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1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
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1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
Volkswagen
Jetta, Golf, GTI
1999, 2000, 2001, 2002, 2003, 2004, 2005
1.8L turbo, 1.9L TDI and PD diese!
2.0L gasoline, 2.8L VR6
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Description
1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
SAMPLE PAGES FROM THE MANUAL:
1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
Volkswagen
Jetta, Golf, GTI
1999, 2000, 2001, 2002, 2003, 2004, 2005
1.8L turbo, 1.9L TDI and PD diese!
2.0L gasoline, 2.8L VR6
Engine number :
The engine number (engine code and serial number) are located next to the vibration damper on the cylinder block. The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters) makes up the engine code and the second part (6 characters), the serial number. If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter. Additionally there is a sticker on the intake manifold with the engine code and serial number. The engine code is additionally included on the vehicle data plate.
TABLE OF CONTENTS:
1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
Capa..................................................................................................................... 1
2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF.................................................................. 3
Technical data....................................................................................................... 4
Engine, removing and installing...................................................................................... 7
Engine, disassembling and assembling................................................................................. 29
Sealing flanges and dualmass flywheel, removing and installing....................................................... 60
Crankshaft, removing and installing.................................................................................. 74
Piston and connecting rod, disassembling and assembling.............................................................. 83
Cylinder head, servicing............................................................................................. 96
Valve gear, servicing................................................................................................ 154
Lubrication system components, servicing............................................................................. 203
Cooling system components, servicing................................................................................. 227
Components of fuel supply system, servicing.......................................................................... 270
Evaporative Emissions................................................................................................ 312
Electronic Power Control (EPC)....................................................................................... 341
Exhaust system components, servicing................................................................................. 354
Secondary air system................................................................................................. 379
2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF.......................................................... 414
On Board Diagnostic (OBD)............................................................................................ 417
DTC memory........................................................................................................... 439
DTC table: SAE P0 codes.............................................................................................. 446
DTC table: SAE P1 codes.............................................................................................. 475
DTC table: SAE P2 codes.............................................................................................. 516
DTC table: SAE P3 codes.............................................................................................. 517
Output Diagnosis Test Mode (DTM)..................................................................................... 518
Readiness code....................................................................................................... 563
Readiness code....................................................................................................... 600
Measured value (data) blocks......................................................................................... 637
Fuel injection system, servicing..................................................................................... 723
Components, checking................................................................................................. 781
Functions, checking.................................................................................................. 868
Motronic Engine Control Module (ECM) -J220-.......................................................................... 905
Additional signals, checking......................................................................................... 931
Ignition system, servicing........................................................................................... 971
5 & 6 Spd. Manual Transmission 02M.......................................................................................1022
Transmission identification..........................................................................................1024
Transmission layout..................................................................................................1029
Calculating overall ratio "i"........................................................................................1031
General repair instructions..........................................................................................1032
Clutch mechanism, repairing..........................................................................................1036
Clutch release mechanism, servicing..................................................................................1060
Clutch, servicing....................................................................................................1063
Clutch, servicing....................................................................................................1071
Gear selector mechanism, servicing...................................................................................1079
Transmission, removing and installing................................................................................1110
Transmission gear oil, checking......................................................................................1137
Transmission, disassembling and assembling...........................................................................1139
Transmission housing, servicing......................................................................................1163
Clutch housing, servicing............................................................................................1177
Transmission selector mechanism, disassembling and assembling........................................................1189
Selector forks, disassembling and assembling.........................................................................1195
Input shaft, disassembling and assembling............................................................................1198
Input shaft, adjusting...............................................................................................1213
Output shaft, 1st-4th gear, disassembling and assembling.............................................................1220
Output shaft for 1st-4th gears, adjusting............................................................................1251
Output shaft for 5th, 6th and reverse gear, disassembling and assembling.............................................1259
Output shaft for 5th, 6th and reverse gear, adjusting................................................................1285
Oil seals for flanged shafts, replacing..............................................................................1293
