................................4638
.16.03.00 Idle Controller .................................................................................................................................................................................4639
.16.04.00 Engine Speed Sensor:..............................................................................................................................................................................4640
.16.05.00 Warm-up Bypass valve:.............................................................................................................................................................................4640
...........................................................................................................................................................................................................4641
.16.06.00 Signal Range Check for different sensor ..........................................................................................................................................................4641
...........................................................................................................................................................................................................4642
.16.07.00 Rationality Mass Air Flow Sensor (MAF)............................................................................................................................................................4642
...........................................................................................................................................................................................................4644
.16.08.00 Vehicle Speed Sensor (VSS)........................................................................................................................................................................4644
...........................................................................................................................................................................................................4645
.16.09.00 Throttle Position Sensor (throttle unit with E-gas actuator).....................................................................................................................................4645
.16.10.00 Accelerator pedal position sensor (APPS)..........................................................................................................................................................4646
.16.11.00 Camshaft Position Sensor..........................................................................................................................................................................4647
.16.12.00 Boost Pressure Control Valve .....................................................................................................................................................................4648
...........................................................................................................................................................................................................4649
.16.13.00 Engine Start Delay Relay (SULEV)..................................................................................................................................................................4649
...........................................................................................................................................................................................................4650
.16.14.00 Exhaust Temperature Sensor (SULEV)...............................................................................................................................................................4650
.16.14.01 General Monitoring Description ...............................................................................................................................................................4650
.16.14.02 Monitor function description..................................................................................................................................................................4650
...........................................................................................................................................................................................................4650
.16.14.03 Chart(s) and Flow Chart (s)...................................................................................................................................................................4651
.16.15.00 reserved.........................................................................................................................................................................................4652
.16.16.00 reserved.........................................................................................................................................................................................4652
.16.17.00 reserved.........................................................................................................................................................................................4652
.16.18.00 reserved.........................................................................................................................................................................................4652
.16.19.00 reserved.........................................................................................................................................................................................4652
...........................................................................................................................................................................................................4653
.16.20.00 Automatic Transmission Monitor....................................................................................................................................................................4653
.16.21.00 Output Stage Check ...............................................................................................................................................................................4653
...............................................................................................................................................................................................................4654
.17.00.00 OTHER EMISSION CONTROL OR SOURCE SYSTEM MONITORING...................................................................................................................................................4654
.18.00.00 EXEMPTIONS TO MONITOR REQUIREMENTS .................................................................................................................................................................4654
.19.00.00 RESERVED ............................................................................................................................................................................................4654
.20.00.00 PARAMETERS AND CONDITIONS FOR CLOSED LOOP OPERATION...................................................................................................................................................4655
...............................................................................................................................................................................................................4658
.21.00.00 PARAMETERS / CONDITIONS FOR 2ND CLOSED LOOP OPERATION.................................................................................................................................................4658
...............................................................................................................................................................................................................4660
.22.00.00 PARAMETERS / CONDITIONS FOR CLOSED LOOP OPERATION ON SULEV............................................................................................................................................4660
02-05B Bosch Motronic ME 9.1 System Strategy........................................................................................................................................................................4668
..............................................................................................................................................................................................................4670
.01.00.00 Catalyst Monitoring .................................................................................................................................................................................4671
...........................................................................................................................................................................................................4671
.01.01.00 Passive measurement of amplitude ratio ...........................................................................................................................................................4671
.01.01.01 General description ..........................................................................................................................................................................4671
...........................................................................................................................................................................................................4671
......................................................................................................................................................................................................4672
.......................................................................................................................................................................................................4672
.01.01.02 Monitoring Structure .........................................................................................................................................................................4672
.......................................................................................................................................................................................................4672
.......................................................................................................................................................................................................4672
.01.01.03 Flow Chart Catalyst Monitoring .............................................................................................................................................................4672
.......................................................................................................................................................................................................4672
..........................................................................................................................................................................................................4673
.01.02.00 Active measurement of OSC ........................................................................................................................................................................4673
.01.02.01 General description ..........................................................................................................................................................................4673
.01.02.02 Monitoring Structure .........................................................................................................................................................................4674
