Volkswagen Golf Cabriolet 2002 Repair Manual – PDF DOWNLOAD

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Volkswagen Golf Cabriolet 2002 Repair Manual – PDF DOWNLOAD

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Volkswagen Golf Cabriolet 2002 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 4322
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Golf Cabriolet 2002 Repair Manual – PDF DOWNLOAD 

00053148620 Wheels and Tyres Guide Archive 1
44 – Wheels, tyres, vehicle geometry 11
1 General notes on wheels and tyres (passenger cars) 11
2 Legislative and technical conditions for converting wheel and tyre combinations 13
2 1 Legislative conditions for converting wheel and tyre combinations 13
2 2 Technical conditions for converting wheel and tyre combinations 13
2 3 Additional wheel housing extensions (flaps) 14
2 4 “Series 80” tyres 14
2 5 Vehicles with Plus running gear 14
3 Documents and codes/designations 16
3 1 New vehicle registration documents since 01 10 2005 16
3 2 COC document (EEC Certificate of Conformity) 17
3 3 Official type designations 17
3 4 EU general type approval number, sales type and sales or trade designation 18
4 Useful information regarding tyres 20
4 1 Identification markings on the tyre sidewall 20
4 2 Explanation of tyre markings 21
4 3 Speed ratings for tyres 22
4 4 Undulations 23
4 5 Tyre storage 24
4 6 Tyre ageing 24
4 7 Winter tyres 25
4 8 Winter tyres with speed symbol “V” 26
4 9 Extra Load (XL) V winter tyres 27
4 10 Maximum speeds for V and Extra Load (XL) winter tyres 27
4 11 Reinforced and Extra Load (XL) tyres 28
4 12 Snow chains 28
5 Tyre wear/ mileage for passenger car tyres 30
5 1 General 30
5 2 Requirements to be met by tyres 30
5 3 Wear behaviour of high-speed tyres 31
5 4 Factors influencing the service life of a tyre 31
5 5 Driving style 31
5 6 Tyre maintenance 32
5 7 Evenly worn tyres 33
5 8 Measuring tread depth 34
5 9 One-sided wear 34
5 10 Outer shoulder wear 37
5 11 Wear in middle of tyre 37
5 12 Diagonal washout 39
6 Tyre noise 40
6 1 General notes on tyre noise 40
6 2 Saw-tooth wear 40
6 3 Flat spots (from locking wheels) 41
7 Rough running caused by wheels/tyres 43
7 1 Causes of rough running 43
7 2 Balancing wheels 43
7 3 Conducting a road test before balancing wheels 43
7 4 Balancing wheels on stationary wheel balancing machine 44
7 5 Vibration control system -VAS 6230- 46
7 6 Finish balancer 46
7 7 Radial and lateral runout of wheels and tyres 47
7 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 47
7 9 Checking radial and lateral runout on wheel rim 48
7 10 Matching 49
7 11 Flat spots caused by storage or handling 50
8 Vehicle pulls to one side 52
8 1 General 52
8 2 Conicity 52
8 3 Remedies when vehicle pulls to one side 53
8 4 Strategic rotation of wheels for non-directional tyres 54
8 5 Strategic rotation of wheels having unidirectional tyres 55
9 Tyre damage 57
9 1 General information 57
9 2 Construction of a radial belted tyre 57
9 3 Impact damage 58
9 4 Cuts 59
9 5 Damage caused by foreign bodies 59
9 6 Loss of air from tyre 60
9 7 Tyre pressure 60
9 8 Tyre damage due to insufficient tyre pressure 61
9 9 Rising tyre temperature caused by insufficient inflation pressure 62
9 10 Tyre damage due to fitting error (fitting damage) 63
10 Tyres with run-flat properties 65
10 1 General 65
10 2 Design and identification 66
10 3 Retrofitting/requirements when using run-flat tyres 66
10 4 Repairs 67
11 Rolling resistance optimised tyres 68
12 Facts about disc-type wheels (passenger cars) 69
12 1 Design of disc-type wheel 69
12 2 Data on wheel rims 69
12 3 Wheel rims – pitch circle diameter 70
12 4 Split rim composite wheels 70
12 5 Alloy wheels with exchangeable trim elements 70
12 6 Alloy wheels with exchangeable trim elements (Zaragoza) 71
12 6 1 Tools 71
12 6 2 Materials 72
12 6 3 Installing trim element 72
12 6 4 Removing trim element 74
12 7 Hub cover for alloy wheels with open threaded connections 75
12 8 Care and maintenance of alloy wheel rims 75
12 9 Restoring alloy wheels 76
12 10 The valve 77
13 Fitting and removing wheels 78
13 1 Rotating wheels 78
13 2 Instructions for changing or fitting wheels 78
13 3 Revised wheel bolts for Sharan from model year 2001 80
13 4 Notes on use of temporary spare wheels 80
14 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 82
14 1 Lupo 3L, type 6E model year 1999 to model year 2006 82
14 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 83
14 2 1 4 J x 14 83
14 2 2 41/2 J x 14 83
14 2 3 5 J x 14 84
14 3 Lupo FSI, type 6E model year 2001 to model year 2006 84
14 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 85
14 4 1 5 J x 14 85
14 4 2 6 J x 14 86
14 5 Lupo GTI, type 6ES model year 2001 to model year 2006 87
14 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 88
14 6 1 6 J x 14 88
14 6 2 61/2 J x 15 89
15 Lupo model year 1999 to model year 2005 90
15 1 Lupo, type 6X model year 1999 to model year 2005 90
15 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 92
15 2 1 41/2 J x 13 92
15 2 2 51/2 J x 13 93
15 2 3 6 J x 14 94
15 2 4 6 J x 15 96
16 Fox from model year 2005 98
16 1 Fox, type 5Z model year 2005 to model year 2012 98
16 2 Wheel allocation for Fox, type 5Z model year 2005 to model year 2012 99
16 2 1 5 J x 14 100
16 2 2 6 J x 14 100
16 2 3 6 J x 15 102
17 Polo model year 1995 to model year 2001 105
17 1 Polo, type 6N up to and including 07 95 105
17 2 Wheel allocation for Polo, type 6N up to and including 07 95 106
17 2 1 41/2 J x 13 106
17 2 2 51/2 J x 13 107
17 3 Polo, type 6N from 08 95 up to and including model year 1996 108
17 4 Polo, type 6N from model year 1997 to model year 1999 109
17 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 110
17 5 1 41/2 J x 13 111
17 5 2 51/2 J x 13 111
17 5 3 6 J x 14 112
17 5 4 6 J x 15 113
17 6 Polo, type 6N from model year 2000 to model year 2001 115
17 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2001 116
17 7 1 41/2 J x 13 117
17 7 2 51/2 J x 13 117
17 7 3 6 J x 14 118
17 7 4 6 J x 15 119
18 Polo Classic model year 1996 to model year 2002 122
18 1 Polo Classic, type 6KV model year 1996 to model year 2002 122
18 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 124
18 2 1 51/2 J x 13 124
18 2 2 6 J x 14 125
18 2 3 6 J x 15 126
19 Polo Variant model year 1998 to model year 2002 128
19 1 Polo Variant type 6KV model year 1998 to model year 2002 128
19 2 Wheel allocation for Polo Variant type 6KV model year 1998 to model year 2002 130
19 2 1 51/2 J x 13 130
19 2 2 6 J x 14 131
19 2 3 6 J x 15 132
20 Polo from model year 2002 134
20 1 Polo, type 9N model year 2002 to model year 2008 134
20 2 Polo, type 9N model year 2009 137
20 3 Wheel allocation for Polo, type 9N model year 2002 to model year 2009 141
20 3 1 5 J x 13 141
20 3 2 5 J x 14 142
20 3 3 6 J x 14 142
20 3 4 6 J x 15 144
20 3 5 61/2 J x 16 offset 38 145
20 3 6 61/2 J x 16 offset 43 145
20 3 7 71/2 J x 17 offset 38 148
21 Polo Fun model year 2004 to model year 2005 149
21 1 Polo Fun, type 9N model year 2004 to model year 2005 149
21 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2005 150
21 2 1 6 J x 15 150
21 2 2 71/2 J x 17 150
22 CrossPolo from model year 2006 152
22 1 CrossPolo, type 9N model year 2006 to model year 2009 152
22 2 Wheel allocation for CrossPolo, type 9N model year 2006 to model year 2009 153
22 2 1 6 J x 15 153
22 2 2 71/2 J x 17 153
23 Polo BlueMotion from model year 2007 155
23 1 Polo BlueMotion, type 9N model year 2007 to model year 2009 155
23 2 Wheel allocation for Polo BlueMotion, type 9N model year 2007 to model year 2009 156
23 2 1 5 J x 14 156
24 Polo GTI from model year 2006 158
24 1 Polo GTI, type 9N model year 2006 to model year 2009 158
24 2 Wheel allocation for Polo GTI, type 9N model year 2006 to model year 2009 159
24 2 1 6 J x 15 159
24 2 2 61/2 J x 16 offset 38 160
24 2 3 61/2 J x 16 offset 43 160
24 2 4 7 J x 17 offset 38 162
24 2 5 71/2 J x 17 offset 38 163
25 Polo GTI Cup Edition from model year 2007 164
25 1 Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 164
25 2 Wheel allocation for Polo GTI Cup Edition, type 9N model year 2007 to model year 2009 165
25 2 1 61/2 J x 16 offset 42 165
25 2 2 61/2 J x 16 offset 43 166
25 2 3 7 J x 17 offset 38 167
25 2 4 71/2 J x 17 offset 38 168
26 Polo saloon/sedan model year 2004 to model year 2005 169
26 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 169
26 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 171
26 2 1 5 J x 14 171
26 2 2 6 J x 14 171
26 2 3 6 J x 15 173
26 2 4 61/2 J x 16 174
27 Golf model year 1992 to model year 1998 176
27 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 176
27 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 180
27 2 1 51/2 J x 13 180
27 2 2 6 J x 14 181
27 2 3 6 J x 15 183
27 2 4 61/2 J x 15 186
27 2 5 7 J x 16 189
28 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 190
28 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 190
28 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 193
28 2 1 6 J x 14 193
28 2 2 6 J x 15 194
28 2 3 51/2 J x 16 197
28 2 4 61/2 J x 16 198
28 2 5 7 J x 17 202
28 2 6 71/2 J x 17 204
28 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 205
28 4 Golf R32, type 1J model year 2003 to model year 2005 206
28 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 206
28 5 1 51/2 J x 17 207
28 5 2 71/2 J x 17 207
28 5 3 71/2 J x 18 207
28 6 Golf Anniversary GTI, type 1J model year 2002 208
28 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 208
28 7 1 51/2 J x 16 209
28 7 2 61/2 J x 16 209
28 7 3 7 J x 17 211
28 7 4 71/2 J x 18 212
28 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 213
29 Golf model year 2004 to model year 2009 214
29 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 214
29 2 Golf, Golf 4Motion, type 1K model year 2007 to model year 2009 217
29 3 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2009 221
29 3 1 6 J x 15 221
29 3 2 61/2 J x 15 222
29 3 3 6 J x 16 223
29 3 4 61/2 J x 16 223
29 3 5 6 J x 17 227
29 3 6 7 J x 17 228
29 3 7 71/2 J x 17 230
29 3 8 71/2 J x 18 231
30 Golf BlueMotion model year 2008 to model year 2009 234
30 1 Golf BlueMotion, type 1K model year 2008 to model year 2009 234
30 2 Wheel allocation for Golf BlueMotion, type 1K model year 2008 to model year 2009 235
30 2 1 6 J x 15 235
30 2 2 61/2 J x 15 236
30 2 3 61/2 J x 16 237
31 Golf GTI model year 2005 to model year 2009 242
31 1 Golf GTI, type 1K model year 2005 to model year 2008 242
31 2 Golf GTI, type 1K model year 2009 243
31 3 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2009 245
31 3 1 6 J x 16 245
31 3 2 61/2 J x 16 245
31 3 3 6 J x 17 249
31 3 4 7 J x 17 250
31 3 5 71/2 J x 17 252
31 3 6 71/2 J x 18 253
32 Pirelli Golf model year 2008 to model year 2009 256
32 1 Pirelli Golf, type 1K model year 2008 to model year 2009 256
32 2 Wheel allocation for Pirelli Golf, type 1K model year 2008 to model year 2009 257
32 2 1 6 J x 16 257
32 2 2 61/2 J x 16 258
32 2 3 6 J x 17 262
32 2 4 7 J x 17 262
32 2 5 71/2 J x 17 265
32 2 6 71/2 J x 18 266
33 Golf R32 model year 2006 to model year 2009 269
33 1 Golf R32, type 1K model year 2006 to model year 2009 269
33 2 Wheel allocation for Golf R32, type 1K model year 2006 to model year 2009 270
33 2 1 6 J x 17 270
33 2 2 7 J x 17 271
33 2 3 71/2 J x 18 273
34 CrossGolf from model year 2007 276
34 1 CrossGolf, type 1KP model year 2007 to model year 2009 276
34 2 Wheel allocation for CrossGolf, type 1KP model year 2007 to model year 2009 279
34 2 1 6 J x 15 279
34 2 2 61/2 J x 15 280
34 2 3 6 J x 16 281
34 2 4 61/2 J x 16 282
34 2 5 6 J x 17 286
34 2 6 7 J x 17 offset 47 286
34 2 7 7 J x 17 offset 54 287
34 2 8 71/2 J x 17 289
35 Golf Plus from model year 2005 290
35 1 Golf Plus, type 1KP model year 2005 to model year 2006 290
35 2 Golf Plus, type 1KP model year 2007 to model year 2009 292
35 3 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2009 295
35 3 1 6 J x 15 296
35 3 2 61/2 J x 15 296
35 3 3 6 J x 16 297
35 3 4 61/2 J x 16 298
35 3 5 6 J x 17 302
35 3 6 7 J x 17 303
35 3 7 71/2 J x 18 305
36 Golf Plus BlueMotion from model year 2008 308
36 1 Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 308
36 2 Wheel allocation for Golf Plus BlueMotion, type 1KP model year 2008 to model year 2009 309
36 2 1 6 J x 15 309
36 2 2 61/2 J x 15 310
36 2 3 61/2 J x 16 311
37 Golf Variant model year 1994 to model year 1998 316
37 1 Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 316
37 2 Wheel allocation for Golf Variant type 1HX0, Golf Variant Syncro type 1HX1, Golf Variant type 1H 319
37 2 1 51/2 J x 13 320
37 2 2 6 J x 14 320
37 2 3 6 J x 15 323
37 2 4 61/2 J x 15 326
38 Golf Variant model year 1999 to model year 2006, Bora Variant model year 1999 to model year 2005 327
38 1 Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 327
38 2 Wheel allocation for Golf Variant, Golf Variant 4Motion, Bora Variant, Bora Variant 4Motion, type 1J 330
38 2 1 6 J x 15 330
38 2 2 51/2 J x 16 333
38 2 3 61/2 J x 16 334
38 2 4 7 J x 17 338
38 2 5 71/2 J x 17 340
38 3 Conditions for fitting 17″ wheels and tyres 341
39 Golf Variant model year 2007 to model year 2010 342
39 1 Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2008 342
39 2 Golf Variant, Golf Variant 4Motion; type 1KM model year 2009 to model year 2010 345
39 3 Wheel allocation for Golf Variant, Golf Variant 4Motion; type 1KM model year 2007 to model year 2010 348
39 3 1 6 J x 15 348
39 3 2 61/2 J x 15 349
39 3 3 6 J x 16 350
39 3 4 61/2 J x 16 351
39 3 5 7 J x 17 355
39 3 6 71/2 J x 18 357
40 Golf Variant BlueMotion model year 2008 to model year 2010 360
40 1 Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 360
40 2 Wheel allocation for Golf Variant BlueMotion, type 1KM model year 2008 to model year 2010 361
40 2 1 6 J x 15 361
40 2 2 61/2 J x 15 362
40 2 3 61/2 J x 16 363
41 Jetta Model Year 2006 to Model Year 2011 368
41 1 Jetta, type 1KM model year 2006 368
41 2 Jetta, type 1KM model year 2007 to model year 2008 370
41 3 Jetta, type 1KM model year 2009 to model year 2011 373
41 4 Wheel allocation for Jetta, type 1KM model year 2006 to model year 2011 380
41 4 1 6 J x 15 380
41 4 2 61/2 J x 15 381
41 4 3 6 J x 16 382
41 4 4 61/2 J x 16 383
41 4 5 7 J x 17 388
41 4 6 71/2 J x 17 391
41 4 7 71/2 J x 18 392
42 Jetta BlueMotion from Model year 2008 397
42 1 Jetta BlueMotion, type 1KM model year 2008 to model year 2011 397
42 2 Wheel allocation for Jetta BlueMotion, type 1KM model year 2008 to model year 2011 398
42 2 1 6 J x 15 398
42 2 2 61/2 J x 15 399
42 2 3 6 J x 16 400
42 2 4 61/2 J x 16 401
43 Golf cabriolet model year 1994 to model year 1997 407
43 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 407
43 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 408
43 2 1 6 J x 14 409
43 2 2 6 J x 15 410
43 2 3 61/2 J x 16 410
44 Golf cabriolet model year 1998 to model year 2002 412
44 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 412
44 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 413
44 2 1 6 J x 14 413
44 2 2 6 J x 15 415
44 2 3 61/2 J x 16 417
45 Vento from model year 1992 to model year 1998 418
45 1 Vento; type 1HX0, 1H 418
45 2 Wheel allocation for Vento; type 1HX0, 1H 420
45 2 1 51/2 J x 13 420
45 2 2 6 J x 14 421
45 2 3 6 J x 15 423
45 2 4 61/2 J x 15 425
46 Bora model year 1999 to model year 2005 429
46 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 429
46 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 432
46 2 1 6 J x 15 432
46 2 2 51/2 J x 16 435
46 2 3 61/2 J x 16 435
46 2 4 7 J x 17 440
46 2 5 71/2 J x 17 442
46 3 Conditions for fitting 17″ wheels and tyres 443
47 New Beetle from model year 1999 444
47 1 New Beetle, type 9C model year 1999 to model year 2010 444
47 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2010 447
47 2 1 6 J x 15 447
47 2 2 51/2 J x 16 449
47 2 3 61/2 J x 16 450
47 2 4 7 J x 17 455
47 2 5 71/2 J x 17 458
47 3 Conditions for fitting 17″ wheels and tyres 458
48 New Beetle Cabriolet from model year 2003 460
48 1 New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 460
48 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2010 462
48 2 1 6 J x 15 462
48 2 2 51/2 J x 16 464
