1999-2005 VOLKSWAGEN JETTA GOLF GTI SERVICE MANUAL – PDF DOWNLOAD
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1999-2005 VOLKSWAGEN JETTA GOLF GTI SERVICE MANUAL – PDF DOWNLOAD
- 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 JETTA GOLF 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
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.
Jeremiah Keanu –
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