main-catalyst.......................................................................................................................................................................................4675
catalyst-system.................................................................................................................................................................................4675
......................................................................................................................................................................................................4677
.01.02.03 Flow Chart Catalyst Monitoring ..............................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4677
...........................................................................................................................................................................................................4678
.02.00.00 Heated Catalyst Monitoring .......................................................................................................................................................................4678
.03.00.00 Misfire Monitoring ...............................................................................................................................................................................4678
.03.00.01 General Description ..........................................................................................................................................................................4678
..................................................................................................................................................................................................4679
.03.01.02 Monitoring function description ..........................................................................................................................................................4679
......................................................................................................................................................................................................4680
......................................................................................................................................................................................................4681
.03.00.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4682
..........................................................................................................................................................................................................4684
.04.00.00 Evaporative System Diagnosis .....................................................................................................................................................................4684
.04.01.00 Leakage Check ..............................................................................................................................................................................4684
.04.01.01 General description .....................................................................................................................................................................4684
..................................................................................................................................................................................................4685
...................................................................................................................................................................................................4685
.04.01.02 Monitoring function description .......................................................................................................................................................4685
..................................................................................................................................................................................................4686
...................................................................................................................................................................................................4686
.04.01.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4686
......................................................................................................................................................................................................4687
......................................................................................................................................................................................................4687
.04.02.00 Purge Check .................................................................................................................................................................................4688
.04.02.01 General description ......................................................................................................................................................................4688
..................................................................................................................................................................................................4689
.04.02,02 Monitoring function description ..........................................................................................................................................................4689
.04.02.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4689
.05.00.00 Secondary Air System Monitoring ..................................................................................................................................................................4690
.06.00.00 Fuel System Monitoring ...........................................................................................................................................................................4690
.06.01.00 General Description ..........................................................................................................................................................................4690
.06.00.02 Monitoring function description ..........................................................................................................................................................4690
.......................................................................................................................................................................................................4690
......................................................................................................................................................................................................4691
.06.00.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4691
.....................................................................................................................................................................................................4693
.06.04.00 Fuel Pressure Monitoring .........................................................................................................................................................................4694
.06.05.00 General Description ..........................................................................................................................................................................4694
.06.05.00 Monitoring function description ..........................................................................................................................................................4695
......................................................................................................................................................................................................4697
.07.00.00 Oxygen Sensor Monitoring .......................................................................................................................................................................4697
.07.01.00 Calibrations with ASIC CJ 110 ...............................................................................................................................................................4697
.07.01.01 General Description ......................................................................................................................................................................4697
.07.01.02 Monitoring function description ..........................................................................................................................................................4697
.07.01.03 Chart(s) and flow chart(s) ...............................................................................................................................................................4699
.07.02.00 Oxygen Sensor Heater Monitoring ............................................................................................................................................................4704
.07.03.01 General description (ASIC CJ 110) ........................................................................................................................................................4704
.07.02.02 Monitor function description ............................................................................................................................................................4704
..................................................................................................................................................................................................4705
...................................................................................................................................................................................................4705
07.02.03 Chart(s) and Flow Chart(s) ..............................................................................................................................................................4705
...................................................................................................................................................................................................4707
.07.03.01 General Description ......................................................................................................................................................................4707
.07.03.02 Monitor function description .............................................................................................................................................................4707
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
...................................................................................................................................................................................................4708
..................................................................................................................................................................................................4709
...................................................................................................................................................................................................4709
.07.03.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4709
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.......................................................................................................................................................................................................4710
.07.04.00 Oxygen Sensor Heater Monitoring (ASIC CJ 125/120) ...........................................................................................................................................4711