48 2 3 61/2 J x 16 465
48 2 4 7 J x 17 470
48 2 5 71/2 J x 17 473
48 3 Conditions for fitting 17″ wheels and tyres 473
49 New Beetle RSi 475
49 1 New Beetle RSi, type 9CR from model year 2001 475
49 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 476
49 2 1 7 J x 16 476
49 2 2 9 x 18 476
50 Passat model year 1994 to model year 1997 478
50 1 Passat, type 35l model year 1994 to model year 1997 478
50 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 480
50 2 1 6 J x 14 480
50 2 2 6 J x 15 482
51 Passat model year 1997 to model year 2005 486
51 1 Passat, Passat Variant, type 3B model year 1997 to model year 2000 486
51 2 Passat, Passat Variant, type 3B model year 1997 to model year 2000 488
51 2 1 6 J x 15 488
51 2 2 7 J x 15 489
51 2 3 7 J x 16 490
51 3 Passat, Passat Variant, type 3BG model year 2001 to model year 2005 491
51 4 Wheel allocation for Passat, Passat Variant, type 3BG model year 2001 to model year 2005 492
51 4 1 6 J x 15 493
51 4 2 7 J x 15 494
51 4 3 6 J x 16 494
51 4 4 7 J x 16 495
51 4 5 7 J x 17 497
51 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 498
51 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 499
51 6 1 7 J x 16 499
51 6 2 6 J x 17 500
51 6 3 71/2 J x 17 500
51 7 Passat Protect, type 3BL model year 2002 to model year 2005 501
51 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 502
51 8 1 6 J x 16 502
51 8 2 7 J x 16 502
52 Passat saloon from model year 2006 504
52 1 Passat saloon, type 3C model year 2006 504
52 2 Passat saloon, type 3C model year 2007 to model year 2008 507
52 3 Passat saloon, type 3C model year 2009 515
52 4 Passat saloon, type 3C model year 2010 to model year 2011 522
52 5 Wheel allocation for Passat saloon, type 3C model year 2006 to model year 2011 526
52 5 1 61/2 J x 16 526
52 5 2 7 J x 16 527
52 5 3 6 J x 17 529
52 5 4 71/2 J x 17 529
52 5 5 8 J x 18 532
53 Passat saloon BlueMotion from model year 2008 535
53 1 Passat saloon BlueMotion, type 3C model year 2008 to model year 2009 535
53 2 Passat saloon BlueMotion, type 3C model year 2010 to model year 2011 537
53 3 Wheel allocation for Passat saloon BlueMotion, type 3C model year 2008 to model year 2011 538
53 3 1 61/2 J x 16 538
53 3 2 7 J x 16 539
53 3 3 6 J x 17 541
53 3 4 71/2 J x 17 541
53 3 5 8 J x 18 544
54 Passat Variant from model year 2006 547
54 1 Passat Variant, type 3C model year 2006 547
54 2 Passat Variant, type 3C model year 2007 to model year 2008 551
54 3 Passat Variant, type 3C model year 2009 561
54 4 Passat Variant, type 3C model year 2010 to model year 2011 569
54 5 Wheel allocation for Passat Variant, type 3C model year 2006 to model year 2011 573
54 5 1 61/2 J x 16 573
54 5 2 7 J x 16 574
54 5 3 6 J x 17 576
54 5 4 71/2 J x 17 576
54 5 5 8 J x 18 579
55 Passat Variant BlueMotion from model year 2008 582
55 1 Passat Variant BlueMotion, type 3C model year 2008 to model year 2009 582
55 2 Passat Variant BlueMotion, type 3C model year 2010 to model year 2011 584
55 3 Wheel allocation for Passat Variant BlueMotion, type 3C model year 2008 to model year 2011 585
55 3 1 61/2 J x 16 585
55 3 2 7 J x 16 586
55 3 3 6 J x 17 588
55 3 4 71/2 J x 17 588
55 3 5 8 J x 18 591
56 Passat R36 from model year 2008 594
56 1 Passat R36, type 3C model year 2008 to model year 2009 594
56 2 Passat R36, type 3C model year 2010 to model year 2011 596
56 3 Wheel allocation for Passat R36, type 3C model year 2008 to model year 2011 597
56 3 1 6 J x 17 597
56 3 2 71/2 J x 17 597
56 3 3 8 J x 18 600
56 3 4 8 J x 19 601
57 Sharan from model year 1996 603
57 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 603
57 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 606
57 2 1 6 J x 15 606
57 2 2 7 J x 15 607
57 2 3 7 J x 16 608
57 3 Sharan, Sharan 4Motion, type 7M model year 2001 608
57 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 611
57 4 1 6 J x 15 611
57 4 2 7 J x 15 611
57 4 3 6 J x 16 612
57 4 4 7 J x 16 613
57 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 615
57 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2010 616
57 6 1 6 J x 16 617
57 6 2 7 J x 16 617
57 6 3 7 J x 17 619
58 Sharan BlueMotion from model year 2009 621
58 1 Sharan BlueMotion, type 7M model year 2009 to model year 2010 621
58 2 Wheel allocation for Sharan BlueMotion, type 7M model year 2009 to model year 2010 622
58 2 1 6 J x 16 622
59 Touareg from model year 2003 624
59 1 Touareg, type 7L, model year 2003 to model year 2010 624
59 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2010 628
59 2 1 7 J x 16 628
59 2 2 71/2 J x 17 629
59 2 3 8 J x 18 630
59 2 4 9 J x 19 632
59 2 5 9 J x 20 634
59 2 6 91/2 J x 20 636
60 Touareg R50 from model year 2008 637
60 1 Touareg R50, type 7L model year 2008 to model year 2010 637
60 2 Wheel allocation for Touareg R50, type 7L model year 2008 to model year 2010 638
60 2 1 9 J x 19 638
60 2 2 9 J x 20 640
60 2 3 91/2 J x 20 641
60 2 4 10 J x 21 641
61 Breakdown set for VW Vehicles 643
62 Temporary spare tyres and wheels for VW vehicles 644
63 Recommended summer tyres 646
63 1 Summer tyres for Lupo 3L model year 1999 to model year 2005 646
63 2 Summer tyres for Lupo FSI model year 1999 to model year 2005 646
63 3 Summer tyres for Lupo GTI model year 1999 to model year 2005 646
63 4 Summer tyres for Lupo model year 1999 to model year 2005 646
63 5 Summer tyres for Fox from model year 2005 647
63 6 Summer tyres for Polo model year 1995 to model year 2001 647
63 7 Summer tyres for Polo saloon/sedan model year 2004 to model year 2005 648
63 8 Summer tyres for Polo Classic model year 1996 to model year 2002 648
63 9 Summer tyres for Polo Variant model year 1998 to model year 2002 649
63 10 Summer tyres for Polo from model year 2002 649
63 11 Summer tyres for Polo Fun model year 2004 to model year 2005 650
63 12 Summer tyres for CrossPolo from model year 2006 650
63 13 Summer tyres for Polo BlueMotion from model year 2007 651
63 14 Summer tyres for Polo GTI from model year 2007 651
63 15 Summer tyres for Polo GTI Cup Edition from model year 2007 651
63 16 Summer tyres for Golf, Vento model year 1992 to model year 1998 651
63 17 Summer tyres for Golf Variant model year 1994 to model year 1998 652
63 18 Summer tyres for Golf cabriolet model year 1994 to model year 1997 653
63 19 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 653
63 20 Summer tyres for Golf model year 2004 to model year 2009 654
63 21 Summer tyres for Golf BlueMotion model year 2008 to model year 2009 656
63 22 Summer tyres for Golf GTI model year 2005 to model year 2009 656
63 23 Summer tyres for Pirelli Golf model year 2008 to model year 2009 656
63 24 Summer tyres for Golf R32 model year 2006 to model year 2009 657
63 25 Summer tyres for CrossGolf from model year 2007 657
63 26 Summer tyres for Golf Plus from model year 2005 658
63 27 Summer tyres for Golf Plus BlueMotion from model year 2008 659
63 28 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 659
63 29 Summer tyres for Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 660
63 30 Summer tyres for Golf R32 661
63 31 Summer tyres for Golf Anniversary GTI 662
63 32 Summer tyres for Golf Variant model year 2007 to model year 2010 662
63 33 Summer tyres for Golf Variant BlueMotion from model year 2008 663
63 34 Summer tyres for Jetta Model Year 2006 to Model Year 2011 663
63 35 Summer tyres for Jetta BlueMotion Model Year 2008 to Model Year 2011 665
63 36 Summer tyres for Golf cabriolet model year 1998 to model year 2002 666
63 37 Summer tyres for New Beetle from model year 1999 667
63 38 Summer tyres for New Beetle Cabriolet from model year 2003 668
63 39 Summer tyres for New Beetle RSi 668
63 40 Summer tyres for Passat model year 1994 to model year 1997 669
63 41 Summer tyres for Passat model year 1997 to model year 2005 669
63 42 Summer tyres for Passat W8 670
63 43 Summer tyres for Passat Protect 670
63 44 Summer tyres for Passat saloon from model year 2006 670
63 45 Summer tyres for Passat saloon BlueMotion from model year 2008 671
63 46 Summer tyres for Passat Variant from model year 2006 672
63 47 Summer tyres for Passat Variant BlueMotion from model year 2008 673
63 48 Summer tyres for Passat R36 from model year 2008 674
63 49 Summer tyres for Sharan from model year 1996 675
63 50 Summer tyres for Sharan BlueMotion from model year 2009 675
63 51 Summer tyres for Touareg model year 2008 to model year 2010 676
63 52 Summer tyres for Touareg R50 model year 2008 to model year 2010 676
64 Recommended all-season tyres 677
64 1 All-season tyres Lupo model year 1999 to model year 2005 677
64 2 All-season tyres Polo model year 1995 to model year 2001 677
64 3 All-season tyres for Polo from model year 2002 677
64 4 All-season tyres Polo saloon/sedan model year 2004 to model year 2005 678
64 5 All-season tyres Golf, Vento model year 1992 to model year 1998 678
64 6 All-season tyres Golf Variant model year 1994 to model year 1998 678
64 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 678
64 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 678
64 9 All-season tyres for Golf model year 2004 to model year 2009 679
64 10 All-season tyres for CrossGolf from model year 2007 679
64 11 All-season tyres for Golf Plus from model year 2005 680
64 12 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 680
64 13 All-season tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 681
64 14 All-season tyres Golf Variant model year 2007 to model year 2010 681
64 15 All-season tyres Jetta Model Year 2006 to Model Year 2011 681
64 16 All-season tyres Golf cabriolet model year 1998 to model year 2002 682
64 17 All-season tyres for New Beetle from model year 1999 682
64 18 All-season tyres for New Beetle Cabriolet from model year 2003 683
64 19 All-season tyres Passat model year 1997 to model year 2005 683
64 20 All-season tyres for Passat W8 683
64 21 All-season tyres for Passat saloon from model year 2006 684
64 22 All-season tyres for Passat saloon BlueMotion from model year 2008 684
64 23 All-season tyres for Passat Variant from model year 2006 684
64 24 All-season tyres for Passat Variant BlueMotion from model year 2008 684
64 25 All-season tyres for Passat R36 from model year 2008 685
64 26 All-season tyres for Touareg model year 2003 to model year 2010 685
65 Recommended winter tyres 686
65 1 Winter tyres Lupo 3L model year 1999 to model year 2005 686
65 2 Winter tyres Lupo FSI model year 1999 to model year 2005 686
65 3 Winter tyres Lupo GTI model year 1999 to model year 2005 686
65 4 Winter tyres Lupo model year 1999 to model year 2005 687
65 5 Winter tyres for Fox from model year 2005 687
65 6 Winter tyres Polo model year 1995 to model year 2001 687
65 7 Winter tyres for Polo from model year 2002 688
65 8 Winter tyres for Polo Fun model year 2004 to model year 2006 688
65 9 Winter tyres for CrossPolo from model year 2006 688
65 10 Winter tyres for Polo BlueMotion from model year 2007 688
65 11 Winter tyres for Polo GTI from model year 2007 689
65 12 Winter tyres for Polo GTI Cup Edition from model year 2007 689
65 13 Winter tyres Polo saloon/sedan model year 2004 to model year 2005 689
65 14 Winter tyres Polo Classic model year 1996 to model year 2002 689
65 15 Winter tyres Polo Variant model year 1998 to model year 2002 690
65 16 Winter tyres Golf, Vento model year 1992 to model year 1998 690
65 17 Winter tyres Golf Variant model year 1994 to model year 1998 691
65 18 Winter tyres Golf cabriolet model year 1994 to model year 1997 691
65 19 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 691
65 20 Winter tyres for Golf model year 2004 to model year 2009 692
65 21 Winter tyres for Golf BlueMotion model year 2004 to model year 2009 693
65 22 Winter tyres for Golf GTI model year 2005 to model year 2009 693
65 23 Winter tyres for Pirelli Golf model year 2008 to model year 2009 693
65 24 Winter tyres for Golf R32 model year 2006 to model year 2009 694
65 25 Winter tyres for CrossGolf from model year 2007 694
65 26 Winter tyres for Golf Plus from model year 2005 694
65 27 Winter tyres for Golf Plus BlueMotion from model year 2008 695
65 28 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 695
65 29 Winter tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model year 1999 to model year 2005 696
65 30 Winter tyres for Golf 32 696
65 31 Winter tyres for Golf Anniversary GTI 696
65 32 Winter tyres Golf Variant model year 2007 to model year 2010 697
65 33 Winter tyres for Golf Variant BlueMotion model year 2008 to model year 2010 697
65 34 Winter tyres Jetta Model Year 2006 to Model Year 2011 698
65 35 Winter tyres Jetta BlueMotion Model Year 2008 to Model Year 2011 698
65 36 Winter tyres Golf cabriolet model year 1998 to model year 2002 698
65 37 Winter tyres for New Beetle from model year 1999 699
65 38 Winter tyres for New Beetle Cabriolet from model year 2003 699
65 39 Winter tyres for New Beetle RSi 700
65 40 Winter tyres Passat model year 1994 to model year 1997 700
65 41 Winter tyres Passat model year 1997 to model year 2005 700
65 42 Winter tyres for Passat W8 701
65 43 Winter tyres for Passat Protect 701
65 44 Winter tyres for Passat saloon from model year 2006 701
65 45 Winter tyres for Passat saloon BlueMotion from model year 2008 702
65 46 Winter tyres for Passat Variant from model year 2006 702
65 47 Winter tyres for Passat Variant BlueMotion from model year 2008 703
65 48 Winter tyres for Passat R36 from model year 2008 703
65 49 Winter tyres for Sharan from model year 1996 704
65 50 Winter tyres for Sharan BlueMotion from model year 2009 704
65 51 Winter tyres for Touareg model year 2003 to model year 2010 704
65 52 Winter tyres for Touareg R50 model year 2008 to model year 2010 704
00053201020 Body repairs Volkswagen cars Golf Vento Cabriolet Passat 94 Golf 98 706
Contents 708
1 Safety instructions 710
1 1 Removing components 710
1 2 Battery, welding work 710
1 3 Electronic control units 710
1 3 1 Procedure for handling electronic control units after accident repairs 710
1 4 Paint, glass, upholstery, trim 711
1 5 Fuel tank or fuel pipes 711
1 6 Air conditioner 711
1 6 1 Remedy: 711
1 7 Airbag system 712
1 8 Checking seat belts 712
1 8 1 Checking belt webbing 713
1 8 2 Checking inertia reel (locking effect) 714
1 8 3 Belt lock – visual check 714
1 8 4 Belt lock – functional check 714
1 8 5 Checking belt guides and lock tongues 715
1 8 6 Checking securing parts and anchorage points 715
1 9 Safety regulations for belt tensioners 715
1 10 Body repairs on vehicles fitted with belt tensioners 716
1 10 1 The following list of vehicles are equipped with: 717
1 11 Cutting, straightening and/or panel beating work on vehicles fitted with airbag 717
1 12 Removing front seats with side airbag 717
2 Fundamental instructions 719
2 1 Diagnosis on accident vehicles 719
2 2 Conditions in which body and/or parts are passed for painting 719
2 3 Straightening 719
2 4 Parting cuts 719
2 5 Replacement body sub-parts and part sections 720
2 6 Original joint 720
2 7 Galvanized body parts 720
2 8 Removing remaining material 720
2 9 New parts 721
2 10 Replacement parts 721
3 Symbols 722
3 1 Symbols for welding operations 722
3 2 Symbols for working procedures 722
3 2 1 Grind 722
3 2 2 Offset 723
3 2 3 Punch 723
3 2 4 Drill 723
3 2 5 Grind 724
3 2 6 Cavity preservation 724
3 2 7 Bond 724
3 2 8 Seal 724
4 Body repair tools 725
4 1 Flanging tool V A G1317 725
4 2 Hole punch V A G1329 725
4 3 Basic equipment V A G1366/3 725
4 4 Underseal spray gun V A G1379 725
4 5 Hot air blower V A G1416 726
4 6 Mechanical door tensioner V A G1438 726
4 7 Body equipment trolley V A G1439 726
4 8 Pneumatic sabre saw V A G1523A 726
4 9 Pneumatic hammer V A G1577 727
4 10 Fold crimping tool V A G1585 727
4 11 Local exhaust ventilation unit V A G1586 727
4 12 Spot weld breaker V A G1731 727
4 13 Pneumatic cartridge gun V A G1761/1 728
4 14 Pneumatic punch and offset tool VAS1996 728
4 15 Pneumatic glue gun V A G2005 728
4 16 Door hinge alignment tool 728
4 17 Hose set 5023 729
4 18 Angle grinder VAS5174 729
4 19 Angle grinder VAS5175 729
4 20 Wire brush VAS5182 729
5 Body bonded joints 730
5 1 Transporter 1991 ‰ 730
5 1 1 Separating procedure: 730
5 1 2 Bonding procedure: 730
