Volkswagen Bora 1999 Bora Variant 1999 Golf 1998 Golf Variant 1998 Maintenance Manual PDF

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Volkswagen Bora 1999 Bora Variant 1999 Golf 1998 Golf Variant 1998 Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Bora 1999 Bora Variant 1999 Golf 1998 Golf Variant 1998 Maintenance Manual – PDF DOWNLOAD 

Language : English
Pages : 189
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volkswagen Bora 1999 Bora Variant 1999 Golf 1998 Golf Variant 1998 Maintenance Manual – PDF DOWNLOAD 

1 Engine list 5
2 Service work 14
2 1 Service tables 14
2 1 1 VW engine oil standards 14
2 1 2 Filter change intervals 14
2 1 3 Toothed belt change intervals 15
2 1 4 Service intervals 16
2 2 Delivery inspection 17
2 3 Oil change service 19
2 3 1 Oil change service for vehicles 2001► with long-life service (PR number QG1), also natural gas vehicles 19
2 3 2 Vehicles 2000► with time or distance-dependent service (PR number QG0 or QG2) and vehicles ►1999 20
2 4 Inspection service ►1999 20
2 4 1 Inspection service every 12 months 21
2 4 2 Inspection service every 30,000 km 23
2 5 Inspection service 2000► 26
2 5 1 Long-life service or time or distance dependent service 26
2 6 Additional work on natural gas system 30
3 General information 32
3 1 Raising vehicle with lifting platform or trolley jack 32
3 1 1 Lifting points for lifting platform 33
3 1 2 Lifting Golf “R32” 33
3 1 3 Jacking points for trolley jack 33
3 2 Sticker 34
3 2 1 “Long-life engine oil” sticker 34
3 2 2 Applying data sticker in luggage compartment 34
3 2 5 Attaching hotline sticker 35
3 3 Connecting vehicle diagnostic tester 35
3 4 Severe operating conditions 37
3 5 Vehicle identification number 38
3 6 Vehicle data sticker 38
3 7 Information on long-life service or time- or distance-dependent service 39
3 7 1 Flexible service interval display (only vehicles with “long-life service”, PR number QG1): 39
3 8 Countries where diesel has a high sulphur content 40
3 9 “Countries with hot climate” includes 41
3 10 Engine code and engine number 41
3 11 RME fuel (biodiesel) 42
3 12 Identification plate 42
4 Descriptions of work: 43
4 1 Exhaust system: inspect for leaks, security and damage 45
4 1 1 Additional visual check Golf R32 45
4 2 Swivel joints: inspecting 45
4 3 Automatic gearbox: changing ATF (01M gearbox) 46
4 4 Automatic gearbox: changing ATF strainer (01M gearbox) 46
4 5 Automatic gearbox: checking gear oil in final drive (01M gearbox) 46
4 6 Automatic gearbox: checking ATF level, top-up if necessary (01M gearbox) 46
4 7 Automatic gearbox: checking ATF level, top-up if necessary (09A gearbox) 46
4 8 Battery: checking battery terminal clamps for secure seating 46
4 9 Battery: checking using battery tester with printer VAS 5097A or VAS 6161 48
4 10 Front airbag for the front passenger: checking activation / deactivation 48
4 11 Tyres: checking condition, wear pattern, tyre pressure and tread depth 49
4 11 1 General information 49
4 11 2 Checking condition 50
4 11 3 Wear pattern: checking 51
4 11 5 Tyre pressures (including spare): checking, correcting if necessary 51
4 11 6 Tyre pressure table for factory-fitted standard tyres 51
4 11 7 Golf 52
4 11 8 Golf with four-wheel drive 55
4 11 9 Bora 57
4 11 10 Bora with four-wheel drive 59
4 11 11 Golf Variant, Bora Variant 61
4 11 12 Golf estate with four-wheel drive, Bora Variant with four-wheel drive 63
4 12 Brake system: inspecting for leaks and damage 65
4 13 Front and rear brake pads/linings: checking thickness 65
4 13 1 Front brake pads: 66
4 13 2 Rear brake pads: 66
4 13 3 Rear drum brake pads: checking 67
4 14 Brake and clutch system: changing brake fluid 68
4 14 1 Operation and safety notes 68
4 14 2 Brake fluid specification 69
4 14 3 Procedure, changing brake fluid 69
4 15 Brake fluid level: checking 72
4 15 1 Procedure, brake fluid level: checking 73