.07.04.01 General description .....................................................................................................................................................................4711
.07.04.02 Monitor function description .............................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
...................................................................................................................................................................................................4711
..................................................................................................................................................................................................4712
.07.04.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4712
.07.05.00 SULEV applications ...........................................................................................................................................................................4713
.07.05.01 General description ......................................................................................................................................................................4713
.07.05.02 Monitor function description .............................................................................................................................................................4713
.07.05.03 Chart(s) and flow chart(s) ...............................................................................................................................................................4715
.07.06.00 Oxygen Sensor Heater Monitoring (SULEV) ....................................................................................................................................................4720
.07.06.01 General description .....................................................................................................................................................................4720
.07.06.02 Monitor function description) ............................................................................................................................................................4720
.................................................................................................................................................................................................4722
...................................................................................................................................................................................................4722
.07.06.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4722
.08.00.00 EGR MONITORING ...................................................................................................................................................................................4724
.09.00.00 PCV Monitoring ...................................................................................................................................................................................4724
..........................................................................................................................................................................................................4725
.10.00.00 Engine Coolant System Monitoring ................................................................................................................................................................4725
.10.01.00 General description ........................................................................................................................................................................4725
..................................................................................................................................................................................................4726
...................................................................................................................................................................................................4726
.10.01.02 Monitor Functional Description ..........................................................................................................................................................4726
...................................................................................................................................................................................................4727
.10.03.00 Charts and Flow Charts ...................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
.......................................................................................................................................................................................................4727
...................................................................................................................................................................................................4728
.......................................................................................................................................................................................................4730
.11.00.00 Cold Start Emission Reduction Strategy Monitoring ..............................................................................................................................................4738
.11.01.00 General Description ..........................................................................................................................................................................4738
.11.02.00 Monitoring function description ..........................................................................................................................................................4739
..................................................................................................................................................................................................4740
...................................................................................................................................................................................................4740
.11.03.00 Charts and flow charts ...................................................................................................................................................................4740
...................................................................................................................................................................................................4740
.12.00.00 Air Conditioning (A/C) System Component Monitoring ..............................................................................................................................................4741
.13.00.00 Variable Valve Timing and/or Control (VVT) System Monitoring ...................................................................................................................................4741
.13.01.00 General Description ..........................................................................................................................................................................4741
.13.02.00 Monitor function description ............................................................................................................................................................4741
...................................................................................................................................................................................................4742
.13.03.00 Charts and flow charts ..................................................................................................................................................................4742
.14.00.00 Direct Ozone Reduction (DOR) System Monitoring ...................................................................................................................................................4743
.15.00.00 Particulate Mater (PM) Trap Monitoring .........................................................................................................................................................4743
.16.00.00 Comprehensive Components Monitoring .............................................................................................................................................................4743
.16.01.00 Injection Valve ..............................................................................................................................................................................4743
.16.02.00 Fuel Pump Relay .............................................................................................................................................................................4743
.16.03.00 Idle Controller ............................................................................................................................................................................4744
.16.04.00 Engine Speed Sensor: .........................................................................................................................................................................4745
.16.05.00 Warm-up Bypass valve: ........................................................................................................................................................................4746
.16.06.00 Signal Range Check for different sensor ....................................................................................................................................................4746
.......................................................................................................................................................................................................4746
.......................................................................................................................................................................................................4746
.......................................................................................................................................................................................................4746
......................................................................................................................................................................................................4747
.16.07.00 Rationality Mass Air Flow Sensor (MAF) ......................................................................................................................................................4747
......................................................................................................................................................................................................4749
.16.08.00 Vehicle Speed Sensor (VSS) ...................................................................................................................................................................4749
......................................................................................................................................................................................................4750
.16.09.00 Throttle Position Sensor (throttle unit with E-gas actuator) ................................................................................................................................4750
.16.10.00 Accelerator pedal position sensor (APPS) .....................................................................................................................................................4751