5 2 Types of bonded joints 730
5 2 1 Joints bonded for strength 730
5 2 2 Spot welded bonded joints 730
5 3 Repair solutions for part section replacement 731
5 3 1 RP spot welding and bonding 731
5 3 2 SG welding and bonding (when spot welding is not possible) 731
5 3 3 Extraction of welding fumes 731
5 3 4 Preparation 731
5 3 5 Supplementary work 731
6 Anti-corrosion measures 732
6 1 Anti-corrosion protection 732
7 Disposal instructions 733
7 1 Disposal 733
7 2 Releasing gas from strut 733
7 3 Airbag 734
7 3 1 Disposal 734
8 Contact corrosion protection 735
8 1 Joining aluminium/magnesium and steel 735
9 Steel sheet repairs 736
9 1 Strengthened steel body panels 736
9 2 Galvanized body parts 737
9 2 1 Preparation 737
9 2 2 Parting cuts 737
9 2 3 Joint techniques 737
9 3 Welding work on galvanized body panels 737
9 3 1 SG inert gas welding of galvanized panels 737
9 3 2 RP welding of galvanized panels 738
9 3 3 Welding transformer 738
9 3 4 Welding clamp 738
9 4 Unbuttoning test 738
10 Aluminium repairs 739
10 1 Paint 739
10 2 Surface preparation 739
10 3 Removing dents 740
10 4 Temperature regulation when heating 740
11 Synthetic material repair procedures 741
11 1 Materials 741
11 2 Repairing dents 743
11 3 Repairing scratches 745
11 4 Repairing cracks (up to 100 mm in length) 746
11 5 Repairing hole (up to 30 mm diameter) 747
11 6 Synthetic material repair (glass fibre materials) 748
11 7 Repair procedures 749
11 7 1 Repairing rupture/hole 749
11 7 2 Repairing damaged surfaces 750
12 Glass repair 751
12 1 Repairing windscreen 751
12 1 1 Prerequisites 751
12 1 2 Special tools, workshop equipment, testers, measuring instruments and auxiliary items requ 752
12 1 3 Description of repair 753
00054005220 Electrical system 756
01 – Self-diagnosis 764
1 – Self-diagnosis 764
1 1 – Self-diagnosis 764
1 2 – Tools 764
1 3 – Connecting fault reader 764
2 – Self-diagnosis of immobilizer 766
2 1 – Self-diagnosis of immobilizer 766
2 2 – Additional information and prerequisites for work requiring the 7-digit PIN 767
2 3 – Performing self-diagnosis of immobilizer 768
2 4 – Reading measured value block 775
2 5 – Adapting ignition keys 778
2 6 – Lost key procedure 783
2 7 – Setting when changing immobilizer control unit (coding control unit) 783
2 8 – Procedure after changing immobilizer control unit 784
2 9 – Procedure after changing engine control unit (Adaption) 787
2 10 – Procedure when immobilizer control unit and engine control unit have been changed 790
2 11 – Procedure for immobilizer malfunctions 791
2 12 – Activating used engine control unit 792
3 – Self-diagnosis of radio systems for Golf Convertible 05 98 > 792
3 1 – Self-diagnosis of radio systems for Golf Convertible 05 98 > 792
3 2 – Self-diagnosis of radio systems 792
3 3 – Final control diagnosis 798
3 4 – Coding radio functions 800
3 5 – Read measured value block 801
27 – Starter, Current supply 803
1 – Battery 803
1 1 – Battery 803
1 2 – Battery handling instructions 803
1 3 – Removing and installing battery 803
1 4 – Visual check 805
1 5 – Checking electrolyte level 805
1 6 – No load voltage measurement 807
1 7 – Checking specific gravity of all cells 808
1 8 – Battery load test 810
1 9 – Battery charging 811
1 10 – Quick charging/starting boost 812
1 11 – Checking main and auxiliary battery, only Ecomatic vehicles 812
2 – Starter 813
2 1 – Starter 813
2 2 – Removing and installing starter 813
3 – Alternator with ribbed belt 818
3 1 – Alternator with ribbed belt 818
3 2 – 4-Cylinder Diesel and petrol engines with power-assisted steering 818
3 3 – Diesel engine with power-assisted steering and air conditioner compressor 820
3 4 – 4-Cylinder injection engine with power-assisted steering and air conditioner compressor 822
3 5 – 6-Cyl petrol engine 824
3 6 – Belt drive 826
3 7 – Checking and adjusting ribbed belt tension 830
3 8 – Removing and installing ribbed belt, 4 cylinder engine 830
3 9 – Removing and installing ribbed belt, 6-Cyl engine 833
3 10 – Checking alternator carbon brushes 834
3 11 – Replacing ribbed belt pulley on alternator 835
3 12 – Removing and installing ribbed belt pulley with freewheel 835
4 – Mechanical cruise control system (CCS) in petrol and diesel engine vehicles (not TDI and SDI) 837
4 1 – Mechanical cruise control system (CCS) in petrol and diesel engine vehicles (not TDI and SDI) 837
4 2 – Assembly overview: Cruise control system (CCS) 837
4 3 – Removing positioning element 840
4 4 – Adjusting positioning element 840
4 5 – Removing and installing vent valve 841
4 6 – Removing and installing CCS control unit (J213) 841
4 7 – Removing and installing CCS vacuum pump (V18) 842
4 8 – Checking vacuum system for leaks 842
5 – Electronic cruise control system (CCS) in vehicles with TDI and SDI engines 843
5 1 – Electronic cruise control system (CCS) in vehicles with TDI and SDI engines 843
90 – Gauges, Instruments 844
1 – Dash panel insert 844
1 1 – Dash panel insert 844
1 2 – Removing and installing dash panel insert 844
1 3 – Renewing bulbs in dash panel insert 846
1 4 – Dash panel insert connector pin assignment 848
1 5 – Ecomatic pin assignment, from August 1995 850
2 – Service interval display 851
2 1 – Service interval display 851
2 2 – Zeroing service interval display 851
2 3 – Setting service interval display 852
2 4 – Flexible service interval display 853
2 5 – Zeroing flexible service interval display 854
2 6 – Entering service interval data 855
91 – Radio, telephone, navigation 857
1 – Radio systems 857
1 1 – Radio systems 857
1 2 – Radio system overview 857
1 3 – Radio system “alpha” 857
1 4 – Radio system “beta” 859
1 5 – Radio system “gamma” 861
1 6 – Radio system “gamma” with active loudspeaker system 865
1 7 – Removing and installing radio >1993 869
1 8 – Removing and installing radio 1994 > 870
1 9 – Electronic anti-theft system for radio units 1994 > 871
1 10 – Activating electronic anti-theft system for radio units 1994 > 872
1 11 – Removing and installing cassette storage box 872
1 12 – Removing and installing CD changer in Golf Convertible 873
2 – Radio systems for Golf Convertible 05 98 > 874
2 1 – Radio systems for Golf Convertible 05 98 > 874
2 2 – Radio system overview 874
2 3 – Radio system “BETA” 875
2 4 – Radio system “GAMMA” 877
2 5 – Removing and installing CD changer 879
2 6 – Removing and installing radio 880
2 7 – Electronic anti-theft system 881
2 8 – Activating electronic anti-theft coding 882
2 9 – Installing radios > 04 98 in vehicles from 05 98 > 882
2 10 – Installing radios of radio generation 05 98 > in vehicles >04 98 884
3 – Loudspeaker system 886
3 1 – Loudspeaker system 886
3 2 – Removing and installing front right treble loudspeaker 886
3 3 – Removing and installing front left treble loudspeaker 886
3 4 – Removing and installing rear bass loudspeakers (2-door) 887
3 5 – Removing and installing rear treble loudspeakers (2-door) 887
3 6 – Removing and installing rear bass loudspeakers (4-door) 888
3 7 – Removing and installing rear treble loudspeakers (4-door) 888
3 8 – Removing and installing front (bass) active loudspeakers 889
3 9 – Removing and installing rear bass speakers with integrated dome type treble speakers (Golf Convertible) 889
4 – Aerial systems 891
4 1 – Aerial systems 891
4 2 – Removing and installing telescopic aerial 891
4 3 – Removing and installing short rod aerial in Golf Convertible 893
4 4 – Removing and installing roof aerial up to Model year 1993 895
4 5 – Removing and installing roof aerial from Model year 1994 > 897
4 6 – Vento window aerial 898
4 7 – Aerial amplifier 899
4 8 – Suppression measures 899
5 – Digital Sound System (DSP), Golf saloon 900
5 1 – Digital Sound System (DSP), Golf saloon 900
5 2 – Removing and installing housing with amplifier and bass loudspeaker 904
5 3 – Removing and installing amplifier 906
5 4 – Removing and installing operating unit in centre console 906
6 – Digital Sound System (DSP), Golf Convertible 908
6 1 – Digital Sound System (DSP), Golf Convertible 908
6 2 – Removing and installing amplifier 911
6 3 – Removing and installing operating unit in centre console 911
6 4 – DSP system in conjunction with “GAMMA” Radio 05 98 > 912
92 – Windscreen wipe and wash system 913
1 – Windscreen wiper system 913
1 1 – Windscreen wiper system 913
1 2 – Windscreen wiper assembly overview 913
1 3 – Adjusting wiper blade rest position 916
1 4 – Removing and installing wiper blade rubber 917
2 – Windscreen washer system 918
2 1 – Windscreen washer system 918
2 2 – Windscreen washer system assembly overview 918
2 3 – Adjusting jets 919
2 4 – Windscreen washer pump connection 920
3 – Rear window wipe and wash system 921
3 1 – Rear window wipe and wash system 921
3 2 – Assembly overview: Rear window wipe and wash system, Golf saloon 921
3 3 – Adjusting rear window wiper rest position 924
4 – Headlight washer system 925
4 1 – Headlight washer system 925
4 2 – Assembly overview: Headlight washer system 925
4 3 – Adjusting jets 927
5 – Headlight washer system for Golf Convertible from March 1998 928
5 1 – Headlight washer system for Golf Convertible from March 1998 928
5 2 – Assembly overview: Headlight washer system 928
5 3 – Adjusting jets 930
5 4 – Removing and installing spray jet retainer 931
5 5 – Removing and installing spray jet lift cylinder 931
94 – Lights, Lamps, Switches – exterior 933
1 – Headlight 933
1 1 – Headlight 933
1 2 – Assembly overview: Headlight 933
1 3 – Adjusting headlights 935
1 4 – Removing and installing headlights 935
1 5 – Removing and installing main and dipped beam bulb 936
1 6 – Removing and installing headlight range control positioning motor 937
1 7 – Assembly overview: Double headlight 938
1 8 – Removing and installing main and dipped beam bulbs 940
2 – Headlight for Golf Convertible from March 1998 941
2 1 – Headlight for Golf Convertible from March 1998 941
2 2 – Assembly overview: Headlight 941
2 3 – Adjusting headlights 944
2 4 – Removing and installing headlights 944
2 5 – Replacing headlight bulb 945
2 6 – Servicing the upper headlight securing lugs 948
2 7 – Removing and installing headlight range control positioning motor 949
2 8 – Converting headlights from driving on right to driving on left and visa versa 950
3 – Front fog lights 951
3 1 – Front fog lights 951
3 2 – Removing and installing front fog lights 952
3 3 – Adjusting foglight 952
3 4 – Removing and installing foglight bulb 953
4 – Front turn signals 953
4 1 – Front turn signals 953
4 2 – Removing front turn signals 954
4 3 – Removing and installing turn signal bulb 954
5 – Side mounted turn signals 955
5 1 – Side mounted turn signals 955
5 2 – Removing and installing side mounted turn signals 955
6 – Tail lights 956
6 1 – Tail lights 956
6 2 – Assembly overview: Tail lights, Golf and Golf Convertible 956
6 3 – Removing tail light bulb holder 957
6 4 – Removing and installing rear light 957
6 5 – Assembly overview: Tail lights, Golf Estate 958
6 6 – Removing tail light bulb holder 959
6 7 – Removing and installing rear light 959
6 8 – Assembly overview: Tail lights, Vento 960
6 9 – Removing tail light bulb holder 962
6 10 – Removing and installing tail light in side panel 962
6 11 – Removing and installing tail light in tailgate 963
7 – Number plate lights 964
7 1 – Number plate lights 964
7 2 – Removing and installing number plate light 964
7 3 – Removing and installing number plate light for Golf Convertible from March 1998 964
8 – Additional brake light 965
8 1 – Additional brake light 965
8 2 – Removing and installing additional brake light for Golf and Golf Estate 965
8 3 – Removing and installing additional brake light for Golf Convertible 966
8 4 – Removing and installing additional brake light for Vento 968
9 – Steering column switch and ignition/starter switch 969
9 1 – Steering column switch and ignition/starter switch 969
9 2 – Removing cover 972
9 3 – Removing horn plate 972
9 4 – Horn contact ring 972
9 5 – Removing and installing horn plate on equipment with driver’s airbag 973
9 6 – Removing turn signal and windscreen wiper switch 973
9 7 – Removing and installing lock cylinder 974
9 8 – Wiring connections on steering column switch 974
96 – Lights, Lamps, Switches – interior 976
1 – Immobilizer 976
1 1 – Immobilizer 976
1 2 – Removing and installing immobilizer 976
1 3 – Removing and installing immobilizer reading coil -D2- 977
1 4 – Retrofitting fuel shut-off valve control unit 978
1 5 – Installing fuel shut-off valve control unit 979
1 6 – Removing fuel shut-off valve control unit 981
1 7 – Adapting fuel cut-off valve control unit to immobilizer control unit 981
1 8 – Immobilizer functional check 984
2 – Servicing anti-theft alarm (ATA) 985
2 1 – Servicing anti-theft alarm (ATA) 985
2 2 – Assembly overview: Anti-theft alarm system (ATA) 986
2 3 – Removing and installing anti-theft alarm system contact switch (F120) 987
2 4 – Removing anti-theft system warning lamp (K 95) 987
2 5 – Removing and installing contact switch in tailgate/anti-theft warning system lock cylinder (F 124) 988
2 6 – Removing and installing anti-theft alarm system horn (H8) 989
2 7 – Removing and installing anti-theft alarm system control unit (J 284) 989
3 – Interior lights and switches 990
3 1 – Interior lights and switches 990
3 2 – Removing and installing sliding roof switch -E8- 990
3 3 – Removing and installing front left door contact switch 990
3 4 – Removing and installing luggage compartment light switch 991
3 5 – Removing and installing luggage compartment light switch for Golf Convertible from March 1998 992
3 6 – Removing and installing front left electric window switch -E40- 992
3 7 – Removing and installing mirror adjustment switch -E43- with mirror adjustment change-over switch -E48- 993
3 8 – Removing and installing light switch 994
3 9 – Removing and installing headlight range control adjuster -E102- 995
3 10 – Removing and installing heated rear window switch 995
3 11 – Removing and installing heated driver’s seat regulating switch -E94- and heated front passenger’s seat regulating switch -E95- 996
3 12 – Removing and installing interior light 997
3 13 – Removing and installing glove box light -W6- 998
3 14 – Removing and installing luggage compartment light -W3- 999
3 15 – Removing and installing hazard warning light switch in Golf Convertible 10 98 > 999
3 16 – Removing and installing hazard warning light switch additional relay in Golf Convertible 10 98 > 1000
97 – Wiring 1002
1 – Relay plate 1002
1 1 – Relay plate 1002
1 2 – Removing and installing relay plate 1002
1 3 – Removing and installing multi-pin plug behind relay plate 1002
00054005320 Heating Air conditioning 1004
01 – Self diagnosis 1008
1 – Self diagnosis of Climatronic 1008
1 1 – Self diagnosis of Climatronic 1008
1 2 – Tools 1008
1 3 – Function 1009
1 4 – Technical data of self diagnosis 1009
1 5 – Test prerequisites for self diagnosis 1009
1 6 – Connecting fault reader V A G 1551 and selecting function 1010
1 7 – Chart of functions that can be selected 1012
1 8 – Interrogating fault memory 1013
1 9 – Fault table 1013
1 10 – Final control diagnosis 1019
1 11 – Read measured value block 1021
1 12 – Erasing fault memory, ending output 1027
80 – Heating 1029
1 – Servicing heating system 1029
1 1 – Servicing heating system 1029
2 – Dismantling and assembling heater 1038
2 1 – Dismantling and assembling heater 1038
3 – Installing and adjusting cables 1042
3 1 – Installing and adjusting cables 1042
4 – Dismantling and assembling heated air and fresh air controls 1046
4 1 – Dismantling and assembling heated air and fresh air controls 1046
5 – Servicing electronic heating control – Thermotronic 1047
5 1 – Tools 1047
87 – Air conditioning 1055
1 – Safety measures for working on air conditioned vehicles and handling refrigerant – R12 1055
1 1 – Safety measures for working on air conditioned vehicles and handling refrigerant – R12 1055
1 2 – Safety precautions for working on air conditioned vehicles and handling refrigerant R12 1055
1 3 – Service work on the air conditioner which can only be carried out in specially-equipped workshops 1057
2 – Refrigerant R12 – Air conditioner with manual controls 1059