Differential, disassembling and assembling...........................................................................1299
Adjustment overview..................................................................................................1320
Differential, adjusting..............................................................................................1322
Brake System On Board Diagnostic (OBD)...................................................................................1330
ABS ITT Mark 20 IE On Board Diagnostic (OBD).........................................................................1332
Electrical/electronic components and locations.......................................................................1340
ABS ITT Mk 20 IE On Board Diagnostic (OBD) program...................................................................1356
ABS, ABS/EDL and ABS/EDL/ASR ITT Mark 20 IE, electrical check........................................................1415
ABS Mark 60 On Board Diagnostic (OBD), vehicles from my 10.00........................................................1448
Electrical/electronic components and installing locations............................................................1458
Diagnostic Trouble Codes (DTCs) displayed by warning lights -K47-, -K118- and -K155-.................................1476
On Board Diagnostic (OBD), performing................................................................................1480
Electrical check of Mark 60..........................................................................................1540
Definitions..........................................................................................................1580
Brake System.............................................................................................................1586
Technical data.......................................................................................................1589
Technical data, brakes...............................................................................................1595
Anti-lock brake system (ABS) and antilock brake system with electronic differential lock (ABS/EDL) ITT Mark 20 IE....1602
Hydraulic unit, brake booster/master cylinder, overview..............................................................1606
ABS system components for front axle, removing and installing........................................................1622
Anti-lock brake system (ABS) Mark 60.................................................................................1639
VAS 5051 Vehicle Diagnostic, Testing and Information System, connecting and electing functions......................1645
Electrical/electronic components and installing locations (ABS) Mark 6...............................................1648
Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview.......................................1657
DTCs displayed by (ABS) Mark 60 warning lights -K32-, -K47-, -K118-, and -K155-......................................1676
ABS system components for front and rear axles, removing and installing..............................................1682
ESP system components, removing and installing.......................................................................1718
Front brakes.........................................................................................................1735
Rear wheel brakes (disc brakes - front wheel drive), assembly overview...............................................1788
Rear wheel brakes/disc brakes (allwheel drive), servicing............................................................1807
Parking brake cables for disc brakes - front wheel drive, removing and installing....................................1823
Parking brake cables for disc brakes - all wheel drive, removing and installing......................................1827
Parking brake lever, assembly overview...............................................................................1831
Brake pedal assembly overview........................................................................................1834
Front brake calipers, servicing......................................................................................1846
FN 3 front brake calipers, servicing.................................................................................1852
Rear brake caliper, servicing........................................................................................1868
Brake pressure regulator, assembly overview..........................................................................1879
Brake system, bleeding...............................................................................................1884
Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 10.00.........1894
Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP Mark 60 from m.y. 10.00, assembly overview.....1903
Brake master cylinder, removing and installing.......................................................................1936
Brake booster, removing and installing...............................................................................1939
Definitions..........................................................................................................1942
Suspension, Wheels, Steering.............................................................................................1944
Technical data.......................................................................................................1948
Check list for evaluating the suspension of accident vehicles........................................................1949
Evaluation of accident vehicles......................................................................................1952
Electrical/electronic components and installation locations..........................................................1953
Front suspension, servicing..........................................................................................1964
Front suspension R32, servicing......................................................................................2015
Front drive axle, servicing..........................................................................................2058
Evaluation of accident vehicles......................................................................................2119
Rear axle, servicing.................................................................................................2120
Wheel bearing, servicing.............................................................................................2152
Rear axle, servicing (all wheel drive vehicles)......................................................................2164
Trailing arm and transverse links (allwheel drive vehicles), assembly overview.......................................2192
Subframe with final drive, assembly overview.........................................................................2236
Rear drive axle, servicing...........................................................................................2251
Evaluation of accident vehicles......................................................................................2264
Tightening torques for wheel bolts...................................................................................2265
Protecting wheel centering seat against corrosion....................................................................2266
Wheels, tires........................................................................................................2267
Wheel alignment......................................................................................................2270
Wheels, tires........................................................................................................2284
Evaluation of accident vehicles......................................................................................2285
Connecting VAS 5051 and selecting functions..........................................................................2286
Airbag...............................................................................................................2289
Steering column......................................................................................................2290