.16.11.00 Camshaft Position Sensor .....................................................................................................................................................................4752
.......................................................................................................................................................................................................4752
.......................................................................................................................................................................................................4752
.......................................................................................................................................................................................................4752
.......................................................................................................................................................................................................4752
......................................................................................................................................................................................................4753
.16.12.00 Boost Pressure Control Valve ................................................................................................................................................................4753
......................................................................................................................................................................................................4754
.16.13.00 Engine Start Delay Relay (SULEV) .............................................................................................................................................................4754
......................................................................................................................................................................................................4755
.16.14.00 Exhaust Temperature Sensor (SULEV) ..........................................................................................................................................................4755
.16.14.01 General Monitoring Description ..........................................................................................................................................................4755
.16.14.02 Monitor function description .............................................................................................................................................................4755
......................................................................................................................................................................................................4755
...................................................................................................................................................................................................4756
.16.14.03 Chart(s) and Flow Chart (s) ..............................................................................................................................................................4756
.16.15.00 reserved ....................................................................................................................................................................................4757
.16.16.00 reserved ....................................................................................................................................................................................4757
.16.17.00 reserved ....................................................................................................................................................................................4757
.16.18.00 reserved ....................................................................................................................................................................................4757
.16.19.00 reserved ....................................................................................................................................................................................4757
......................................................................................................................................................................................................4758
.......................................................................................................................................................................................................4758
.16.20.00 Automatic Transmission Monitor ...............................................................................................................................................................4758
.16.21.00 Output Stage Check ..........................................................................................................................................................................4758
.17.00.00 Other Emission Control or Source System Monitoring ..............................................................................................................................................4759
.17.01.00 Intake manifold runner flap monitoring ..........................................................................................................................................................4759
...........................................................................................................................................................................................................4759
.17.01.01 General Description ..........................................................................................................................................................................4759
.17.01.02 Monitoring function description ..........................................................................................................................................................4759
.17.01.03 Charts and flow charts ...................................................................................................................................................................4760
..................................................................................................................................................................................................4762
.18.00.00 Exemptions to Monitor Requirements ...........................................................................................................................................................4762
.19.00.00 reserved .......................................................................................................................................................................................4762
.20.00.00 Parameters and conditions for closed loop operation ..............................................................................................................................................4762
..........................................................................................................................................................................................................4765
...........................................................................................................................................................................................................4765
.21.00.00 Parameters / conditions for 2nd closed loop operation ..........................................................................................................................................4765
..........................................................................................................................................................................................................4767
.22.00.00 Parameters / conditions for closed loop operation on SULEV .......................................................................................................................................4767
02-06A 2004-2006 VW ECM Calibrations IDs............................................................................................................................................................................4775
02-06B 2005-2010 VW diesel ECM Calibration IDs and CVNs.............................................................................................................................................................4777
VW Q3-09 Diesel.................................................................................................................................................................................................4777
02-06C 2005-2010 VW Gas ECM Calibration IDs and CVNS................................................................................................................................................................4778
VW Q3-09 Gasoline...............................................................................................................................................................................................4778
02-06D VW ECM Part Numbers..........................................................................................................................................................................................4786
03-Manual Transmission.pdf (p.4842-5444)................................................................................................................................................................................4842
03-01 Manual Transmission 1998......................................................................................................................................................................................4842
03-02 Manual Transmission 1999......................................................................................................................................................................................4988
03-03 Manual Transmission BJS.......................................................................................................................................................................................5152
04-Automatic Transmission.pdf (p.5445-6065).............................................................................................................................................................................5445
04-01 Automatic Transmission 1998-99................................................................................................................................................................................5445
04-02 Automatic Transmission 1999-2001..............................................................................................................................................................................5697
04-03 Automatic Transmission 2000-01................................................................................................................................................................................5812
04-04 Automatic Transmission OBD R32-1..............................................................................................................................................................................5933
04-05 Automatic Transmission OBD R32-2..............................................................................................................................................................................6005
05-Steering & Suspension.pdf (p.6066-7145)..............................................................................................................................................................................6066