2 1 – Refrigerant R12 – Air conditioner with manual controls 1059
2 2 – Servicing air conditioning and heating – Passenger compartment 1059
2 3 – Servicing air conditioning and heating – Engine compartment 1066
2 4 – Installing and adjusting cables 1075
2 5 – Vacuum hose connection diagram 1078
2 6 – Removing and installing compressor bracket – 4 Cyl petrol engine 1081
2 7 – Removing and installing compressor bracket – 6 Cyl petrol engine 1084
3 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 1088
3 1 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 1088
3 2 – Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a 1088
4 – Refrigerant R134a – Air conditioner with manual controls 1090
4 1 – Refrigerant R134a – Air conditioner with manual controls 1090
4 2 – Servicing air conditioning and heating – Passenger compartment 1090
4 3 – Servicing air conditioning and heating – Engine compartment 1098
4 4 – Installing and adjusting cables 1106
4 5 – Vacuum hose connection diagram 1109
4 6 – Removing and installing compressor bracket – 4 Cyl petrol engine 1112
4 7 – Removing and installing compressor bracket – 6 Cyl petrol engine >08 93 1115
4 8 – Removing and installing compressor bracket – 6 Cyl petrol engine 08 93 > 1119
4 9 – Removing and installing compressor bracket – Turbo Diesel engine 1123
4 10 – Removing and installing compressor bracket (“Harrison” compressor with “Diavia” bracket), Engine codes AAM, ADY, ADZ, AEK 1126
5 – Climatronic – Air conditioner with automatic regulation (R134a refrigerant) 1136
5 1 – Climatronic – Air conditioner with automatic regulation (R134a refrigerant) 1136
5 2 – Operation and function of the control and display unit 1136
5 3 – Servicing Climatronic – Passenger compartment 1137
5 4 – Servicing Climatronic – engine compartment 1152
5 5 – Checking and adjusting end position of installed temperature flap positioning motor 1160
5 6 – Vacuum hose connection diagram 1161
6 – Repair work on the refrigerant circuit which can only be carried out by properly trained mechanics (Specialist workshops for air conditioning systems) 1166
6 1 – Repair work on the refrigerant circuit which can only be carried out by properly trained mechanics (Specialist workshops for air conditioning systems) 1166
6 2 – Tools 1166
6 3 – Servicing components in the refrigerant circuit 1167
6 4 – Removing expansion valve 1180
6 5 – Servicing magnetic coupling -N25- when compressor is removed; Manufacturer Sanden 1184
6 6 – Removing and installing condenser 1192
6 7 – Dismantling and assembling evaporator housing 1195
7 – Capacities 1198
7 1 – Capacities 1198
7 2 – Refrigerant R134a 1198
7 3 – Refrigerant oil 1198
00054005720 4 Cyl diesel engine Mechanics 1199
00 – Technical data 1205
1 – Technical data 1205
1 1 – Technical data 1205
1 2 – Engine number 1205
1 3 – Engine data 1205
10 – Removing and installing engine 1207
1 – Removing and installing engine 1207
1 1 – Removing and installing engine 1207
1 2 – Notes on removing 1207
1 3 – Notes on installing 1209
1 4 – Tightening torques 1211
1 5 – Assembly mountings 1211
1 6 – Renewing engine carrier rubber mounting 1212
1 7 – Additional information and removal instructions for vehicles with air conditioner 1213
13 – Crankshaft group 1214
1 – Dismantling and assembling engine 1214
1 1 – Dismantling and assembling engine 1214
1 2 – Removing and installing ribbed belt 1228
1 3 – Removing and installing toothed belt 1231
1 4 – Checking semi-automatic toothed belt tensioning roller 1237
1 5 – Removing single part injection pump sprocket 1237
2 – Removing and installing sealing flange and pressure plate/flywheel/drive plate 1238
2 1 – Removing and installing sealing flange and pressure plate/flywheel/drive plate 1238
2 2 – Renewing crankshaft oil seal – pulley end – 1242
2 3 – Removing and installing drive plate 1243
3 – Removing and installing crankshaft 1247
3 1 – Removing and installing crankshaft 1247
3 2 – Crankshaft dimensions 1250
4 – Dismantling and assembling pistons and conrods 1251
4 1 – Dismantling and assembling pistons and conrods 1251
4 2 – Checking piston projection at TDC 1258
4 3 – Piston and cylinder dimensions 1259
15 – Cylinder head, Valve gear 1260
1 – Removing and installing cylinder head 1260
1 1 – Removing and installing cylinder head 1260
1 2 – Removing and installing cylinder head 1267
1 3 – Checking compressions 1269
2 – Servicing valve gear 1271
2 1 – Servicing valve gear 1271
2 2 – Reworking valve seats 1277
2 3 – Checking valve guides 1279
2 4 – Renewing valve guides 1280
2 5 – Renewing valve stem seals 1280
2 6 – Removing and installing camshaft 1282
2 7 – Checking hydraulic bucket tappets 1284
2 8 – Replacing swirl chambers 1285
17 – Lubrication 1286
1 – Removing and installing parts of the lubrication system 1286
1 1 – Removing and installing parts of the lubrication system 1286
1 2 – Checking oil pressure and oil pressure switch 1293
1 3 – Removing and installing oil sump cap 1294
19 – Cooling system 1295
1 – Removing and installing parts of cooling system 1295
1 1 – Removing and installing parts of cooling system 1295
1 2 – Parts of cooling system body side 1296
1 3 – Parts of cooling system – engine side 1299
1 4 – Dismantling and assembling coolant pump 1302
1 5 – Draining and filling cooling system 1303
1 6 – Removing and installing radiator and radiator fan 1305
20 – Fuel supply system 1307
1 – Removing and installing parts of fuel supply system 1307
1 1 – Removing and installing parts of fuel supply system 1307
1 2 – Removing and installing fuel tank with its attachments, front drive 1308
1 3 – Fuel tank with its attachments, four wheel drive 1311
1 4 – Safety precautions when working on the fuel supply system 1315
1 5 – Rules for cleanliness 1316
1 6 – Removing and installing fuel delivery unit, four wheel drive 1316
1 7 – Servicing accelerator mechanism 1320
1 8 – Servicing cold start accelerator (CSA) operating cable 1322
1 9 – Adjusting CSA operating cable 1323
21 – Charging 1324
1 – Charge air system with turbocharger 1324
1 1 – Charge air system with turbocharger 1324
1 2 – Removing and installing turbocharger with attachments 1324
1 3 – Removing and installing parts of charge air cooling system 1335
1 4 – Rules for cleanliness 1336
1 5 – Turbocharger hose/pipe connections 1337
1 6 – Removing and installing turbocharger 1339
1 7 – Checking turbocharger 1343
1 8 – Checking pressure unit for charge pressure regulating valve 1346
1 9 – Removing and installing pressure unit for charge pressure regulating valve 1347
26 – Exhaust system 1348
1 – Removing and installing parts of exhaust system, front wheel drive 1348
1 1 – Removing and installing parts of exhaust system, front wheel drive 1348
1 2 – Engine code 1Y 1349
1 3 – Front exhaust pipe and catalyst with attachments, engine codes 1Z, AHU, ALE 1351
1 4 – Front exhaust pipe and catalyst with attachments, engine codes AFN, AVG 1352
1 5 – Exhaust manifold, front exhaust pipe and catalyst with attachments, engine code AEY 1353
1 6 – Silencer with mountings, engine codes 1Z, AEY, AFN, AVG, AHU, ALE 1354
1 7 – Engine code AAZ 1357
2 – Removing and installing parts of exhaust system, four wheel drive 1359
2 1 – Removing and installing parts of exhaust system, four wheel drive 1359
2 2 – Front exhaust pipe and catalyst with attachments 1360
2 3 – Silencer with mountings 1362
3 – Exhaust gas recirculation system, engine codes 1Y, AEY 1364
3 1 – Exhaust gas recirculation system, engine codes 1Y, AEY 1364
3 2 – Removing and installing parts of exhaust gas recirculation system 1365
3 3 – Checking exhaust gas recirculation 1366
3 4 – Checking exhaust gas recirculation valve 1367
3 5 – Checking two-way valve 1367
4 – Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z 1368
4 1 – Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z 1368
4 2 – Removing and installing parts of exhaust gas recirculation system 1369
4 3 – Vacuum hose connection diagram 1372
4 4 – Checking exhaust gas recirculation valve (mechanical) 1374
5 – Exhaust gas recirculation system, engine code AAZ 1375
5 1 – Exhaust gas recirculation system, engine code AAZ 1375
5 2 – Removing and installing parts of exhaust gas recirculation system 1376
5 3 – Checking exhaust gas recirculation 1377
5 4 – Checking exhaust gas recirculation valve 1378
5 5 – Checking two-way valve 1378
00054005820 4 cylinder injection engine (2 valve) mechanics 1380
00 – Technical data 1384
1 Engine number 1384
2 Engine data 1385
10 – Removing and installing engine 1387
1 Removing and installing engine 1387
1 1 Notes on removing 1387
1 2 Notes on installing 1388
1 3 Specified torques 1390
1 4 Assembly mountings 1390
1 4 1 Specified torques 1390
1 5 Renewing engine carrier rubber mounting 1391
1 6 Additional information and assembly work for vehicles with air conditioner 1391
13 – Crankshaft group 1393
1 Crankshaft group 1393
1 1 Dismantling and assembling engine 1393
1 1 1 Part I 1394
1 1 2 Part II 1395
1 1 3 Part III 1396
1 2 Removing and installing poly V-belt 1398
1 2 1 Belt drive without tensioning roller 1398
1 2 2 Belt drive with tensioning roller 1398
1 3 Removing, installing and tensioning toothed belt (adjusting valve timing) 1399
1 3 1 Removing 1399
1 3 2 Installing 1400
1 3 3 A – Toothed belt completely removed 1400
1 3 4 B – Toothed belt only removed from camshaft pulley 1401
2 Removing and installing sealing flange and pressure plate/drive plate 1402
2 1 Renewing crankshaft oil seal – pulley end 1404
2 2 Removing and installing drive plate 1406
2 2 1 Loosening and tightening drive plate 1406
2 2 2 Installing drive plate 1407
2 3 Removing and installing crankshaft 1407
2 3 1 Crankshaft dimensions 1408
3 Dismantling and assembling pistons and conrods 1410
3 1 Piston and cylinder dimensions 1412
15 – Cylinder head, valve gear 1413
1 Removing and installing cylinder head 1413
1 1 Removing and installing cylinder head 1414
1 1 1 Removing 1415
1 1 2 Installing 1415
1 2 Checking compression 1416
2 Repairing valve gear 1417
2 1 Assembly overview – valve gear 1417
2 1 1 Checking camshaft axial clearance 1418
2 1 2 Installation position of camshaft bearing caps 1419
2 1 3 Exchange cylinder heads with camshaft bearing shells 1419
2 1 6 Valve timing at 1 mm valve lift 1421
2 2 Reworking valve seats 1421
2 3 Renewing camshaft oil seal 1423
2 4 Removing and installing camshaft 1425
2 4 1 Removing 1425
2 4 2 Installing 1426
2 5 Checking hydraulic bucket tappets 1426
2 6 Checking valve guides 1427
2 7 Renewing valve guides 1427
2 8 Renewing valve stem seals 1428
17 – Lubrication 1429
1 Lubrication 1429
1 1 Removing and installing parts of lubrication system 1429
1 1 1 Oil capacities: 1429
1 1 3 Engine oil specifications: 1429
1 1 4 Assembly overview – parts of lubrication system 1429
1 2 Checking oil pressure and oil pressure switch 1432
19 – Cooling 1433
1 Removing and installing parts of cooling system 1433
1 1 Parts of cooling system, body side 1433
1 2 Parts of cooling system, engine side 1435
1 3 Dismantling and assembling coolant pump 1436
1 4 Draining and filling with coolant 1436
1 4 1 Draining 1436
1 4 2 Filling 1437
1 4 3 With cooling system charge unit -VAS 6096- 1438
1 4 4 Without cooling system charge unit -VAS 6096- 1438
1 4 5 With or without cooling system charge unit -VAS 6096- 1438
1 5 Removing and installing radiator and fan 1438
1 5 1 Removing 1438
1 5 2 Installing 1439
1 5 3 Additional information and assembly work for vehicles with air conditioner 1439
20 – Fuel supply system 1440
1 Removing and installing parts of fuel supply system 1440
1 1 Removing and installing fuel tank with attachments and fuel filter, front-wheel drive 1440
1 2 Removing and installing fuel tank with attachments and fuel filter, four-wheel drive 1443
1 2 1 Installation position of fuel delivery unit flange 1444
1 2 2 Checking breather valve 1444
1 3 Safety precautions when working on fuel supply system 1444
1 4 Rules for cleanliness 1445
1 5 Removing and installing fuel tank, four-wheel drive 1445
1 5 1 Removing 1445
1 5 2 Installing 1448
1 6 Adjusting accelerator cable 1448
1 6 1 Vehicles with automatic gearbox 1448
1 6 2 Vehicles with automatic gearbox or manual gearbox 1448
1 7 Removing and installing fuel delivery unit 1449
1 7 1 Removing 1449
1 7 2 Installing 1449
1 8 Checking fuel pump 1450
1 8 1 Checking function and voltage supply 1450
1 8 2 Checking delivery rate 1451
1 8 3 Checking fuel pump non-return valve 1453
1 9 Removing and installing parts of activated charcoal filter system 1454
1 9 1 Removing and installing parts of activated charcoal filter system (engine codes AAM, ABS, ADZ, ANN, ANP) 1454
1 9 2 Removing and installing parts of activated charcoal filter system (engine codes 2E, ADY, AGG, AKR) 1456
26 – Exhaust system 1457
1 Removing and installing parts of exhaust system, front-wheel drive 1457
1 1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments – engine codes AAM, ABS, ADZ, ANN, ANP 1457
1 2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments – engine codes 2E, ADY, AGG, AKR 1459
1 3 Silencer with mountings – engine codes AAM, ANN 1460
1 4 Silencer with mountings – engine codes ABS, ADZ, ANP 1461
1 5 Silencer with mountings – engine codes 2E, ADY, AGG, AKR 1462
2 Removing and installing parts of exhaust system, four-wheel drive 1464
2 1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments 1464
2 2 Silencer with mountings 1465
00054005920 Digifant Injection and Ignition system (2 valve) 1467
01 – Self diagnosis, Electrical check 1471
1 – Self diagnosis 1471
1 1 – Self diagnosis 1471
1 2 – Function 1471
1 3 – Technical data of self diagnosis 1471
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1472
1 5 – Interrogating and erasing fault memory 1473
1 6 – Fault table 1474
1 7 – Final control diagnosis 1476
2 – Electrical check 1479
2 1 – Electrical check 1479
2 2 – Wiring and component check with test box V A G 1598/18 1479
24 – Mixture preparation, Injection 1484
1 – Digifant injection and ignition system 1484
1 1 – Digifant injection and ignition system 1484
1 2 – Fitting locations overview 1484
1 3 – Servicing injection part 1486
1 4 – Safety precautions 1502
1 5 – Rules for cleanliness 1503
1 6 – Technical data 1503
1 7 – Idling check 1503
1 8 – Checking Lambda probe and Lambda control 1506
1 9 – Checking acceleration/full throttle enrichment and overrun cut-off 1508
1 10 – Checking engine operating mode 1509
1 11 – Checking throttle valve potentiometer 1510
1 12 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 1512
1 13 – Checking coolant temperature sender 1512
1 14 – Checking intake air temperature sender 1513
1 15 – Checking air mass meter potentiometer 1515
1 16 – Checking control unit voltage supply 1517
1 17 – Checking fuel pressure regulator and holding pressure 1518
1 18 – Checking cold start valve 1520
1 19 – Removing and installing injectors 1522
1 20 – Checking injectors 1523
1 21 – Checking intake air system for leaks (unmetered air) 1525
1 22 – Checking intake air preheating 1526
1 23 – Basic throttle valve setting 1527
1 24 – Vacuum hose connection diagram 1528
28 – Ignition system 1532
1 – Digifant injection and ignition system 1532
1 1 – Digifant injection and ignition system 1532
1 2 – Servicing ignition part 1532
1 3 – Safety precautions 1535
1 4 – Test data, spark plugs 1536
1 5 – Installing distributor 1536
1 6 – Checking ignition timing control 1537
1 7 – Checking Hall sender 1538
1 8 – Checking ignition transformer 1539
1 9 – Checking ignition transformer output stage 1540
00054006020 Mono Motronic injection and ignition system 1542
01 – Self-diagnosis 1546
1 – Self-diagnosis 1546
1 1 – Self-diagnosis 1546
1 2 – Function 1546
1 3 – Technical data of self-diagnosis 1546
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1547
1 5 – Interrogating fault memory 1549
1 6 – Fault table 1550
1 7 – Erasing fault memory 1552
1 8 – Final control diagnosis 1553
1 9 – Coding control unit 1556
1 10 – Erasing values learnt by engine electronics control unit 1557
1 11 – Read measured value block and basic settings 1558
1 12 – Display group overview 1558
24 – Mixture preparation, Injection 1561