4 16 6-speed dual clutch gearbox 02E (four-wheel drive) 73
4 17 Electric windows, 8-way memory seat: initialising (activation) 73
4 17 1 Electric windows: initialising 73
4 17 2 8-way memory seat: initialising 74
4 18 Vehicle system test: carrying out test 74
4 19 Boots: inspecting 75
4 20 Installing noise insulation: Golf R32 76
4 21 Haldex coupling: renewing oil filter (four-wheel drive) 77
4 22 Haldex coupling: changing oil (four-wheel drive) 77
4 23 Checking first aid box expiry date 78
4 24 Rear lid: lubricating left and right multi-joint hinge 78
4 25 Fuel filter: renewing (diesel engine) 79
4 26 Fuel filter: draining water (diesel engine) 81
4 27 Poly V-belt: checking condition 81
4 28 Cooling system: checking frost protection and coolant level 83
4 28 1 Frost protection: checking, replenishing coolant additive if necessary 83
4 28 2 Coolant level: checking, replenishing coolant if necessary 84
4 28 3 Mixing ratio: 85
4 29 Air filter: cleaning housing and renewing filter element 85
4 29 1 Air filter: cleaning housing and renewing filter element, if necessary cleaning snow screen, if fitted (all engines except engine code AQN) 85
4 29 3 Engine code: AQN 86
4 30 Engine cover panel -top-: removing and installing 87
4 30 1 Removing and installing engine cover, 1 4 l engines with ignition transformer 88
4 30 3 Removing and installing engine cover, 1 6 l injection engines 89
4 30 4 Removing and installing engine cover, 1 8 l injection engines 90
4 30 7 Removing and installing engine cover, 2 8l injection engines 92
4 30 8 Removing and installing engine cover, 3 2l injection engines 92
4 30 10 Removing and installing engine cover, 4-cylinder TDI unit injector diesel engines 93
4 31 Engine cover panel, -bottom- (noise insulation): removing and installing 94
4 32 Engine oil level: checking 96
4 33 Engine oil: draining or extracting and replenishing; renewing oil filter 96
4 33 1 Engine oil: draining or extracting and replenishing 97
4 33 2 Oil filter: renewing 98
4 33 3 Engine oil: replenishing 101
4 34 Engine and components in engine compartment: inspecting for leaks and damage (from above and below) 102
4 35 Carrying out road test 102
4 36 Radio and radio-navigation system: sticking serial number and code number onto unit card 103
4 37 Radio/radio-navigation system: activating anti-theft coding 103
4 37 1 Activate fixed code on “ALPHA” radio units as follows: 103
4 37 3 Activate fixed code on “radio navigation system” as follows: 104
4 38 Wheel bolts: tightening to specified torque 104
4 39 Securing wheel housing liner to front apron (only Golf Anniversary GTI with 132 kW) 107
4 40 Tyre repair set: checking 108
4 41 Power assisted steering: checking fluid level 109
4 41 1 Cold fluid: 109
4 41 2 Oil at operating temperature (above approx 50°C): 110
4 42 Sunroof: checking function, cleaning and greasing guide rails 110
4 43 Sliding sunroof drains: checking for blockage, cleaning if necessary 111
4 44 Windscreen wash/wipe system and headlight washer system: checking for damage, function and spray jet settings 112
4 44 1 Windscreen wash/wipe system anti-freeze concentration: checking and replenishing fluid if necessary 112
4 44 2 Window washer system: checking jet setting, adjusting jets if necessary 114
4 44 3 Headlight washer system: checking jet setting 115
4 45 Wiper blades: checking for damage, park position and setting angle if wiper blades judder 116
4 45 1 Wiper blade park position: checking and adjusting if necessary 116
4 45 2 Wiper blades: checking setting angle, adjusting if necessary 116
4 46 Manual gearbox/final drive: checking oil level 117
4 46 1 Final drive for 5-speed manual gearbox 02K: checking oil level 117
4 46 2 Final drive for 5-speed manual gearbox 02J: checking oil level 117
4 46 3 Front final drive for 5 and 6-speed manual gearbox 02M: checking oil level 117
4 46 4 Rear final drive for 5 and 6-speed manual gearbox 02M: checking oil level 117