05-01 Suspension, Wheels & Steering.................................................................................................................................................................................6066
05-02 Wheel and Tire Guide..........................................................................................................................................................................................6341
06-Brakes Systems.pdf (p.7146-7423).....................................................................................................................................................................................7146
06-01 Brake System..................................................................................................................................................................................................7146
06-02 Brake System OBD..............................................................................................................................................................................................7290
07-HVAC Systems.pdf (p.7424-7777).......................................................................................................................................................................................7424
07-01 HVAC..........................................................................................................................................................................................................7424
07-02 HVAC Refrigerant R134a Servicing..............................................................................................................................................................................7567
08-Body.pdf (p.7778-8599)...............................................................................................................................................................................................7778
08-01 Body Repair...................................................................................................................................................................................................7778
08-02 Body Repair-Body Collision Repair.............................................................................................................................................................................7959
08-03 Body Interior.................................................................................................................................................................................................8030
08-04 Body Exterior.................................................................................................................................................................................................8316
09-Electrical Equipment.pdf (p.8600-9384)...............................................................................................................................................................................8600
09-01 Electrical Equipment General Information......................................................................................................................................................................8600
09-02 Electrical Equipment..........................................................................................................................................................................................8745
09-03 Electrical Equipment OBD......................................................................................................................................................................................9020
09-04 Body OBD-SRS & Central Locking................................................................................................................................................................................9097
09-05 Communication-Radio & Controls................................................................................................................................................................................9269
10-Electrical Wiring Diagrams.pdf (p.9385-9578).........................................................................................................................................................................9385
006-Automatic transmission, 4 speed automatic.......................................................................................................................................................................9385
Automatic transmission, 4 speed automatic, from September 1998..................................................................................................................................................9385
Park/neutral position (PNP) relay...........................................................................................................................................................................9386
Transmission control module (TCM), multi-function transmission range (TR) switch............................................................................................................................9387
Transmission control module (TCM), solenoid valves, transmission vehicle speed sensor (VSS), kick down switch...............................................................................................9388
Transmission control module (TCM), vehicle speed sensor (VSS)...............................................................................................................................................9389
Transmission control module (TCM), shift lock solenoid......................................................................................................................................................9390
011-Coolant Fan-single speed........................................................................................................................................................................................9391
Coolant Fan (single speed), from September 1998.................................................................................................................................................................9391
Coolant fan, coolant fan control (FC) thermal switch........................................................................................................................................................9392
038-Air conditioning (manual control)...............................................................................................................................................................................9393
Air conditioning (manual control), from May 1999................................................................................................................................................................9393
Fresh air blower switch, fresh air/recirculating flap switch, fresh air blower, servo motor for fresh-/recirculating air flap...............................................................................9394
Coolant fan control (FC) control module, A/C switch, ambient temperature switch.............................................................................................................................9395
Coolant fan control (FC) control module, A/C clutch, coolant fan, after-run coolant pump....................................................................................................................9396
Coolant fan control (FC) control module, coolant fan control (FC) thermal switch, high pressure sensor......................................................................................................9397
041-1.8L Engine-Motronic Multiport Fuel Injection (MFI) 110kW code AWD..............................................................................................................................................9398
1.8L - Engine - Motronic Multiport Fuel Injection (MFI)/110 kW, code AWD, from November 1999....................................................................................................................9398
Generator (GEN), starter....................................................................................................................................................................................9399
Motronic engine control module (ECM), power supply relay....................................................................................................................................................9400
Motronic engine control module (ECM), ignition system.......................................................................................................................................................9401
Motronic engine control module (ECM)........................................................................................................................................................................9402
Motronic engine control module (ECM), (ECT) sensor, charge air pressure sensor, camshaft position (CMP) sensor 2, wastegate bypass regulator valve, recirculating valve for turbocharger...................9403
Motronic engine control module (ECM), angle sensor for throttle drive (power accelerator actuation), intake air temperature (IAT) sensor, knock sensor (KS) 1, leak detection pump (LDP)....................9404
Motronic engine control module (ECM), pressure switch, power steering, engine speed (RPM) sensor, knock sensor (KS) 2.......................................................................................9405
Motronic engine control module (ECM), heated oxygen sensor (H02S), injectors................................................................................................................................9406
Motronic engine control module (ECM), throttle position (TP) sensor, oxygen sensor (O2S) behind three way catalytic converter (TWC), evaporative emission (EVAP) canister purge.............................9407
Motronic engine control module (ECM), fuel pump (FP) relay, cruise control switch, mass air flow (MAF) sensor...............................................................................................9408
Motronic engine control module (ECM), secondary air injection (AIR) pump system, break light switch, clutch vacuum vent valve switch, brake vacuum vent valve switch........................................9409
Fuel pump (FP), fuel level sensor, engine coolant level (ECL) sensor........................................................................................................................................9410
Instrument cluster, oil pressure switch, speedometer vehicle speed sensor, oil pressure warning light.......................................................................................................9411
Instrument cluster, multi-function indicator (MFI), fuel gauge, tachometer, speedometer, generator (GEN) warning light......................................................................................9412
Instrument cluster, multi-function indicator (MFI), outside air temperature sensor, electronic power control (EPC) warning lamp.............................................................................9413
052-Standard Equipment-Golf, Jetta..................................................................................................................................................................................9414
52 - Golf/Jetta - Standard Equipment, from January 2001.........................................................................................................................................................9414
Battery, ignition/starter switch............................................................................................................................................................................9415