1 – Mono-Motronic injection and ignition system 1561
1 1 – Mono-Motronic injection and ignition system 1561
1 2 – Fitting locations overview 1561
1 3 – Servicing injection part 1564
1 4 – Servicing injection unit 1573
1 5 – Safety precautions 1579
1 6 – Rules for cleanliness 1580
1 7 – Technical data 1580
1 8 – Idling speed check 1580
1 9 – Checking Lambda probe and Lambda control 1581
1 10 – Checking Lambda probe heating 1583
1 11 – Checking engine operating mode 1584
1 12 – Checking overrun cut-off 1586
1 13 – Checking throttle valve positioner 1586
1 14 – Checking and adjusting idling switch 1588
1 15 – Checking sender for throttle valve positioner 1592
1 16 – Checking throttle valve potentiometer 1594
1 17 – Checking coolant temperature sender 1596
1 18 – Checking intake air temperature sender 1599
1 19 – Checking injector 1604
1 20 – Testing speed signal 1606
1 21 – Checking control unit voltage supply 1607
1 22 – Checking air conditioner and air conditioner compressor signals 1608
1 23 – Matching engine electronic control unit to electronic immobilizer 1610
1 24 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 1611
1 25 – Checking signal for automatic gearbox control unit 1611
1 26 – Checking fuel pressure regulator and holding pressure 1612
1 27 – Checking intake air system for leaks (unmetered air) 1615
1 28 – Checking intake air preheating 1616
28 – Ignition system 1618
1 – Mono-Motronic injection and ignition system 1618
1 1 – Mono-Motronic injection and ignition system 1618
1 2 – Servicing ignition part 1618
1 3 – Safety precautions 1621
1 4 – Adjustment data, Spark plugs 1622
1 5 – Installing distributor 1622
1 6 – Checking and adjusting ignition timing 1623
1 7 – Checking ignition timing control 1625
1 8 – Checking Hall sender 1625
1 9 – Checking ignition transformer 1627
1 10 – Checking ignition transformer output stage 1627
00054006220 Running gear 1630
00 – Technical data 1636
1 Technical data 1636
1 1 Running gear 1636
1 2 Wheels, tyres 1636
1 3 Steering 1636
1 4 Braking 1636
1 4 1 Vehicles with front brake discs ∅ 239 mm and rear brake drums 1636
1 4 2 Vehicles with front brake discs ∅ 256 mm and rear brake drums 1637
1 4 3 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 1638
1 4 4 Vehicles with front brake discs ∅ 256 mm and rear brake drums 1638
1 4 5 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 1639
1 4 6 Vehicles with front brake discs ∅ 239 mm and rear brake drums 1639
1 4 7 Vehicles with front brake discs ∅ 239 mm and rear brake drums 1639
1 4 8 Vehicles with front brake discs ∅ 256 mm and rear brake drums 1640
1 4 9 Vehicles with front brake discs ∅ 239 mm and rear brake drums 1640
1 4 10 Vehicles with front brake discs ∅ 256 mm and rear brake drums 1640
1 4 11 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 1641
1 4 12 Vehicles with front brake discs ∅ 239 mm and rear brake drums 1641
1 4 13 Vehicles with front brake discs ∅ 256 mm and rear brake drums 1642
1 4 14 Vehicles with front brake discs ∅ 288 mm and rear brake discs ∅ 239 mm 1642
1 4 15 Vehicles with Plus running gear 1642
1 4 16 Vehicles with front brake discs ∅ 280 mm and rear brake discs ∅ 226 mm 1642
1 4 17 Vehicles with Plus running gear 1643
1 4 18 Vehicles with front brake discs ∅ 288 mm and rear brake discs ∅ 226 mm 1643
40 – Front suspension 1644
1 Repairing front suspension (basic running gear) 1644
1 1 Removing and installing subframe, anti-roll bar and suspension link (basic running gear) 1645
1 1 1 Modified bonded rubber bush in suspension link 1648
1 2 Allocation of anti-roll bar to Golf/Vento basic running gear 1648
1 3 Checking swivel joint 1649
1 3 1 Checking axial play 1649
1 3 2 Checking radial play 1649
1 4 Reworking cap nut in longitudinal member 1649
1 5 Removing and installing wheel bearing, suspension strut, drive shaft (basic running gear) 1650
1 6 Removing and installing drive shaft, vehicles with automatic gearbox 1654
1 6 1 Removing right drive shaft 1654
1 6 2 Removing left drive shaft: 1654
1 6 3 Installing 1655
1 7 Repairing front suspension strut (basic running gear) 1655
1 8 Allocation of suspension strut mounting to vehicle 1657
2 Repairing front suspension (Plus running gear) 1658
2 1 Removing and installing subframe, anti-roll bar and suspension link (Plus running gear) 1659
2 2 Removing and installing swivel joint 1661
2 2 1 Removing 1661
2 2 2 Installing 1662
2 3 Allocation of anti-roll bar to Golf/Vento Plus running gear 1662
2 4 Removing and installing wheel bearing, suspension strut (Plus running gear) 1662
2 5 Repairing front suspension strut (Plus running gear) 1666
2 6 Modified suspension strut from 06 93, vehicles with Plus running gear 1667
2 6 1 Determining the part number on coil springs 1668
2 7 Removing and installing drive shaft (Plus running gear), vehicles with bonded drive shaft 1668
2 7 1 Removing 1668
2 7 2 Installing 1669
2 7 3 Specified torques: 1669
2 8 Removing and installing drive shaft with triple roller joint 1670
2 8 1 Removing right drive shaft 1670
2 8 2 Removing left drive shaft: 1670
2 8 3 Installing 1671
2 9 Wheel hubs with compressed splines, vehicles with Plus running gear 1671
2 10 Removing and installing drive shafts on vehicles with compressed splines in the wheel hub 1672
2 10 1 Removing 1672
2 10 2 Installing 1672
2 10 3 Specified torque: 1673
3 Repairing drive shaft 1674
3 1 Checking outer constant velocity joint 1679
3 1 1 Removing 1679
3 1 2 Installing 1680
3 2 Checking inner constant velocity joint 1680
3 2 1 Installing 1681
3 2 2 Checking function of constant velocity joint 1682
3 3 Repairing drive shaft with triple roller joint 1682
3 4 Dismantling and assembling triple roller joint 1683
3 4 1 Dismantling 1683
3 4 2 Assembling 1685
42 – Rear suspension 1687
1 Repairing rear axle (front-wheel drive vehicles) 1687
1 1 Repairing rear axle 1687
1 2 Removing and installing bonded rubber bush 1689
1 2 1 Removing 1689
1 2 2 Installing 1691
1 3 Track width change on Golf/Vento from 08 93 – model year 1994 1693
1 4 Modified weld studs on rear axle 1694
1 4 1 Rear axle for Golf/Vento up to July 1994 1694
1 4 2 Rear axle for Golf/Vento from August 1994 1695
1 5 Reworking cap nut in longitudinal member, vehicles with front-wheel drive 1695
1 6 Allocation of rear axle assembly and anti-roll bar 1696
1 7 Dismantling and assembling suspension strut 1696
1 8 Removing and installing rear axle, Golf Variant 1698
1 8 1 Removing 1698
1 8 2 Installing 1699
1 9 Assembly overview: Rear axle, Golf Variant 1699
1 10 Removing and installing bonded rubber bush 1701
1 10 1 Removing 1702
1 10 2 Installing 1704
1 11 Modified weld studs on rear axle, Golf Variant 1706
1 11 1 Rear axle for Golf Variant up to July 1994 1706
1 11 2 Rear axle for Golf Variant from August 1994 1707
1 12 Modified rear axle for Golf Variant 1708
1 13 Removing and installing rear shock absorber, Golf Variant 1709
1 13 1 Removing 1709
1 13 2 Installing 1709
1 14 Dismantling and assembling shock absorber, Golf Variant 1710
2 Repairing rear axle (vehicles with four-wheel drive) 1712
2 1 Assembly overview – rear axle, vehicles with four-wheel drive 1712
2 2 I – Assembly overview – rear axle assembly 1713
2 3 II – Assembly overview – suspension link 1716
2 4 Removing and installing rear axle 1718
2 4 1 Removing 1718
2 4 2 Installing 1720
2 5 Determining installation position with bonded rubber bush removed 1720
2 6 Reworking cap nut in longitudinal member, vehicles with four-wheel drive 1720
3 Repairing wheel bearing 1722
3 1 Repairing wheel bearing, vehicles with front-wheel drive – drum brakes 1722
3 2 Repairing wheel bearing, vehicles with front-wheel drive – disc brakes 1725
3 3 Repairing wheel bearings, vehicles with four-wheel drive – drum brakes 1729
3 4 Repairing wheel bearing, vehicles with four-wheel drive – disc brakes 1732
44 – Wheels, tyres, vehicle geometry 1736
1 Wheel alignment 1736
1 1 Test prerequisites: 1736
1 2 Specifications for wheel alignment, vehicles with front and four-wheel drive 1736
1 3 Adjusting front wheel camber 1738
1 4 Calculating the direction of travel: 1738
45 – Anti-lock brake system 1739
1 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL) Teves 04 1739
1 1 Notes for repairs on ABS, ABS/EDL 1739
1 2 Removing and installing control unit 1740
1 2 1 Location 1740
1 2 2 Removing 1740
1 2 3 Installing 1740
1 3 Removing and installing speed sensor and speed sensor rotor 1740
1 3 1 Speed sensor 1740
1 3 2 Rotors 1740
1 3 3 Front axle 1740
1 3 4 Rear axle 1740
2 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04 – LHD 1742
2 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, LHD 1742
2 2 Modified Teves 04 ABS/EDL units 1743
2 3 Removing and installing hydraulic unit, LHD 1744
2 3 1 Removing 1744
2 3 2 Installing 1744
2 4 Removing and installing brake pedal position sender, LHD 1745
2 4 1 Removing 1745
2 4 2 Installing 1746
3 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04, RHD 1747
3 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, RHD 1747
3 2 Removing and installing hydraulic unit, RHD 1750
3 2 1 Removing 1750
3 2 2 Installing 1750
3 3 Removing and installing brake pedal position sender, RHD 1751
3 3 1 Removing 1751
3 3 2 Installing 1751
4 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL), Teves 20 GI 1753
4 1 General information on this ABS 1753
4 2 Notes for repairs on ABS, ABS/EDL 1753
4 3 Removing and installing control unit and hydraulic unit 1754
4 3 3 Removing 1755
4 3 4 Installing 1756
5 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 20 GI – LHD 1757
5 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, LHD 1757
6 Assembly overview – hydraulic unit Teves 20 Gl, RHD 1758
6 1 Assembly overview – hydraulic unit Teves 20 Gl, RHD 1758
7 Initiating basic setting, vehicles with ABS/EDL 1760
46 – Brakes – mechanism 1761
1 Repairing front brakes 1761
1 1 Repairing front brakes, brake caliper VW II 1761
1 2 Removing and installing brake pads/brake calipers 1763
1 2 1 Removing 1763
1 2 2 Installing 1763
1 3 Removing and installing brake pads/brake calipers as of model year 1996 (T) 1764
1 3 1 Removing 1764
1 3 2 Installing 1764
1 4 Repairing front brakes, Girling brake caliper 1765
1 5 Removing and installing brake pads or linings 1767
1 5 1 Removing 1767
1 5 2 Installing 1768
1 6 Repairing front brakes, Teves/ATE 1768
1 7 Removing and installing brake pads or linings 1770
1 7 1 Removing 1770
1 7 2 Installing 1771
2 Repairing rear brakes (drum brakes) 1773
2 1 Removing and installing rear brakes 1773
2 2 Removing and installing impulse rotor 1774
2 2 1 Removing 1774
2 2 2 Installing 1774
2 3 Repairing rear brakes 1774
2 4 Removing and installing brake shoes 1776
2 4 1 Removing 1776
2 4 2 Installing 1777
2 5 Adjusting handbrake 1777
3 Repairing rear brakes (disc brakes) 1779
3 1 Repairing rear brakes (disc brakes) 1779
3 2 Modified brake caliper 1781
3 3 Removing and installing brake pads or linings 1781
3 3 1 Removing 1781
3 3 2 Installing 1782
3 4 Adjusting handbrake 1783
4 Assembly overview – handbrake lever 1784
47 – Brakes – hydraulics 1785
1 Assembly overview – brake servo/brake master cylinder 1785
1 1 Ecomatic vacuum supply 1786
1 2 Assembly overview: pedal cluster, brake pedal 1787
1 3 Separating brake pedal from, and clipping to, brake servo 1788
1 3 1 Separating brake pedal from brake servo 1788
1 3 2 Clipping brake pedal to brake servo 1789
1 4 Removing and installing brake pedal 1789
1 4 1 Removing 1789
1 4 2 Installing 1789
2 Removing and installing brake servo/brake master cylinder, RHD 1790
2 1 Removing and installing brake servo/brake master cylinder, RHD 1790
2 1 1 Removing 1790
2 1 2 Installing 1790
3 Repairing front brake caliper, brake caliper VW II 1791
3 1 Removing and installing front brake caliper piston 1792
3 1 1 Removing 1792
3 1 2 Installing 1792
4 Repairing Girling front brake calipers 1794
4 1 Assembly overview – Girling front brake calipers 1794
4 2 Removing and installing front brake caliper piston 1795
4 2 1 Removing 1795
4 2 2 Installing 1795
5 Repairing rear brake caliper 1797
5 1 Removing and installing rear brake caliper piston 1798
5 1 1 Removing: 1798
5 1 2 Reworking wedge -V A G 1474/5- 1798
5 1 3 Installing: 1799
5 1 4 Pre-bleeding brake caliper 1799
6 Checking and adjusting brake pressure regulator 1800
6 1 Checking and adjusting brake pressure regulator, load-dependent 1800
6 2 Specifications for load dependent brake pressure regulator 1800
6 2 1 Adjusting regulator 1801
6 3 Checking brake pressure regulator, pressure-dependent 1801
7 Bleeding brake system on vehicles with and without ABS or ABS/EDL 1803
7 1 Bleeding brake system 1803
7 1 1 Notes 1803
7 1 2 Bleeding brake system with brake filling and bleeding unit -VW 1238/1- or -V A G 1238 B- 1803
7 2 Bleeding brake system without brake filling and bleeding unit 1804
48 – Steering 1805
1 Assembly overview: steering column, column tube, steering wheel and airbag steering wheel 1805
1 1 Modified teeth on steering rack steering pinion and steering column drive shaft 1807
1 2 Assembly overview: Steering wheel with airbag 1808
1 3 Removing and installing airbag module 1809
1 3 1 Removing 1809
1 3 2 Installing 1810
1 4 Removing and installing steering wheel with airbag 1810
1 4 1 Removing 1810
1 4 2 Installing steering wheel 1811
1 5 Removing and installing coil connector with slip ring 1811
1 6 Removing and installing column tube for height adjustable steering wheel 1812
2 Assembly overview: mechanical steering rack 1813
2 1 Adjusting steering rack 1814
2 2 Removing and installing mechanical (manual) steering rack 1815
2 2 1 Removing 1815
2 2 2 Installing 1815
2 3 Bolting track rod onto steering rack 1816
2 3 1 Checking track rod length and adjusting if necessary 1817
3 Repairing power steering 1818
3 1 Checking pump delivery pressure 1818
3 2 Checking function of steering hydraulics pump -V119-, Ecomatic 1819
3 3 Checking delivery pressure of steering hydraulics pump -V119-, Ecomatic 1819
3 4 Removing and installing steering hydraulics pump -V119-, Ecomatic 1820
3 4 1 Removing 1820
3 4 2 Installing 1821
3 4 3 Filling steering system with hydraulic fluid 1821
3 5 Removing and installing power steering rack 1821
3 5 1 Removing 1822
3 5 2 Installing 1822
3 6 Assembly overview – power steering rack (TRW) 1823
3 7 Modified teeth on steering rack steering pinion and steering column drive shaft 1825
3 8 Modified track rod ball joint for Golf Variant, Golf convertible 1825
3 9 Removing and installing track rod (TRW and ZF power steering rack) 1826
3 9 1 Removing 1826
3 9 2 Installing 1827
3 10 Checking and/or adjusting left-hand track rod length 1827
3 10 1 Installing boots 1827
3 11 Repairing TRW power steering 1828
3 12 Dismantling and assembling power steering rack (TRW) 1831
3 12 1 Assembling 1834
3 13 Adjusting power steering rack when installed 1840
3 14 Adjusting power steering rack with new steering rack (TRW) 1841
3 15 Assembly overview – power steering rack (ZF) 1842
3 16 Repairing ZF power assisted steering rack 1845
3 17 Dismantling and assembling power assisted steering rack (ZF) 1847
3 17 1 Dismantling 1847
3 17 2 Assembling 1851
3 18 Adjusting power steering rack (ZF) 1857
4 Assembly overview: vane pump, reservoir and hydraulic lines 1858
4 1 Assembly overview: steering hydraulics pump -V119-, hydraulic lines, Ecomatic 1859
4 2 Removing and installing power steering vane pump, vehicles with 1 4 l engine 1862
4 3 Removing and installing poly-V belt 1863
4 4 Removing and installing power steering vane pump, vehicles with 1 8l, 1 9l, 2 0l engine 1864
4 5 Installing vane pump 1865
4 6 Tensioning V-belt 1866
4 7 Removing and installing power-assisted steering vane pump, vehicles with 128 kW engine 1867
00054006620 4 and 5 speed manual gearbox 020 02K 1869
00 – Technical data 1873
1 Identification of gearbox 1873
1 1 Location on gearbox 1873
1 2 Code letters, allocation, ratios, capacities 1874
2 Overview – power transmission 1884
3 Calculating overall gear ratio “i” 1886
4 General repair instructions 1887
4 1 Components 1887
4 1 1 Gearbox 1887
4 1 2 Gaskets and seals 1887
4 1 3 Locking devices 1888
4 1 4 Nuts and bolts 1888