4 46 5 Final drive for 5-speed manual gearbox 02T: checking oil level 117
4 47 Headlight adjustment: checking and adjusting as necessary 117
4 47 1 Checking headlight adjustment (using new test screen without 15° setting line) 119
4 47 2 Adjusting headlights for Golf 120
4 47 3 Adjusting headlights for Bora 120
4 47 4 Headlight adjustment: checking headlights with gas discharge bulbs 121
4 48 Service interval display: resetting 122
4 49 Service interval display: recoding 124
4 50 Track rod ends: checking clearance, firm seating and boots 125
4 51 Dash panel insert: adapting to required language 125
4 52 Dust and pollen filter: cleaning housing and renewing filter element 126
4 53 Transportation device: removing blocking pieces from front axle springs 126
4 54 Door arrester: lubricating 128
4 55 Clock: setting to correct time 128
4 56 Underbody: inspecting for damage to underbody sealant, underbody panels, routing of lines, plugs 128
4 57 Toothed belt and camshaft drive tensioning roller: renewing 129
4 57 1 Camshaft drive toothed belt and tensioning roller: renewing (diesel engine – codes AGP, AGR, AHF, ALH, AQM, ASV, AJM, ASZ, AXR, BEW, AUY, ATD, ARL, BEW) 129
4 57 2 Camshaft drive toothed belt: renewing (4-cylinder 5-valve petrol engine – codes AGN, AGU, AQA, ARZ, AVC, AUM, AUQ, AWU, AWP) 129
4 58 Camshaft drive toothed belt: checking (4-cylinder petrol engine) 129
4 59 Toothed belt: checking for wear (diesel engine) 130
4 60 Camshaft drive toothed belt: checking condition and tension (diesel engine code ALH with automatic gearbox) 130
4 60 1 Toothed belt: checking condition 130
4 60 2 Checking toothed belt tension 131
4 60 3 Tensioning toothed belt 131
4 61 Additional work on natural gas system 131
4 61 1 Checking function of electromagnetic cut-off valves: 132
4 61 2 Checking condition of breather line and boots at natural gas tank: 134
4 61 3 Checking natural gas tanks and natural gas lines for leaks, attachment and damage: 134
4 61 4 Sealing cap and natural gas filler connection: checking condition, cleaning if necessary and checking O-rings 137
4 61 5 Spark plugs: renewing 137
4 61 6 Removing and installing natural gas tanks 137
4 62 Spark plugs: renewing 137
4 62 1 Spark plugs: renewing, 1 4 l engines with ignition transformer 140
4 62 2 Spark plugs: renewing, 1 4 l engines with ignition coils with output stages 141
4 62 3 Spark plugs: renewing, 2 3 l engines (2-valve) 142
4 62 4 Spark plugs: renewing, 2 3 l engines (4-valve) 143
4 62 5 Spark plugs: renewing, 2 8 l engines (4-valve) with ignition transformer 144
4 62 6 Spark plugs: renewing, 2 8 l and 3 2 l engines (4-valve) with ignition coils with output stages 144
4 62 7 Spark plugs: renewing, 1 8 l engines with ignition transformer 146
4 62 8 Spark plugs: renewing, 1 8 l engines with screwed ignition coils with output stages 146
4 62 9 Spark plugs: renewing, 1 8 l engines with pushed-on ignition coils with output stages 147
4 62 10 Spark plugs: renewing, 1 6l engines 150
4 62 11 Spark plugs: renewing, 2 0 l engines 151
5 Exhaust emissions test 152
5 1 Exhaust emissions test for petrol engines without OBD 152
5 1 1 Exhaust emissions test for petrol engines, methods to activate disturbance variable for control circuit test according to basic procedure 159
5 1 2 Engine codes: AEH, AKL 159
5 1 3 Engine code: AGN 160
5 1 4 Engine codes: AGU, AQA, ARZ 162
5 1 5 Engine codes: AHW, AKQ, ATN 165
5 1 6 Engine code: AGZ 166
5 1 7 Engine code: APE 167
5 1 8 Engine code: APF 168
5 2 Exhaust emissions test for petrol engines with OBD 169
5 3 Exhaust emissions test for diesel engines without OBD 171
5 3 1 Exhaust emissions test for diesel engines without OBD with diesel tester V A G 1743 171
5 3 2 Exhaust emissions test for diesel engines without OBD with emissions testing station VAS 6300 176
5 4 Exhaust emissions test for diesel engines with OBD 184
6 Glossary 188

S.V 27/01/2025