Instrument cluster, clutch pedal position (CPP) switch, starting interlock relay............................................................................................................................9416
Instrument cluster, tachometer, speedometer, odometer display, anti-theft immobilizer, warning light for anti-theft immobilizer sensor......................................................................9417
Instrument cluster, generator (GEN) warning light, low fuel level warning light, warning light for rear lid unlocked/door ajar indicator lamp...............................................................9418
Instrument cluster, left front brake padwear sensor, brake padwear indicator light,headlight highbeam indicator light, digital clock........................................................................9419
Instrument cluster, parking brake warning light switch, brake fluid level warning switch, low windshield washer fluid level indication, left and right turn signal indicator lights.........................9420
Turn signal switch, headlight dimmer/flasher switch, left front turn signal light, light for side marker front left, left headlight.........................................................................9421
Emergency flasher switch, turn signal relay, right front turn signal light, light for side marker front right, right headlight..............................................................................9422
Left rear turn signal light, left back-up light, left brake/tail light, high-mount brake light (Golf only)..................................................................................................9423
Back-up light switch, brake light switch, right rear turn signal light, right back-up light, right brake/tail light.........................................................................................9424
Data Link Connector (DLC)...................................................................................................................................................................................9425
Radio connection, cigarette lighter, instrument panel vent illumination.....................................................................................................................................9426
Light switch................................................................................................................................................................................................9427
License plate light, glove compartment light................................................................................................................................................................9428
Dual tone horn, fuel tank door remote.......................................................................................................................................................................9429
Instrument panel light dimmer switch, rearwindow defogger switch, heated rear window........................................................................................................................9430
Fresh air blower switch, fresh air/recirculating flap switch, fresh air blower..............................................................................................................................9431
Motor for rear windshield wiper, windshield and rear window washer pump.....................................................................................................................................9432
Windshield wiper/washer switch, windshield wiper intermittent regulator, windshield wiper motor, wiper/washer intermittent relay............................................................................9433
056-Comfort system-Jetta Wagon with power windows...................................................................................................................................................................9434
Comfort system (vehicles with power windows), from May 2001.....................................................................................................................................................9434
Door control module (driver side), switch for window regulator, safety switch for window regulator rear, switch for interior lock (driver side).............................................................9435
Door control module (driver side), lock unit for central locking (driver side), warning light for central locking -SAFE-, left door warning light...........................................................9436
Door control module (driver side), mirror adjustment switch, mirror selector switch, switch for outside mirror heating......................................................................................9437
Door control module (driver side), switch for remote/fuel tank door, motor for fuel tank lid unlock, power mirror (driver side), heated outside mirror (driver side)........................................9438
Switch for remote unlock rear lid (driver side), key switch for switching off remote unlock rear lid........................................................................................................9439
Door control module (passenger side), switch for window regulator (passenger side), lock unit for central locking (passenger side)..........................................................................9440
Door control module (passenger side), switch for interior lock (passenger side), right door warning light, power mirror (passenger side), heated outside mirror............................................9441
Door control module (rear left), left rear window switch (in LR door), lock unit for central locking (rear left), motor for window regulator (rear left)....................................................9442
Door control module (rear right), right rear window switch (in RR door), lock unit for central locking (rear right), motor for window regulator (rear right)................................................9443
Interior lights, make-up mirror lights......................................................................................................................................................................9444
Central control module for comfort system...................................................................................................................................................................9445
Central control module for comfort system, switch for unlocking (rear lid handle), motor to unlock rear lid.................................................................................................9446
Central control module for comfort system, trunk lid release switch, luggage compartment light..............................................................................................................9447
Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9448
Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9449
Central control module for comfort system...................................................................................................................................................................9450
057-Comfort system-Golf, Jetta without power windows................................................................................................................................................................9451
Comfort system (vehicles without power windows), from May 2001..................................................................................................................................................9451
Switch for remote/fuel tank door, motor for fuel tank lid unlock............................................................................................................................................9452
Central control module for comfort system, switch for interior lock (driver side), switch for remote unlock rear lid........................................................................................9453
Central control module for comfort system, lock unit for central locking, warning light for central locking -SAFE-..........................................................................................9454
Central control module for comfort system, switch for interior lock (passenger side), left door warning light, heated outside mirrors.......................................................................9455
Central control module for comfort system, locking unit for central locking (passenger side), right door warning light......................................................................................9456
Central control module for comfort system, lock unit for central locking (rear left)........................................................................................................................9457
Central control module for comfort system, lock unit for central locking (rear right), trunk lock alarm/central locking switch, decklid central locking system motor........................................9458
Central control module for comfort system, trunk lid release switch, luggage compartment light switch.......................................................................................................9459
Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9460
Central control module for comfort system, interior lights, make-up mirror lights...........................................................................................................................9461
Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9462
Central control module for comfort system...................................................................................................................................................................9463
058-Comfort system-Golf, Jetta with power windows...................................................................................................................................................................9464
Comfort system (vehicles with power windows), from May 2001.....................................................................................................................................................9464
Door control module (driver side), switch for window regulator, safety switch for window regulator rear, switch for interior lock (driver side).............................................................9465
Door control module (driver side), lock unit for central locking (driver side), warning light for central locking -SAFE-, left door warning light...........................................................9466
Door control module (driver side), mirror adjustment switch, mirror selector switch, switch for outside mirror heating......................................................................................9467
Door control module (driver side), switch for remote/fuel tank door, motor for fuel tank lid unlock, power mirror (driver side), heated outside mirror (driver side)........................................9468
Switch for remote unlock rear lid (driver side), key switch for switching off remote unlock rear lid........................................................................................................9469
Door control module (passenger side), switch for window regulator (passenger side), lock unit for central locking (passenger side)..........................................................................9470
Door control module (passenger side), switch for interior lock (passenger side), right door warning light, power mirror (passenger side), heated outside mirror............................................9471
Door control module (rear left), left rear window switch (in LR door), lock unit for central locking (rear left), motor for window regulator (rear left)....................................................9472