4 1 5 Bearings 1888
4 1 6 Shims 1888
4 1 7 Synchro-rings 1888
4 1 8 Gear wheels 1889
30 – Clutch 1890
1 Repairing clutch mechanism 1890
1 1 Repairing clutch mechanism in Ecomatic vehicles 1890
1 2 Assembly overview – pedals – hydraulic and mechanical clutch mechanism 1891
1 3 Removing and installing over-centre spring 1892
1 3 1 Removing 1892
1 3 2 Installing 1893
1 4 Removing and installing clutch pedal 1893
1 4 1 Removing from vehicles with hydraulic clutch mechanism 1894
1 4 2 Removing from vehicles with mechanical clutch mechanism 1894
1 4 3 Installing in vehicles with hydraulic clutch mechanism 1894
1 4 4 Installing in vehicles with mechanical clutch mechanism 1895
1 5 Assembly overview – hydraulic system 1895
1 6 Removing and installing master cylinder 1897
1 6 1 Removing 1898
1 6 2 Installing 1899
1 7 Bleeding clutch system 1899
1 8 Assembly overview – mechanics 1900
1 9 Removing and installing clutch cable 1901
1 10 Checking function of clutch cable 1902
1 10 1 Returning adjustment mechanism of clutch cable to functional condition 1903
2 Repairing clutch mechanism – Ecomatic 1905
2 1 Assembly overview – Ecomatic 1905
2 2 Removing and installing clutch actuator 1907
2 2 1 Removing 1907
2 2 2 Installing 1909
2 3 Clutch mechanism/servo-assistance vacuum system 1910
2 3 1 Removing clutch system pressure switch -F210- 1911
2 3 2 Removing vacuum reservoir 1912
2 4 Checking clutch mechanism/servo-assistance vacuum system for leaks 1912
2 4 1 Checking overall system – vehicles ► March 94: 1913
2 4 2 Checking overall system – vehicles March 94 ► 1916
3 Repairing clutch 1918
3 1 Removing and installing clutch 1919
3 1 1 Removing 1920
3 1 2 Installing 1921
34 – Controls, housing 1923
1 Repairing selector mechanism 1923
1 1 Installation position of selector mechanism 1923
1 2 Assembly overview – selector housing and gear lever 1925
1 2 1 Installing selector lever gaiter 1926
1 2 2 Retaining plate installation position 1927
1 3 Removing and installing gear shift switch -F191- 1927
1 3 1 Removing 1928
1 3 2 Installing 1928
1 4 Assembly overview – gear selector relay points on gearbox 1928
1 5 Adjusting selector mechanism 1931
1 5 1 Adjusting 1931
1 5 2 Function 1932
1 5 3 Fine adjustment 1932
1 6 Removing and installing selector lever and selector rod 1933
1 6 1 Removing 1933
1 6 2 Installing 1934
2 Removing and installing gearbox 1935
2 1 Removing gearbox 1935
2 1 1 Transporting gearbox 1941
2 2 Install gearbox 1941
2 2 1 Specified torques 1942
3 Checking or topping up gear oil 1945
3 1 Checking gear oil 1945
4 Dismantling and assembling gearbox 1946
4 1 Overview – gearbox 1946
4 2 Assembly overview 1947
4 3 Part I – Removing and installing cover for gearbox housing and 5th gear 1948
4 4 Part II – Dismantling and assembling gearbox housing and selector mechanism 1949
4 5 Part III – Removing and installing input shaft, output shaft, differential and selector forks 1950
4 6 Assembly sequence 1952
4 6 1 Removing and installing cover, gearbox housing, selector shaft, input shaft, output shaft, differential, selector forks 1952
5 Repairing clutch housing 1969
6 Repairing gearbox housing and selector shaft 1975
7 Repairing gearbox housing cover 1980
35 – Gears, shafts 1986
1 Dismantling and assembling input shaft 1986
2 Dismantling and assembling output shaft 1994
2 1 Allocation/output shafts 2001
3 Output shaft 2002
3 1 Adjusting output shaft 2002
3 1 1 Determining thickness of shim 2004
3 1 2 Checking friction torque 2004
39 – Final drive – rear differential 2006
1 Removing and installing drive flange seals (gearbox installed) 2006
1 1 Removing 2007
1 2 Installing 2008
2 Differential 2009
2 1 Dismantling and assembling differential 2009
2 1 1 Adjustment overview 2016
2 2 Adjusting differential 2016
2 2 1 Determining shim S1 thickness 2018
00054007220 Running gear self diagnosis for ABS 2020
01 – Self-diagnosis, Electrical check 2024
1 – Self-diagnosis function, ITT Mark 04 2024
1 1 – Self-diagnosis function, ITT Mark 04 2024
1 2 – Function 2024
1 3 – Distinguishing features of ABS and the ABS/EDL, ITT Mark 04 2025
1 4 – Technical data of self-diagnosis 2027
1 5 – Safety precautions and fundamental points regarding fault finding 2027
1 6 – Fault finding with fault reader V A G 1551 on ABS, ITT Mark 04 and ABS/EDL ITT Mark 04 (flow chart) 2028
2 – Electrical/electronic components and fitting locations 2029
2 1 – Electrical/electronic components and fitting locations 2029
3 – Executing self diagnosis 2034
3 1 – Executing self diagnosis 2034
3 2 – Test prerequisites for self-diagnosis 2035
3 3 – Connecting fault reader V A G 1551 and selecting function 2035
3 4 – List of selectable functions 2038
3 5 – Interrogating fault memory 2038
3 6 – Fault table 2039
3 7 – Erasing fault memory, ending output 2044
4 – Electrical check of the ABS and ABS/EDL ITT Mark 04 2045
4 1 – Electrical check of the ABS and ABS/EDL ITT Mark 04 2045
4 2 – Test prerequisites 2045
4 3 – Contact assignment of multi-pin connector 2046
4 4 – Fault table 2049
4 5 – Removing and installing control unit 2062
4 6 – Adjusting brake light switch 2063
5 – Self-diagnosis function ITT Mark 20 GI 2063
5 1 – Self-diagnosis function ITT Mark 20 GI 2063
5 2 – Function 2063
5 3 – Distinguishing features of ABS ITT Mark 20 GI and the ABS/EDL ITT Mark 20 GI 2064
5 4 – Technical data of self-diagnosis 2066
5 5 – Safety precautions and fundamental points regarding fault finding 2066
5 6 – Fault finding with fault reader V A G 1551 on ABS and ABS/EDL ITT Mark 20 (flow chart) 2067
6 – Electrical/electronic components and fitting locations 2068
6 1 – Electrical/electronic components and fitting locations 2068
7 – Faults displayed by warning lamps K47 and K118 2072
7 1 – Faults displayed by warning lamps K47 and K118 2072
7 2 – Vehicle with ABS/EDL has no EDL function 2073
8 – Executing self diagnosis 2073
8 1 – Executing self diagnosis 2073
8 2 – Test prerequisites for self-diagnosis 2073
8 3 – List of selectable functions 2073
8 4 – Connecting fault reader V A G 1551 and selecting functions 2074
8 5 – Interrogating fault memory 2076
8 6 – Fault table 2077
8 7 – Erasing fault memory, ending output 2079
8 8 – Coding control unit 2080
8 9 – Read measured value block 2081
8 10 – Final control diagnosis 2084
8 11 – Initiating basic setting 2091
9 – Electrical check of the ABS and ABS/ EDL ITT Mark 20 GI 2096
9 1 – Electrical check of the ABS and ABS/ EDL ITT Mark 20 GI 2096
9 2 – Test prerequisites 2096
9 3 – Multi-pin connector with contact assignment 2097
9 4 – Test table 2098
9 5 – Adjusting brake light switch 2102
00054007320 4 Cyl injection engine (cross flow cylinder head) Mechanics 2104
00 – Technical data 2108
1 – Technical data 2108
1 1 – Technical data 2108
1 2 – Engine number 2108
1 3 – Engine data 2108
10 – Removing and installing engine 2110
1 – Removing and installing engine 2110
1 1 – Removing and installing engine 2110
1 2 – Notes on removing 2111
1 3 – Notes on installing 2113
1 4 – Tightening torques 2114
1 5 – Assembly mountings 2115
1 6 – Replacing engine carrier rubber mounting 2117
1 7 – Additional information and removal instructions for vehicles with air conditioner 2118
13 – Crankshaft group 2120
1 – Dismantling and assembling engine 2120
1 1 – Dismantling and assembling engine 2120
1 2 – Removing and installing ribbed belt 2135
1 3 – Removing and installing toothed belt 2138
2 – Removing and installing sealing flange and pressure plate/drive plate 2142
2 1 – Removing and installing sealing flange and pressure plate/drive plate 2142
2 2 – Renewing crankshaft oil seal -pulley side- 2146
2 3 – Removing and installing drive plate 2149
3 – Removing and installing crankshaft 2152
3 1 – Removing and installing crankshaft 2152
3 2 – Crankshaft dimensions 2154
4 – Dismantling and assembling pistons and conrods 2155
4 1 – Dismantling and assembling pistons and conrods 2155
4 2 – Piston and cylinder dimensions 2161
15 – Cylinder head, Valve gear 2162
1 – Removing and installing cylinder head 2162
1 1 – Removing and installing cylinder head 2162
1 2 – Removing and installing cylinder head 2169
1 3 – Checking compressions 2171
2 – Servicing valve gear 2173
2 1 – Servicing valve gear 2173
2 2 – Reworking valve seats 2179
2 3 – Removing and installing camshaft oil seal 2182
2 4 – Removing and installing camshaft 2184
2 5 – Checking hydraulic bucket tappets 2186
2 6 – Checking valve guides 2187
2 7 – Renewing valve guides 2188
2 8 – Renewing valve stem seals 2190
17 – Lubrication 2193
1 – Removing and installing parts of the lubrication system 2193
1 1 – Removing and installing parts of the lubrication system 2193
1 2 – Checking oil pressure and oil pressure switch 2200
19 – Cooling system 2202
1 – Removing and installing parts of cooling system 2202
1 1 – Removing and installing parts of cooling system 2202
1 2 – Parts of cooling system body side 2203
1 3 – Parts of cooling system – engine side 2209
1 4 – Dismantling and assembling coolant pump 2216
1 5 – Draining and filling cooling system 2218
1 6 – Removing and installing radiator and radiator fan 2220
20 – Fuel supply system 2222
1 – Removing and installing parts of fuel supply system 2222
1 1 – Removing and installing parts of fuel supply system 2222
1 2 – Removing and installing fuel tank with its attachments and fuel filter 2223
1 3 – Safety precautions when working on the fuel supply system 2228
1 4 – Rules for cleanliness 2229
1 5 – Adjusting throttle cable 2229
1 6 – Removing and installing fuel delivery unit 2232
1 7 – Checking fuel pump 2234
1 8 – Crash fuel shut-off 2235
2 – Activated charcoal filter system 2239
2 1 – Activated charcoal filter system 2239
2 2 – Function 2239
2 3 – Servicing parts of the activated charcoal filter system 2241
2 4 – Checking activated charcoal filter solenoid valve 1 2246
2 5 – Checking fuel tank breather 2248
26 – Exhaust system 2251
1 – Removing and installing parts of exhaust system 2251
1 1 – Removing and installing parts of exhaust system 2251
1 2 – Exhaust manifold, front exhaust pipe and catalyst with attachments 2251
1 3 – Silencer with mountings 2255
1 4 – Checking catalyst 2257
2 – Secondary air system 2259
2 1 – Secondary air system 2259
2 2 – Function 2259
2 3 – Removing and installing parts of the secondary air system 2260
2 4 – Checking combi-valve 2263
2 5 – Checking secondary air pump motor 2265
2 6 – Checking secondary air inlet valve 2266
00054007420 Motronic injection and ignition system (4 Cyl engine) 2268
01 – Self diagnosis, Electrical check 2272
1 – Self diagnosis 2272
1 1 – Self diagnosis 2272
1 2 – Function 2272
1 3 – Technical data of self diagnosis 2272
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2273
1 5 – Interrogating fault memory 2274
1 6 – Fault table 2274
1 7 – Erasing fault memory 2280
1 8 – Final control diagnosis 2281
1 9 – Reading measuring value block 2284
1 10 – Display group overview 2284
2 – Electrical check 2286
2 1 – Electrical check 2286
2 2 – Wiring and component check with test box V A G 1598/18 2286
24 – Mixture preparation, Injection 2293
1 – Motronic injection and ignition system 2293
1 1 – Motronic injection and ignition system 2293
1 2 – Fitting locations overview 2293
1 3 – Servicing injection part 2296
1 4 – Dismantling and assembling intake manifold – upper part 2304
1 5 – Dismantling and assembling intake manifold – lower part 2307
1 6 – Dismantling and assembling air cleaner 2308
1 7 – Safety precautions 2309
1 8 – Rules for cleanliness 2310
1 9 – Technical data 2310
1 10 – Idling check 2310
1 11 – Checking idling stabilization 2311
1 12 – Checking Lambda probe and Lambda control 2313
1 13 – Checking engine operation 2315
1 14 – Checking throttle valve potentiometer 2316
1 15 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 2317
1 16 – Checking intake manifold temperature sender 2318
1 17 – Checking coolant temperature sender 2319
1 18 – Checking speed signal 2320
1 19 – Matching engine electronic control unit to electronic immobilizer 2321
1 20 – Checking fuel pressure regulator and holding pressure 2322
1 21 – Checking injectors 2324
1 22 – Checking intake air system for leaks (outside air) 2326
1 23 – Checking intake air preheating 2327
28 – Ignition system 2329
1 – Motronic injection and ignition system 2329
1 1 – Motronic injection and ignition system 2329
1 2 – Servicing ignition part 2329
1 3 – Safety precautions 2333
1 4 – Test data, spark plugs 2333
1 5 – Installing distributor 2333
1 6 – Checking ignition transformer 2335
1 7 – Checking ignition transformer output stage 2336
1 8 – Checking Hall sender 2337
00054007520 General body repairs – Cabriolet 2339
01 – Self-diagnosis 2347
1 Self-diagnosis 2347
1 1 Tools 2347
1 2 Connecting fault reader 2348
2 Self-diagnosis of airbag system ▸ 08 94 2350
2 1 Function 2350
2 2 Starting self-diagnosis of airbag 2350
2 3 Overview of the selectable functions 2351
2 4 Interrogating control unit version 2351
2 5 Interrogating fault memory 2352
2 6 Fault table 2353
2 7 Erasing fault memory 2354
2 7 1 Prerequisites: 2354
2 8 End output 2355
3 Self-diagnosis of airbag system 09 94 ▸ 2356
3 1 Function 2356
3 2 Starting self-diagnosis of airbag 2356
3 3 Overview of the selectable functions 2357
3 4 Interrogating control unit version 2358
3 4 1 Control unit -VW 3-(example) 2358
3 4 2 Control unit -VW 3-(example) 2358
3 5 Interrogating fault memory 2358
3 6 Erasing fault memory 2359
3 7 End output 2360
3 8 Fault table 2360
3 9 Coding airbag control unit using fault reader -V A G 1551- 2371
3 10 Read measured value block 2373
3 10 1 Display group 001 2374
3 10 2 Evaluating display group number 001 2374
3 10 3 Display group 003 2375
3 10 4 Evaluating display group number 003 2376
3 10 5 Display group 005 2376
3 10 6 Evaluating display group number 005 2377
3 11 Deactivating and activating front passenger’s airbag unit (matching) 09 94 ▸ 2377
3 11 1 Deactivating front passenger’s airbag 2377
3 11 2 Activating front passenger’s airbag 2380
3 12 Auxiliary airbag tester -VAS 5056- 2383
3 12 1 Connecting auxiliary airbag tester -VAS 5056- with driver’s airbag components 2383
3 12 2 Connecting auxiliary airbag tester -VAS 5056- with passenger’s airbag components 2384
3 13 Final control diagnosis 2384
4 Self-diagnosis of central locking remote control 2387
4 1 Functional description 2387
4 2 Initiating self-diagnosis of central locking remote control 2387
4 3 Overview of the selectable functions 2388
4 4 Interrogating control unit version 2388
4 5 Interrogating fault memory 2389
4 6 Final control diagnosis 2389
4 6 1 Tools 2390
4 6 2 Procedure 2390
4 7 Erasing fault memory 2390
4 8 End output 2391
4 9 Fault table 2391
4 10 Read measured value block 2393
4 10 1 Tools 2393
4 10 2 Procedure 2393
4 11 Display group overview 2394
4 11 1 Breakdown of display content for display group number 001 2394
4 11 2 Evaluating display group number 001 2394
4 11 3 Breakdown of display content for display group number 002 2395
4 11 4 Evaluating display group number 002 2395
4 11 5 Breakdown of display content for display group number 003 2395
4 11 6 Evaluating display group number 003 2396
4 12 Adapting ignition keys to remote control 2397
4 13 Adapting a new, additional key 2399
4 13 1 With fault reader -V A G 1551- 2399
4 13 2 Without fault reader -V A G 1551- 2400
4 14 Synchronising ignition keys to remote control 2401
4 15 Removing and installing batteries for the main key with radio wave remote control 2401
4 15 1 Removing 2402
4 15 2 Installing 2402
4 16 Removing and installing batteries for hinged main key with remote control system 2403
4 16 2 Removing 2403
4 16 3 Installing 2404
50 – Body – front 2405
1 Body – front 2405
1 1 Repairing lock carrier with attachments 2405
1 2 Removing and installing front wing 2406
1 2 1 Removing 2406
1 2 2 Installing 2407
55 – Bonnet, rear lid 2408
1 Bonnet 2408
1 1 Removing and installing bonnet lock cable 2408
1 2 Assembly overview – bonnet 03 98 ▸ 2409
1 3 Removing gas strut 2410
2 Rear lid ▸ 02 98 2411
2 1 Removing gas strut 2411
2 2 Releasing gas from gas strut 2411
2 3 Removing and installing rear lid lock 2411
2 4 Adjusting pull rod 2412