Power steering, servicing............................................................................................2310
Power steering pump, reservoir and hydraulic lines...................................................................2329
Definitions..........................................................................................................2362
Body Collision Repair....................................................................................................2364
Technical data.......................................................................................................2367
Body foam insulation.................................................................................................2372
Reinforced body sheet metal..........................................................................................2374
Laser welding........................................................................................................2375
Galvanized body panels...............................................................................................2376
Body panel gaps/mating lines.........................................................................................2377
Body dimensions......................................................................................................2383
Straightening fixture................................................................................................2406
50 40 55 50 Engine mount bracket, replacing..........................................................................2424
50 52 55 50 Intermediate piece, replacing............................................................................2426
50 53 55 50 fender connecting plate, replacing.......................................................................2428
50 72 55 50 long member for upper wheel house, replacing.............................................................2431
50 74 55 00 Front wheel house, partial replacing.....................................................................2434
50 75 55 50 Front inner fender, replacing............................................................................2436
50 79 55 00 Front long member, replacing.............................................................................2438
50 79 55 02 Front long member, partial replacing.....................................................................2441
50 80 55 00 Long member front section, replacing.....................................................................2444
51 03 55 00 Roof, replacing (Golf)...................................................................................2447
51 03 55 00 Roof, replacing (Jetta)..................................................................................2452
51 03 55 20 Roof, replacing (Jetta wagon)............................................................................2456
51 07 55 50 Front roof cross member, replacing.......................................................................2464
51 08 55 50 Roof reinforcement, replacing............................................................................2466
51 09 55 50 Rear roof cross member, replacing (Golf).................................................................2468
51 09 55 50 Rear cross member, replacing (Jetta).....................................................................2470
51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)...........................................................2472
51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)...........................................................2474
51 37 55 00 Apillar, inner, replacing................................................................................2476
51 38 55 50 Apillar, inner, replacing................................................................................2480
51 41 55 62 B-pillar, replacing (4 door), 51 41 55 52 B-pillar, replacing (Jetta)....................................2485
51 42 55 50 Inner B-pillar, replacing (2-door).......................................................................2489
51 42 55 60 Inner B-pillar, replacing (4-door), 51 42 55 50 inner B-pillar, replacing (Jetta)........................2493
51 45 55 00 Outer side member, replacing (2-door)....................................................................2500
51 45 55 10 Outer side member, replacing (4-door), 51 45 55 00 outer side member, replacing (Jetta)..................2503
51 49 55 50 Side member reinforcement, replacing.....................................................................2506
51 73 55 50 Floor plate, partial replacement.........................................................................2510
53 05 55 50 Rear cross panel, replacing..............................................................................2514
53 05 55 20 Rear cross panel, exterior, replacing (Jetta wagon)......................................................2515
53 05 55 23 Rear cross panel, complete, replacing (Jetta wagon)......................................................2520
53 10 55 50 Tail light mount, replacing (Golf).......................................................................2536
53 05 55 50 Rear center cross panel carrier, replacing (Jetta).......................................................2541
53 05 55 50 Rear cross panel, replacing (Jetta)......................................................................2545
53 16 55 00 End cross panel, replacing (Golf)........................................................................2548
53 16 55 00 Outer wheel house, replacing (Jetta).....................................................................2550
53 29 55 70 Reinforcement for C-pillar, replacing (Jetta wagon)......................................................2552
53 48 55 50 Rear long member, replacing (Jetta)......................................................................2554
53 47 55 52 Long member, partial replacement (Jetta).................................................................2556
53 55 55 10 Quarter panel, partial replacement (Golf 4-door).........................................................2558
53 55 55 00 Quarter panel, partial replacement (Jetta)...............................................................2563
53 55 55 20 Side panel, partial replacement (Jetta wagon)............................................................2569
53 69 55 50 Quarter panel, partial replacement (Golf)...............................................................2577
53 69 55 50 Wheel house connecting panel, partial replacement (Jetta)................................................2579
53 36 55 50 Connecting panel, replacing (Jetta)......................................................................2581
53 69 55 70 Rear wheelhousing, outer, replacing - partial section- (Jetta wagon).....................................2583
53 80 55 50 Spare wheel well, replacing (Golf).......................................................................2587
53 80 55 52 Spare wheel well, partial replacement (Golf).............................................................2589
53 80 55 50 Spare wheel well, replacing (Jetta)......................................................................2591
Body Exterior............................................................................................................2595
Body, front..........................................................................................................2600
Hood.................................................................................................................2609
Rear lid (Golf)......................................................................................................2618
Rear lid (Jetta).....................................................................................................2630
Rear lid, (Jetta Wagon)..............................................................................................2641
Tank flap unit.......................................................................................................2651
Front door...........................................................................................................2655