Door control module (rear right), right rear window switch (in RR door), lock unit for central locking (rear right), motor for window regulator (rear right)................................................9473
Interior lights, make-up mirror lights......................................................................................................................................................................9474
Central control module for comfort system...................................................................................................................................................................9475
Central control module for comfort system, switch for unlocking (rear lid handle), motor to unlock rear lid.................................................................................................9476
Central control module for comfort system, trunk lid release switch, luggage compartment light switch.......................................................................................................9477
Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9478
Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9479
Central control module for comfort system...................................................................................................................................................................9480
059-Headlight washer................................................................................................................................................................................................9481
Headlight washer, from May 2000.................................................................................................................................................................................9481
Wiper/washer intermittent relay, windshield wiper internmittent regulator, windshield washer fluid level sensor, headlight washer pump, instrument cluster..................................................9482
Wiper/washer intermittent relay, windshield wiper/washer switch, windshield wiper motor, windshield and rear window washer pump.............................................................................9483
060-Fog lights......................................................................................................................................................................................................9484
Fog lights, from May 2000.......................................................................................................................................................................................9484
Left headlight light, light for side marker front left, fog light relay, left front fog light, left parking light...........................................................................................9485
Right headlight light, light for side marker front right, fog light relay, right front fog light, right parking light.......................................................................................9486
Light switch, fog light switch..............................................................................................................................................................................9487
Instrument cluster, headlight high beam indicator light, turn signal indicator lights.......................................................................................................................9488
061-Daytime running lights..........................................................................................................................................................................................9489
Daytime running lights, from May 2000...........................................................................................................................................................................9489
Instrument cluster, left and right turn signal indicator lights, parking brake indicator light, warning light for brake system, headlight high beam indicator light.........................................9490
Turn signal switch, headlight dimmer/flasher switch, left front turn signal light, light for side marker front left, left headlight.........................................................................9491
Daytime running lights change-over relay, parking brake warning light switch, right front turn signal light, light for side marker front right, right headlight.............................................9492
Light switch................................................................................................................................................................................................9493
Left rear turn signal light, left back-up light, left brake/tail light, high-mount brake light (Jetta Wagon/Golf)...........................................................................................9494
Right rear turn signal light, right back-up light, right brake/tail light, high-mount brake light (Jetta Sedan).............................................................................................9495
068-Heated seats....................................................................................................................................................................................................9496
Heated seats, from May 1999.....................................................................................................................................................................................9496
Driver's heated seat control module, driver's heated seat temperature sensor, driver's seat heating element, driver's backrest heating element..............................................................9497
Passenger's heated seat control module, passenger's heated seat temperature sensor, passenger's seat heating element, passenger's backrest heating element..................................................9498
074-CAN-Bus, Powertrain and Comfort System..........................................................................................................................................................................9499
74 - CAN-Bus, Powertrain and Comfort System, from May 2001......................................................................................................................................................9499
CAN connection for: door control module (driver side, passenger side), door control module (rear, left and rear, right), central control module for comfort system..........................................9500
CAN connection for: telematic control module, control module for multi-function steering wheel, radio.......................................................................................................9501
instrument cluster, Data Link Connector (DLC)...............................................................................................................................................................9502
instrument cluster, data bus on board diagnostic interface, CAN connection for: airbag control module, ABS control module (w/EDL)...........................................................................9503
CAN connection for: transmission control module (TCM), motronic engine control module (ECM), diesel direct fuel injection (DFI) engine control module (ECM), all-wheel drive control module.................9504
077-Heated power mirrors (Canada)...................................................................................................................................................................................9505
77 - Heated power mirrors (Canada), from May 2002...............................................................................................................................................................9505
Mirror adjustment switch, mirror selector switch, switch for outside mirror heating, motor for mirror adjustment (driver side), heated outside mirror (driver side).........................................9506
Heated mirror relay, motor for mirror adjustment (passenger side), heated outside mirror (passenger side)...................................................................................................9507
078-1.8L Engine - Motronic MFI code AWW, 1.8L code AWP..............................................................................................................................................................9508
78 - 1.8L - Engine - Motronic Multiport Fuel Injection (MFI)/132 kW, code AWP, from May 2002....................................................................................................................9508
Generator (GEN), starter....................................................................................................................................................................................9509
Power supply relay..........................................................................................................................................................................................9510
Motronic engine control module (ECM), ignition
system.......................................................................................................................................................9511
Motronic engine control module (ECM)........................................................................................................................................................................9512
Charge air pressure sensor, camshaft position (CMP) sensor,wastegate bypass regulator valve, recirculating valve for turbocharger, valve for camshaft adjustment............................................9513
Motronic engine control module (ECM), angle sensor for throttle drive (power accelerator actuation), intake air temperature (IAT) sensor, (ECT) sensor, leak detection pump (LDP)...........................9514
Motronic engine control module (ECM), engine speed (RPM) sensor, knock sensor (KS) 1, knock sensor (KS) 2...................................................................................................9515
Motronic engine control module (ECM), pressure switch/power steering, injectors.............................................................................................................................9516
Motronic engine control module (ECM), heated oxygen sensor (HO2S), oxygen sensor (O2S) behind three way catalytic converter (TWC), (EVAP) canister purge regulator valve....................................9517
Motronic engine control module (ECM), brake booster control module, brake system vacuum pump................................................................................................................9518
Motronic engine control module (ECM), secondary air injection (AIR) pump system, brake light switch, brake pedal switch.....................................................................................9519
Motronic engine control module (ECM), cruise control switch, mass air flow (MAF) sensor, clutch vacuum vent valve switch....................................................................................9520
Motronic engine control module (ECM), throttle position (TP) sensor, fuel pump (FP) relay...................................................................................................................9521
Fuel pump (FP), fuel level sensor, engine coolant level (ECL) sensor........................................................................................................................................9522