2 5 Removing the push button 2413
2 6 Repairing push button 2413
2 7 Maintaining single-key locking 2414
3 Rear lid 03 98 ▸ 2415
3 1 Assembly overview 2415
3 2 Assembly overview – lock components 2416
3 3 Removing and installing rear lid lock 2417
3 3 1 Removing 2417
3 3 2 Installing 2417
3 4 Assembly overview – handle and lock cylinder housing 2418
3 5 Removing and installing lock cylinder housing 2419
3 5 1 Removing 2419
3 5 2 Installing 2422
3 6 Removing and installing handle 2423
3 6 1 Removing 2423
3 6 2 Installing 2423
57 – Front doors, door components, central locking 2424
1 Front door 2424
1 1 Tools 2424
1 2 Assembly overview – front door 2424
1 3 Removing and installing door 2426
1 3 1 Removing 2426
1 3 2 Installing 2426
1 4 Removing and installing door window 2426
1 4 1 Removing 2426
1 4 2 Installing 2426
1 5 Adjusting door window 2426
1 5 1 Aligning door window to the front window channel 2427
1 5 2 Adjusting window regulator 2427
1 5 3 Adjusting the height of the door window 2427
1 5 4 Aligning door window to B pillar 2428
1 5 5 Adjusting the height of the front window 2429
1 5 6 Adjusting window position on B pillar 2430
1 5 7 Adjusting preload on the door window 2430
1 6 Removing and installing window regulator 2432
1 6 1 Removing 2432
1 6 2 Installing 2432
1 7 Repairing door lock with actuating components 2432
1 8 Removing and installing door lock 2433
1 8 1 Removing 2433
1 8 2 Installing 2434
1 9 Assembly overview – door handle 2434
1 10 Removing and installing door handle 2436
1 10 1 Removing 2436
1 10 2 Installing 2437
1 11 Maintaining single-key locking 2437
1 12 Assembly overview – door handle with interior profile key 2437
1 13 Removing and installing lock cylinder with interior profile key 2438
1 13 1 Removing 2438
1 13 2 Installing 2439
1 14 Removing inner release handle 2442
2 Repairing central locking system 2443
2 1 Assembly overview 2443
2 2 New couplings and distributor elements for pipe connections 2444
2 3 Removing and installing dual pressure pump 2444
2 3 1 Removing 2444
2 3 2 Installing 2445
2 4 Removing and installing positioning element for fuel tank flap 2445
2 4 1 Removing 2445
2 4 2 Installing 2445
2 5 Removing and installing door lock positioning element 2445
2 5 1 Removing 2445
2 6 Removing and installing rear lid positioning element 2446
2 6 1 Removing 2446
2 6 2 Installing 2447
2 7 Functional check of central locking 2448
2 8 Activating separate opening of doors with central locking 2449
61 – Convertible roof, hardtop, canopy 2450
1 Convertible top 2450
1 1 Tools 2450
1 2 Assembly overview ▸ 09 00 2450
1 3 Assembly overview 10 00 ▸ 2452
1 4 Adjusting top 2453
1 5 Removing and installing convertible top 2453
1 5 1 Removing 2453
1 5 2 Installing 2455
1 6 Renewing top cover ▸ 09 00 2456
1 6 1 Removing 2456
1 6 2 Installing 2458
1 7 Renewing top cover 10 00 ▸ 2461
1 7 1 Removing 2461
1 7 2 Installing 2464
1 8 Renewing padding ▸ 08 98 2466
1 8 1 Removing 2466
1 8 2 Installing 2467
1 9 Renewing padding 09 98 ▸ 2469
1 9 1 Removing 2469
1 9 2 Installing 2470
1 10 Renewing top liner 2474
1 10 1 Removing 2474
1 10 2 Installing 2475
2 Electrical/hydraulic top 2476
2 1 Assembly overview 2476
2 2 Filling and bleeding the hydraulic system 2477
2 2 1 Filling the hydraulic system 2477
2 2 2 Bleeding the hydraulic system 2478
2 3 Removing and installing hydraulic pump 2478
2 3 1 Removing 2478
2 3 2 Installing 2479
2 4 Assembly overview – impeller for hydraulic pump 2479
2 5 Removing and installing impeller for hydraulic pump 2480
2 5 1 Removing 2480
2 5 2 Installing 2481
2 6 Assembly overview – oil reservoir, electrical/hydraulic top 2483
2 7 Removing and installing oil reservoir 2483
2 7 1 Removing 2483
2 7 2 Installing 2485
2 8 Removing and installing the hydraulic cylinder 2486
2 8 1 Removing 2486
2 8 2 Installing 2486
2 9 Removing and installing hydraulic hose 2487
2 9 1 Removing 2487
2 9 2 Installing 2487
3 Windscreen frame 2488
3 1 Removing and installing windscreen frame seal 2488
3 1 1 Removing 2488
3 1 2 Installing 2489
63 – Bumpers 2490
1 Front bumper ▸ 02 98 2490
1 1 Removing front bumper 2490
1 2 Removing and installing cover 2490
1 2 1 Removing 2490
1 2 2 Installing 2491
2 Front bumper 03 98 ▸ 2492
2 1 Assembly overview – bumper cover 2492
2 2 Assembly overview – bumper carrier 2494
3 Rear bumper ▸02 98 2495
3 1 Assembly overview 2495
3 2 Removing and installing rear bumper 2496
3 2 1 Removing 2496
3 2 2 Installing 2496
4 Rear bumper 03 98 ▸ 2497
4 1 Assembly overview – bumper cover 2497
4 2 Assembly overview – bumper carrier 2498
64 – Glazing 2499
1 Flush bonded windows 2499
1 1 Tools 2499
1 2 Materials 2501
1 3 Assembly overview – windscreen 2501
1 4 Removing and installing windscreen 2502
1 4 1 Removing 2502
1 4 2 Installing 2503
1 5 Removing and installing water deflector strips 2503
1 5 1 Removing 2503
1 5 2 Installing 2504
1 6 Preparing old undamaged window for glazing 2505
1 7 Preparing new window for glazing 2505
1 8 Preparing body flange for glazing 2506
1 9 Installation instructions 2507
1 10 Curing time 2507
1 11 Touching up paint damage 2507
1 12 Cleaning off excess adhesive sealing material 2508
2 Side window 2509
2 1 Assembly overview – side window 2509
2 2 Removing outer B-pillar trim 2509
2 3 Removing side window 2510
2 4 Adjusting side window 2510
2 4 1 Adjusting window guide 2510
2 4 2 Adjusting window position on B pillar 2511
2 4 3 Adjusting the height of the side window 2512
2 5 Removing and installing electrical window regulator 2513
2 5 1 Removing 2513
2 5 2 Installing 2513
66 – Exterior equipment 2514
1 Trim 2514
1 1 Removing and installing radiator grille ▸ 02 98 2514
1 1 1 Removing 2514
1 1 2 Installing 2515
1 2 Removing and installing radiator grille 03 98 ▸ 2515
1 2 1 Removing 2515
1 2 2 Installing 2516
2 Removing and installing wheel housing liner 2517
2 1 Front wheel housing liner 2517
2 1 1 Removing 2517
2 1 2 Installing 2517
3 Exterior mirror 2518
3 1 Removing and installing exterior mirror 2518
68 – Interior equipment 2519
1 Interior mirror 2519
1 1 Removing and installing interior mirror 2519
1 1 1 Removing 2519
1 1 2 Installing 2519
1 2 Repair method using glass-to-metal adhesive 2519
1 2 1 Materials 2519
2 Compartments, covers and trims 2521
2 1 Removing and installing centre console 2521
2 1 1 Removing 2521
2 1 2 Installing 2522
3 Windbreak 2523
3 1 Assembly overview – windbreak 2523
3 2 Retrofitting windbreak 2523
69 – Passenger protection 2525
1 Removing and installing seat belts 2525
1 1 Assembly overview – seat belts 2525
1 2 Removing and installing belt height adjustment 2525
1 3 Removing and installing front belt reel and anchor rail 2526
1 4 Safety regulations for belt tensioners 2527
1 5 Disposal of belt tensioner units 2528
1 6 Checking belt tensioner 2528
1 7 Removing and installing front seat belt with belt tensioner 2528
1 8 Assembly overview – belt reel with tensioner unit 2530
1 9 Removing and installing belt reel with tensioner unit 2530
1 9 1 Removing 2530
1 9 2 Installing 2531
1 10 Removing and installing rear belt reel 2531
1 11 Removing and installing rear belt buckle 2532
1 11 1 Removing 2532
1 11 2 Installing 2532
1 12 Removing and installing front belt buckle 2533
1 12 1 Removing 2533
1 12 2 Installing 2533
2 Inspecting seat belts 2534
2 1 Points to check 2534
2 1 1 Checking belt webbing 2534
2 1 2 Checking inertia reel (locking mechanism) 2535
2 1 3 Visually checking belt buckle 2536
2 1 4 Checking operation of belt buckle 2536
2 1 5 Checking belt anchors, belt guides and latch plates 2536
2 1 6 Checking securing parts and anchorage points 2536
3 Airbag 2538
3 1 Overview – installation locations 2538
3 2 Safety precautions when working on the airbag 2538
3 3 Disposal of airbag units 2539
3 4 Deactivating the airbag 2539
3 5 Renewing airbag units following an accident 2539
3 5 1 Accident involving triggering of airbag 2539
3 5 2 Accident not involving triggering of airbag 2540
3 6 Assembly overview – driver airbag unit ▸ 02 98 2540
3 7 Removing and installing driver’s airbag unit ▸ 02 98 2541
3 7 1 Removing 2542
3 7 2 Installing 2543
3 8 Assembly overview – driver airbag unit 03 98 ▸ 2543
3 9 Removing and installing driver’s airbag unit 03 98 ▸ 2544
3 9 1 Removing 2544
3 9 2 Installing 2547
3 10 Removing and installing steering wheel 2547
3 10 1 Removing 2548
3 10 2 Installing 2549
3 11 Removing and installing return spring with slip ring 2549
3 11 1 Removing 2549
3 11 2 Installing 2549
3 12 Removing and installing front passenger airbag unit 2549
3 12 1 Removing 2550
3 12 2 Installing 2551
3 13 Removing and installing driver and front passenger side airbag 2551
3 13 1 Removing 2551
3 13 2 Installing 2552
3 14 Assembly overview – driver/front passenger side airbag sensor 2553
3 15 Removing and installing sensor for driver’s/front passenger’s side airbag 2553
3 15 1 Removing 2554
3 15 2 Installing 2554
3 16 Removing and installing airbag control unit (J 234) 2555
3 16 1 Removing 2555
3 16 2 Installing 2555
70 – Trim, insulation 2557
1 Dash panel 2557
1 1 Removing and installing centre console 2557
1 1 1 Removing 2557
1 1 2 Installing 2558
1 2 Removing and installing dash panel 2558
1 2 1 Removing 2558
1 2 2 Installing 2560
1 3 Removing and installing cover for relay plate 2560
1 3 1 Removing 2560
1 3 2 Installing 2560
1 4 Removing and installing driver side storage compartment 2560
1 4 1 Removing 2560
1 4 2 Installing 2560
1 5 Removing and installing passenger side storage compartment 2561
1 5 1 Removing 2561
1 5 2 Installing 2561
1 6 Removing and installing heating controls 2561
1 6 1 Removing 2561
1 6 2 Installing 2561
1 7 Removing and installing instrument panel 2562
1 7 1 Removing 2562
1 7 2 Installing 2562
1 8 Repairing glove box 2562
2 Door trims 2564
2 1 Removing trim 2564
2 1 1 Removing window crank 2565
2 1 3 Removing door stowage compartment with loudspeaker mount 2565
2 2 Renewing insulation film 2565
3 Pillar and side trims 2567
3 1 Removing and installing windscreen frame trim 2567
3 1 1 Removing 2567
3 1 2 Installing 2567
3 2 Removing and installing A-pillar trim 2567
3 2 1 Removing 2567
3 3 Removing and installing B-pillar trim 2568
3 3 1 Removing 2568
3 3 2 Installing 2568
3 4 Removing and installing side trim 2569
3 4 1 Removing 2569
3 4 2 Installing 2569
3 5 Removing and installing roll bar trim 2570
3 5 1 Removing 2570
3 5 2 Installing 2570
4 Rear lid trim 2571
4 1 Removing and installing rear lid trim 2571
4 1 1 Removing 2571
4 1 2 Installing 2571
72 – Seat frames 2572
1 Front seats 2572
1 1 Tools 2572
1 2 Removing and installing front seat 2572
1 2 1 Removing 2572
1 2 2 Installing 2575
1 3 Assembly overview – backrest 2576
1 4 Removing and installing backrest 2576
1 4 1 Removing 2576
1 4 2 Installing 2577
2 Rear seats 2578
2 1 Removing and installing lower part of backrest 2578
2 1 1 Removing 2578
2 1 2 Installing 2578
2 2 Removing and installing upper part of backrest 2578
2 2 1 Removing 2578
2 2 2 Installing 2579
2 3 Removing and installing rear seat 2580
2 3 1 Removing 2580
2 3 2 Installing 2580
74 – Seat – padding, covers 2581
1 Front seat covers and padding 2581
1 1 Removing and installing seat cover and padding 2581
1 2 Removing and installing backrest cover and padding 2582
2 Seat heater elements 2583
2 1 Removing and installing seat heater element 2583
2 1 1 Removing 2583
2 1 2 Installing 2583
2 2 Removing and installing heater element for backrest 2583
2 2 1 Removing 2583
3 Rear seat covers and padding 2585
3 1 Removing and installing cover and padding for rear seat bench 2585
3 2 Removing and installing backrest cover and padding 2586
3 2 1 Upper part of backrest 2586
3 2 2 Lower part of backrest 2586
00054007620 Diesel direct injection and glow plug system 2587
01 – Self-diagnosis 2591
1 – Self-diagnosis 2591
1 1 – Self-diagnosis 2591
1 2 – Features of self-diagnosis 2591
1 3 – Technical data of self-diagnosis 2591
1 4 – Connecting fault reader V A G 1551 and selecting engine control unit 2592
2 – Fault memory 2593
2 1 – Fault memory 2593
2 2 – Interrogating fault memory 2593
2 3 – Fault table 2594
2 4 – Erasing fault memory 2601
3 – Final control diagnosis 2602
3 1 – Final control diagnosis 2602
3 2 – Performing final control diagnosis 2602
4 – Measured value blocks 2606
4 1 – Measured value blocks 2606
4 2 – Safety precautions 2606
4 3 – Reading measured value block 2606
4 4 – Display group overview engine codes AFN, AVG, AHU, ALE, 1Z 2607
4 5 – Evaluating measured value blocks, engine codes AHU, 1Z 2610
4 6 – Evaluating measured value blocks, engine codes AFN, AVG 2622
4 7 – Evaluating measured value blocks, engine code ALE 2632
4 8 – Display group overview engine code AEY 2643
4 9 – Evaluating measured value blocks, engine code AEY 2645
23 – Mixture preparation, Injection 2655
1 – Servicing Diesel direct injection system 2655
1 1 – Servicing Diesel direct injection system 2655
1 2 – Safety precautions 2655
1 3 – Rules for cleanliness 2655
1 4 – Fitting locations overview 2656
1 5 – Servicing injection pump 2663
1 6 – Servicing fuel filter 2667
1 7 – Servicing accelerator linkage 2669
1 8 – Setting engine to TDC number 1 cylinder, engine removed 2671
1 9 – Removing, installing and adjusting accelerator position sender 2671
1 10 – Checking sender adjustment 2673
1 11 – Checking throttle valve positioner housing 2674
1 12 – Removing and installing injection pump 2675
1 13 – Dynamically checking and adjusting commencement of injection 2678
1 14 – Checking valve timing 2680
1 15 – Removing and installing injectors 2681
1 16 – Servicing injectors 2682
1 17 – Renewing injection timing device cover O-ring 2683
2 – Checking components and functions 2684
2 1 – Checking components and functions 2684
2 2 – Wiring and component check with test box V A G 1598/18 2684
2 3 – Checking engine speed sender 2684
2 4 – Checking intake manifold pressure sender and elevation sender 2686
2 5 – Checking coolant temperature sender 2687
2 6 – Checking brake light switch and brake pedal switch 2689
2 7 – Checking clutch pedal switch 2691
2 8 – Checking intake manifold temperature sender 2693
2 9 – Checking intake air temperature sender 2695
2 10 – Checking Diesel direct injection system voltage supply 2697
2 11 – Checking fuel temperature sender 2697
2 12 – Checking modulating piston movement sender and quantity adjuster 2699
2 13 – Checking needle lift sender 2702
2 14 – Checking injection timing control range 2703
2 15 – Checking charge pressure control 2707
2 16 – Hose connection diagram for charge pressure control, engine codes AFN, AVG 2713
2 17 – Checking valve for throttle butterfly 2714
2 18 – Checking exhaust gas recirculation and air mass meter function 2716
2 19 – Checking speedometer sender 2724
2 20 – Checking accelerator position sender 2725
3 – Replacing, coding and matching engine control unit 2727
3 1 – Replacing, coding and matching engine control unit 2727
3 2 – Replacing engine control unit 2727
3 3 – Coding engine control unit 2727
3 4 – Matching engine electronic control unit to electronic immobilizer 2729
28 – Glow plug system 2731
1 – Checking glow plug system 2731
1 1 – Checking glow plug system 2731
1 2 – Checking glow plugs 2731
00054007820 Simos injection and ignition system 2733
01 – Self-diagnosis 2737
1 – Self-diagnosis 2737
1 1 – Self-diagnosis 2737
1 2 – Function 2737
1 3 – Technical data of self-diagnosis 2737
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2738
1 5 – Coding Simos control unit 2739
1 6 – Interrogating and erasing fault memory 2740
1 7 – Fault table 2742
1 8 – Final control diagnosis 2748
1 9 – Read measured value block 2752
1 10 – Display group overview, engine codes ADY, AGG, AKR 2753
1 11 – Display group overview, engine codes AFT, AKS 2756
24 – Mixture preparation, Injection 2761
1 – Simos injection and ignition system 2761
1 1 – Simos injection and ignition system 2761
1 2 – Fitting locations overview 2761
1 3 – Servicing injection part 2767
1 4 – Dismantling and assembling intake manifold, engine codes ADY, AGG, AKR 2781
1 5 – Dismantling and assembling intake manifold upper part, engine codes AFT, AKS 2784
1 6 – Dismantling and assembling intake manifold lower part, engine codes AFT, AKS 2787