Central locking system...............................................................................................2683
Rear doors...........................................................................................................2700
Sunroof..............................................................................................................2723
Sunroof with glass panel (Webasto)...................................................................................2727
Sunroof with glass panel (Meritor)...................................................................................2749
Front bumper.........................................................................................................2770
Rear bumper..........................................................................................................2782
Flush-bonded windows.................................................................................................2796
Door windows.........................................................................................................2832
Wheelhousing liner, removing and installing..........................................................................2870
Outside rear view mirror.............................................................................................2873
Roof moldings........................................................................................................2878
Roof rail............................................................................................................2880
Trim.................................................................................................................2883
Protective side moldings.............................................................................................2886
Rear spoiler with integrated stoplight...............................................................................2888
Special components of Golf "GTI 337 Edition"/Jetta GLI Sport and Golf R32............................................2896
Body Interior............................................................................................................2919
Seatbelts............................................................................................................2925
Seatbelts, inspecting................................................................................................2940
Inspecting child seat anchors after accident (ISOFIX)................................................................2945
Airbag...............................................................................................................2946
Crash sensors........................................................................................................3001
Instrument panel.....................................................................................................3008
Door trim............................................................................................................3023
Pillar and side trim.................................................................................................3036
Luggage compartment trim.............................................................................................3106
Rear lid trim........................................................................................................3131
Headliner............................................................................................................3144
Front seats..........................................................................................................3158
Rear seats...........................................................................................................3185
Front seat cushion and cover.........................................................................................3197
Seat heating elements................................................................................................3211
Rear seat upholstery and cover.......................................................................................3214
Body On Board Diagnostic (OBD)...........................................................................................3219
On Board Diagnostic (OBD)............................................................................................3221
Airbag system, On Board Diagnostic (OBD).............................................................................3225
Convenience system (vehicles with power windows), On Board Diagnostic (OBD)..........................................3310
Central locking system (vehicles without power windows), On Board Diagnostic (OBD)...................................3524
Driver's side seat adjustment, On Board Diagnostic (OBD).............................................................3606
Heating and Air Conditioning.............................................................................................3659
On Board Diagnostic (OBD) through m.y. 2001..........................................................................3661
On Board Diagnostic (OBD) from m.y. 2002.............................................................................3665
Climatronic On Board Diagnostic (OBD) through m.y. 2001..............................................................3666
Heating and ventilation system, servicing............................................................................3718
Manual A/C...........................................................................................................3754
Climatronic..........................................................................................................3788
A/C refrigerant system...............................................................................................3849
A/C refrigerant system, servicing....................................................................................3870
A/C refrigerant system, troubleshooting..............................................................................3921
A/C refrigerant system, capacities...................................................................................3931
Compressor bracket, removing and installing..........................................................................3935
Refrigerant R134a - Servicing............................................................................................3970
General information for A/C system...................................................................................3972
General information on refrigerant circuit...........................................................................3991
Laws and regulations.................................................................................................4012
Refrigerant circuit..................................................................................................4018
Complaints...........................................................................................................4029
Service station, connecting..........................................................................................4031
Pressures, checking on vehicles......................................................................................4032
Components, replacing................................................................................................4065
Testing equipment and tools..........................................................................................4072
Electrical Equipment On Board Diagnostic (OBD)...........................................................................4080
On Board Diagnostic (OBD) through m.y. 2001..........................................................................4082
On Board Diagnostic (OBD) from m.y. 2002.............................................................................4086
Instrument cluster through m.y. 1999, On Board Diagnostic (OBD)......................................................4087
Instrument cluster m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)............................................4150
Data Bus On Board Diagnostic Interface -J533- ("Gateway") m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD).....4225
Anti-theft immobilizer, On Board Diagnostic (OBD)....................................................................4246