Instrument cluster, oil pressure switch, speedometer vehicle speed sensor (VSS),oil pressurewarning light...................................................................................................9523
Instrument cluster, engine coolant temperature (ECL/ECT) gauge, fuel gauge, tachometer, speedometer, generator (GEN) warning light, low fuel level warning light............................................9524
Instrument cluster, multi-function indicator (MFI), outside air temperature sensor, electronic power control (EPC)warning lamp, cruise control indicator light, malfunction indicator lamp..................9525
082-1.9L Turbo Diesel PD Fuel Injection (DFI) 74 kW, code BEW.......................................................................................................................................................9526
82 - 1.9L - Engine - Turbo Diesel PD Fuel Injection (DFI)/74 kW, code BEW, (with automatic transmission),.......................................................................................................9526
Generator (GEN), starter....................................................................................................................................................................................9527
Glow plug activation control module, engine glow............................................................................................................................................................9528
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9529
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9530
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9531
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9532
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9533
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9534
Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9535
Diesel direct fuel injection (DFI) engine control module ...................................................................................................................................................9536
Diesel direct fuel injection (DFI) engine controlmodule.....................................................................................................................................................9537
Fuel pump (FP) relay, fuel pump (FP), Fuel level Sensor.....................................................................................................................................................9538
Instrument cluster, oil pressure switch, speedometer........................................................................................................................................................9539
Instrument cluster, engine coolant temperature..............................................................................................................................................................9540
Instrument cluster, multi-function indicator (MFI),.........................................................................................................................................................9541
085-Telematics......................................................................................................................................................................................................9542
85 - Telematics, from May 2003..................................................................................................................................................................................9542
Telematic Control Module, Dual tone horn, Dual horn auxiliary relay.........................................................................................................................................9543
Telematic Control Module, warning lamp auxiliary relay, auxiliary emergency flasher relay...................................................................................................................9544
Telematic Control Module, Emergency Flasher Switch..........................................................................................................................................................9545
Telematic Control Module, Lock unit for central locking (driver side).......................................................................................................................................9546
Telematic Control Module, Telematic Control Head, Roadside Assistance Button, Emergency Call Button, End Conversation Button (Telematic USA), Telematics Indicator Lamp.....................................9547
Telematic Control Module, Antenna, Antenna for Navigation System (GPS), Telephone Microphone................................................................................................................9548
092-Heated rear window with timer...................................................................................................................................................................................9549
Heated rear window with timer, from May 1999 Additional Fuse, Relay, Control Module and Connector locations -> Compontent Locations Troubleshooting Procedures -> Guided Fault Finding using VAS 5051/5052
....9549
Relay location on thirteen position auxiliary relay panel, above
relay panel:...............................................................................................................................9549
Fuse 26 in fuse holder......................................................................................................................................................................................9550
Rear windowdefogger switch, heated rear window..............................................................................................................................................................9551
501-Threaded connection -2- (30) on the relay plate.................................................................................................................................................................9552
C-Generator (GEN)...................................................................................................................................................................................................9553
F220-Lock unit for central locking driver side......................................................................................................................................................................9554
G2-Engine Coolant Temperature (ECT) sensor (1.9L TDI)...............................................................................................................................................................9555
G17-Outside Air Temperature Sensor (vehicles without Multi-Function Indicator MFI)..................................................................................................................................9556
G22-Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission).............................................................................................................................................9557
G39-Heated Oxygen Sensor (HO2S) (3.2L engine).......................................................................................................................................................................9558
G62-Engine Coolant Temperature (ECT) sensor (1.8L engine)...........................................................................................................................................................9559
G68-Vehicle Speed Sensor (VSS)......................................................................................................................................................................................9560
G130-Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC)_(1.8L engine)...................................................................................................................................9561
G163-Camshaft Position (CMP) sensor 2...............................................................................................................................................................................9562
N112-Secondary Air Injection (AIR) solenoid valve (2.0L engine).....................................................................................................................................................9563
N112-Secondary Air Injection (AIR) solenoid valve (2.8L VR6)........................................................................................................................................................9564
N205-Valve 1 for camshaft adjustment................................................................................................................................................................................9565
N292-Ignition Coil 4 with Power Output Stage........................................................................................................................................................................9566
R12-Amplifier Sedan only............................................................................................................................................................................................9567
S164-Fuse 3 (30) in fuse bracket battery............................................................................................................................................................................9568
T3b-3 pin connector (1.8L engine)...................................................................................................................................................................................9569
T3b-3 pin connector.................................................................................................................................................................................................9570
T4c-4 Pin Connector (3.2L engine)...................................................................................................................................................................................9571
T4e-4-pin connector.................................................................................................................................................................................................9572
T10a-10 pin connector (2.0L engine).................................................................................................................................................................................9573
TA10 A-10-pin connector (2.8L VR6)..................................................................................................................................................................................9574
V51-After-run coolant pump..........................................................................................................................................................................................9575
V60-Throttle Position (TP) actuator.................................................................................................................................................................................9576
V139-Motor for remote unlock rear lid...............................................................................................................................................................................9577
V148-Motor for window regulator passenger side......................................................................................................................................................................9578
1997-2004 Volkswagen Golf MK4 Service Manual IMAGES PREVIEW OF THE MANUAL:
1997-2004 Volkswagen Golf MK4 Service Manual1997-2004 Volkswagen Golf MK4 Service Manual
PLEASE NOTE:
This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