Electrical Equipment.....................................................................................................4247
Battery..............................................................................................................4253
Battery, checking....................................................................................................4260
Battery, charging....................................................................................................4288
Battery, disconnecting and reconnecting..............................................................................4293
Battery, removing and installing.....................................................................................4306
Battery, tightening torques..........................................................................................4315
Starter..............................................................................................................4316
Starter, tightening torques..........................................................................................4325
Generator (GEN)......................................................................................................4326
Generator (GEN) through 04.99........................................................................................4327
Generator (GEN) from 05.99...........................................................................................4331
Generator (GEN) -4- cylinder gasoline engines........................................................................4337
Generator (GEN) -6- cylinder gasoline engines........................................................................4348
Generator (GEN) -4- cylinder TDI engines.............................................................................4360
Generator (GEN) -4- cylinder TDI - PD engines........................................................................4377
Generator (GEN), tightening torques..................................................................................4390
Cruise Control System (CCS) through m.y. 2001........................................................................4395
Cruise Control System (CCS) from m.y. 2002...........................................................................4409
Instrument cluster...................................................................................................4410
Windshield wiper system..............................................................................................4430
Windshield wiper system, tightening torques..........................................................................4448
Washer system........................................................................................................4449
Rear window wiper & washer system....................................................................................4459
Rear window wiper system, tightening torques.........................................................................4469
Washer hoses, repairing..............................................................................................4470
Headlights - Golf....................................................................................................4474
Headlights - Jetta...................................................................................................4494
Side mounted turn signals............................................................................................4511
Rear lights..........................................................................................................4513
Rear lights, tightening torques......................................................................................4524
License plate lights.................................................................................................4525
High-mount brake light...............................................................................................4526
Steering column switches.............................................................................................4532
Ignition/starter switch and lock cylinder............................................................................4540
Interior lights and switches.........................................................................................4547
Anti-theft Immobilizer...............................................................................................4574
Fuse holder and relay carriers.......................................................................................4582
Fuse holder and relay carriers, tightening torques...................................................................4591
Wiring harnesses and connectors, repairing...........................................................................4592
Antenna cables, replacing............................................................................................4599
Communication............................................................................................................4603
Radio system - "Premium IV" and "Premium V" (including "Monsoon") through 11.01, On Board Diagnostic (OBD)...........4606
Radio system - "Premium VI" (including "Monsoon) from 12.01, On Board Diagnostic (OBD)...............................4632
Multi-function steering wheel through 11.01, On Board Diagnostic (OBD)...............................................4661
Multi-function steering wheel from 12.01, On Board Diagnostic (OBD)..................................................4688
Communication........................................................................................................4691
Radio systems........................................................................................................4694
Radio, "Premium IV"..................................................................................................4695
Radio, "Premium V" & "Premium V - Monsoon"...........................................................................4705
Radio, "Premium VI" & "Premium VI - Monsoon".........................................................................4715
Amplifier system - "Monsoon".........................................................................................4727
Speaker system.......................................................................................................4733
Antenna systems......................................................................................................4737
CD Changer / CD Player...............................................................................................4748
Multi-function steering wheel........................................................................................4758
Telematics...........................................................................................................4769
Mobile telephone and two-way radio operation, notes..................................................................4804
Maintenance..............................................................................................................4815
Engine overview......................................................................................................4818
Service work.........................................................................................................4819
Oil change service...................................................................................................4820
Delivery inspection..................................................................................................4821
Maintenance service..................................................................................................4822
General..............................................................................................................4823
Description of work (part 1 of 2)....................................................................................4846
Description of work (part 2 of 2)....................................................................................4896
Need help? Contact: [email protected]
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