1 7 – Dismantling and assembling air cleaner 2788
1 8 – Safety precautions 2791
1 9 – Rules for cleanliness 2791
1 10 – Technical data 2792
1 11 – Idling check 2792
1 12 – Performing basic setting 2793
1 13 – Checking Lambda probe and Lambda control 2794
1 14 – Checking Lambda probe heating 2798
1 15 – Checking engine operating mode 2800
1 16 – Checking intake manifold change-over valve 2801
1 17 – Checking air mass meter 2802
1 18 – Checking throttle valve control part 2804
1 19 – Checking coolant temperature sender 2811
1 20 – Checking intake air temperature sender 2813
1 21 – Checking engine speed sender 2817
1 22 – Testing speed signal 2818
1 23 – Checking control unit voltage supply 2820
1 24 – Matching engine electronic control unit to electronic immobilizer 2822
1 25 – Checking air conditioner and air conditioner compressor signals 2823
1 26 – Checking starter signal 2824
1 27 – Checking injectors 2824
1 28 – Checking fuel pressure regulator and holding pressure 2828
1 29 – Checking intake air system for leaks (unmetered air) 2830
28 – Ignition system 2832
1 – Simos injection and ignition system 2832
1 1 – Simos injection and ignition system 2832
1 2 – Servicing ignition part 2832
1 3 – Safety precautions 2836
1 4 – Test data, spark plugs 2836
1 5 – Checking position of distributor 2836
1 6 – Removing and installing distributor 2837
1 7 – Checking ignition timing control 2841
1 8 – Checking Hall sender 2841
1 9 – Checking knock sensor 2843
1 10 – Checking ignition transformer 2845
1 11 – Checking ignition transformer output stage 2845
00054007920 Automatic gearbox 01M from 01 95 2848
00 – Technical data 2852
1 – Identification of gearbox 2852
1 1 – Identification of gearbox 2852
2 – Information on “Automatic gearbox 01M” 2853
2 1 – Information on “Automatic gearbox 01M” 2853
3 – Code letters, gearbox allocation, ratios, equipment 2853
3 1 – Code letters, gearbox allocation, ratios, equipment 2853
4 – Capacities 2860
4 1 – Capacities 2860
5 – Repair instructions 2861
5 1 – Repair instructions 2861
32 – Torque converter 2864
1 – Torque converter 2864
1 1 – Torque converter 2864
1 2 – Identification of torque converter 2864
1 3 – Torque converter allocation 2865
1 4 – Removing and installing torque converter oil seal 2867
1 5 – Draining torque converter 2868
37 – Controls, Housing 2870
1 – Servicing shift mechanism 2870
1 1 – Servicing shift mechanism 2870
1 2 – Checking shift mechanism 2870
1 3 – Checking and adjusting selector lever cable 2870
1 4 – Checking ignition key removal lock (vehicles with ignition key removal lock) 2871
1 5 – Dismantling and assembling selector mechanism 2871
1 6 – Dismantling and assembling shift mechanism (vehicles with ignition key removal lock) 2880
1 7 – Dismantling and assembling selector lever (vehicles with ignition key removal lock) 2888
1 8 – Removing and installing locking cable (vehicles with ignition key removal lock) 2894
1 9 – Adjusting locking cable (vehicles with ignition key removal lock) 2897
2 – Checking gearbox 2897
2 1 – Checking gearbox 2897
2 2 – Checking shift points 2898
2 3 – Checking stall speed 2898
2 4 – Measuring main pressure 2898
2 5 – Fault finding table for “4-speed automatic gearbox” 2898
3 – Removing and installing gearbox 2898
3 1 – Removing and installing gearbox 2898
3 2 – Removing and installing starter bush 2904
4 – Checking and topping up ATF level 2906
4 1 – Checking and topping up ATF level 2906
4 2 – Checking ATF level 2907
4 3 – Topping up ATF 2909
4 4 – Renewing ATF 2910
5 – Gearbox with selector elements 2911
5 1 – Gearbox with selector elements 2911
5 2 – Position of selector elements 2912
6 – Dismantling and assembling gearbox 2914
6 1 – Dismantling and assembling gearbox 2914
6 2 – Removing and installing ATF cooler and ATF filler tube 2914
6 3 – Dismantling and assembling planetary gearbox -Overview- 2916
6 4 – I – Removing and installing ATF pump to supporting tube 2917
6 5 – II – Removing and installing reverse gear clutch -K2- to large sun wheel 2921
6 6 – III – Removing and installing freewheel and reverse gear brake -B1- 2924
6 7 – IV – Planet carrier and gearbox housing with input gear and cover 2926
6 8 – Dismantling and assembling planetary gearbox 2928
6 9 – Overview of all planetary gearbox adjustments 2945
6 10 – Adjusting planet carrier 2946
6 11 – Adjusting reverse gear brake -B1- 2952
6 12 – Adjusting clutch play between -K1- and -K2- 2957
6 13 – Adjusting 2nd and 4th gear brake -B2- 2962
38 – Gears, Hydraulic controls 2975
1 – Dismantling and assembling ATF pump 2975
1 1 – Dismantling and assembling ATF pump 2975
2 – Dismantling and assembling freewheel with -B1- piston 2978
2 1 – Dismantling and assembling freewheel with -B1- piston 2978
3 – Dismantling and assembling 1st to 3rd gear clutch -K1- 2980
3 1 – Dismantling and assembling 1st to 3rd gear clutch -K1- 2980
4 – Dismantling and assembling reverse gear clutch -K2- 2985
4 1 – Dismantling and assembling reverse gear clutch -K2- 2985
5 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 2988
5 1 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 2988
6 – Removing and installing valve chest 2992
6 1 – Removing and installing valve chest 2992
7 – Dismantling and assembling parking lock 3001
7 1 – Dismantling and assembling parking lock 3001
39 – Final drive, Differential 3008
1 – Checking oil in final drive 3008
1 1 – Checking oil in final drive 3008
2 – Removing and installing oil seal for drive flange 3008
2 1 – Removing and installing oil seal for drive flange 3008
3 – Dismantling and assembling final drive 3011
3 1 – Dismantling and assembling final drive 3011
3 2 – Repair overview of final drive 3011
3 3 – Removing and installing input gear 3013
3 4 – Removing and installing drive pinion 3017
3 5 – Removing and installing differential 3024
3 6 – Dismantling and assembling differential 3032
4 – Adjusting final drive 3038
4 1 – Adjusting final drive 3038
4 2 – Overview of adjustments 3038
4 3 – Adjustments to be completed after replacing individual components 3039
4 4 – Adjusting drive pinion 3040
4 5 – Adjusting input gear 3042
4 6 – Adjusting differential 3043
00054008620 Automatic gearbox self diagnosis 01M from 01 95 3044
01 – Self-diagnosis, Electrical check 3048
1 – Self-diagnosis function 3048
1 1 – Self-diagnosis function 3048
1 2 – Technical data of self-diagnosis 3049
1 3 – Self-diagnosis – Guide 3050
2 – Locations of electrical/electronic components 3051
2 1 – Locations of electrical/electronic components 3051
3 – Performing self-diagnosis 3063
3 1 – Performing self-diagnosis 3063
3 2 – Connecting fault reader V A G 1551 and selecting functions 3063
3 3 – List of selectable functions 3065
3 4 – Interrogating fault memory 3065
3 5 – Fault table 3066
3 6 – Erasing fault memory 3071
3 7 – Initiating basic setting 3072
3 8 – Read measured value block 3073
3 9 – Test table 3074
4 – Gearbox: Electrical test 3082
4 1 – Gearbox: Electrical test 3082
4 2 – Electrical check 3083
4 3 – Test table 3085
00054008720 5 speed manual gearbox 02J 3090
00 – Technical data 3094
1 – Gearbox identification 3094
1 1 – Gearbox identification 3094
1 2 – Code letters, gearbox allocation, ratios, capacities 3095
2 – Transmission layout 3097
2 1 – Transmission layout 3097
3 – Calculating overall ratio “i” 3099
3 1 – Calculating overall ratio “i” 3099
4 – General repair instructions 3099
4 1 – General repair instructions 3099
30 – Clutch 3101
1 – Servicing clutch control 3101
1 1 – Servicing clutch control 3101
1 2 – Assembly overview – pedal cluster 3102
1 3 – Removing and installing over-centre spring 3106
1 4 – Removing and installing clutch pedal 3107
1 5 – Assembly overview – Hydraulic system 3109
1 6 – Removing and installing master cylinder 3112
1 7 – Bleeding clutch system 3115
2 – Servicing clutch release mechanism 3115
2 1 – Servicing clutch release mechanism 3115
3 – Servicing clutch 3118
3 1 – Servicing clutch 3118
34 – Controls, Housing 3123
1 – Servicing gear selector mechanism 3123
1 1 – Servicing gear selector mechanism 3123
1 2 – Installation position of gear selector mechanism 3123
1 3 – Assembly overview – removing and installing selector cables 3125
1 4 – Removing and installing gear selector mechanism 3130
1 5 – Servicing gear stick housing 3132
1 6 – Servicing gear stick 3135
1 7 – Adjusting selector mechanism 3139
2 – Removing and installing gearbox 3143
2 1 – Removing and installing gearbox 3143
3 – Checking gear oil 3157
3 1 – Checking gear oil 3157
4 – Dismantling and assembling gearbox 3159
4 1 – Dismantling and assembling gearbox 3159
4 2 – Overview 3159
4 3 – Assembly overview 3161
4 4 – Removing and installing cover for gearbox housing and 5th gear 3162
4 5 – Removing and installing gearbox housing and selector mechanism 3165
4 6 – Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks 3167
4 7 – Assembly sequence 3170
5 – Servicing gearbox housing and clutch housing 3188
5 1 – Servicing gearbox housing and clutch housing 3188
6 – Dismantling and assembling gearbox selector mechanism 3198
6 1 – Dismantling and assembling gearbox selector mechanism 3198
7 – Dismantling and assembling selector forks 3203
7 1 – Dismantling and assembling selector forks 3203
35 – Gears, Shafts 3210
1 – Dismantling and assembling input shaft 3210
1 1 – Dismantling and assembling input shaft 3210
2 – Adjusting input shaft 3223
2 1 – Adjusting input shaft 3223
2 2 – Table of adjustment shims 3225
2 3 – Performing measurement check 3227
3 – Dismantling and assembling output shaft 3228
3 1 – Dismantling and assembling output shaft 3228
3 2 – From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified 3254
4 – Adjusting output shaft 3258
4 1 – Adjusting output shaft 3258
5 – Dismantling and assembling reverse shaft 3261
5 1 – Dismantling and assembling reverse shaft 3261
39 – Final drive, Differential 3266
1 – Renewing flanged shaft oil seals (gearbox installed) 3266
1 1 – Renewing flanged shaft oil seals (gearbox installed) 3266
2 – Dismantling and assembling differential 3269
2 1 – Dismantling and assembling differential 3269
3 – Adjustment overview 3282
3 1 – Adjustment overview 3282
4 – Adjusting differential 3283
4 1 – Adjusting differential 3283
00054008920 Motronic injection and ignition system (4 cyl engine) 3287
01 – Self-diagnosis 3291
1 – General to self-diagnosis 3291
1 1 – General to self-diagnosis 3291
1 2 – Features of self-diagnosis 3291
1 3 – Technical data of self-diagnosis 3291
1 4 – Significance of exhaust emissions warning lamp 3293
1 5 – Connecting fault reader V A G 1551 and selecting engine control unit 3294
1 6 – Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit 3296
2 – Fault memory 3298
2 1 – Fault memory 3298
2 2 – Interrogating and erasing fault memory 3298
2 3 – Automatic test sequence 3299
3 – Fault table: SAE P0 codes 3300
3 1 – Fault table: SAE P0 codes 3300
4 – Fault table: SAE P1 codes 3304
4 1 – Fault table: SAE P1 codes 3304
5 – Final control diagnosis 3307
5 1 – Final control diagnosis 3307
5 2 – Performing final control diagnosis 3307
6 – Readiness code 3313
6 1 – Readiness code 3313
6 2 – Reading readiness code 3313
6 3 – Generating readiness code 3314
7 – Measured value blocks 3320
7 1 – Measured value blocks 3320
7 2 – Safety precautions 3320
7 3 – Read measured value block 3320
8 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3321
8 1 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 3321
9 – Evaluating measured value blocks, display groups 10 29, 212 -Ignition- 3325
9 1 – Evaluating measured value blocks, display groups 10 29, 212 -Ignition- 3325
10 – Evaluating measured value blocks, display grps 30 49, 99 -Lambda regulation- 3328
10 1 – Evaluating measured value blocks, display grps 30 49, 99 -Lambda regulation- 3328
11 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3333
11 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 3333
12 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3335
12 1 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 3335
13 – Evaluating measured value blocks, display groups 80 100 -Readiness code- 3336
13 1 – Evaluating measured value blocks, display groups 80 100 -Readiness code- 3336
24 – Mixture preparation, Injection 3338
1 – Servicing injection system 3338
1 1 – Servicing injection system 3338
1 2 – Fitting locations overview 3338
1 3 – General notes on injection 3342
1 4 – Removing and installing parts of the injection system 3344
1 5 – Dismantling and assembling intake manifold – Upper part 3353
1 6 – Dismantling and assembling intake manifold – lower part 3355
1 7 – Dismantling and assembling air cleaner 3356
1 8 – Safety precautions 3357
1 9 – Rules for cleanliness 3358
1 10 – Technical data 3358
2 – Checking components 3359
2 1 – Checking components 3359
2 2 – Checking Lambda probe heating for Lambda probe before catalyst 3359
2 3 – Checking Lambda probe heating for Lambda probe after catalyst 3361
2 4 – Checking air mass meter 3364
2 5 – Checking throttle valve control part 3366
2 6 – Checking coolant temperature sender 3373
2 7 – Checking intake air temperature sender 3377
2 8 – Checking engine speed sender 3380
2 9 – Checking injectors 3382
2 10 – Checking fuel pressure regulator and holding pressure 3386
2 11 – Checking intake air system for leaks (unmetered air) 3389
3 – Checking functions 3390
3 1 – Checking functions 3390
3 2 – Idling check 3390
3 3 – Adapting idling speed 3391
3 4 – Checking Lambda probe and Lambda regulation before catalyst 3393
3 5 – Checking Lambda probe and Lambda regulation after catalyst 3396
3 6 – Checking Lambda probe ageing Lambda probe 1 3401
3 7 – Checking engine operating mode 3402
3 8 – Checking intake air preheating 3403
4 – Engine control unit 3405
4 1 – Engine control unit 3405
4 2 – Checking control unit voltage supply 3405
4 3 – Procedure after voltage supply open circuit 3406
4 4 – Replacing engine control unit 3407
4 5 – Coding engine control unit 3407
4 6 – Adapting engine control unit to throttle valve control part 3409
5 – Checking additional signals 3410
5 1 – Checking additional signals 3410
5 2 – Checking speed signal 3410
5 3 – Checking signal from/to air conditioning system 3412
5 4 – Checking driving range signal 3413
5 5 – Checking data bus 3414
28 – Ignition system 3416
1 – Servicing ignition system 3416
1 1 – Servicing ignition system 3416
1 2 – General notes on ignition system 3416
1 3 – Removing and installing parts of the ignition system 3417
1 4 – Safety precautions 3420
1 5 – Test data, spark plugs 3421
1 6 – Installing distributor 3421
1 7 – Checking and adjusting distributor basic setting 3423
1 8 – Checking Hall sender 3424
1 9 – Checking ignition transformer and output stage 3425
1 10 – Checking knock sensor 3428
1 11 – Check misfiring recognition 3430
CAB53201020 Body Repairs 3432
00 – Technical data 3436
1 Vehicle identification data 3436
1 1 Identification plate 3436
1 2 Vehicle data plate 3436
1 3 Vehicle identification number 3436
2 Body dimensions 3437
2 1 Floor group – front 3437
2 2 Floor group – front 3438
2 3 Floor group – centre 3439
2 4 Floor group – rear 3440
2 5 Body – front 3441
2 6 Body – centre 3446
2 7 Body – rear 3451
3 Alignment jig 3453
4 Convertible roof mounting gauge -V A G 1898- 3463
5 Galvanized body parts 3468
50 – Body – front 3469
1 Renewing wishbone support 3469
1 1 Removing 3469
1 1 1 Cutting locations 3469
1 1 2 Replacement part 3470
2 Renewing front wheel housing 3471
2 1 Removing 3471
2 1 1 Cutting locations 3471
2 1 2 Replacement parts 3472
2 1 3 Welding in 3472
3 Renewing front wheel housing – partial renewal 3474
3 1 Removing 3474
3 1 1 Cutting locations 3474
3 1 2 Replacement parts 3475
3 1 3 Welding in 3475
4 Front longitudinal member – partial renewal in front of auxiliary link mounting 3476
4 1 Removing 3476
4 1 1 Cutting locations 3476
4 1 2 Replacement part 3477
4 1 3 Welding in 3477
5 Front longitudinal member – partial renewal behind auxiliary link mounting 3478
5 1 Removing 3478
5 1 1 Cutting locations 3478
5 1 2 Replacement part 3479
5 1 3 Welding in 3479
5 2 Welding in mounting bracket balance weight 3479
6 Renewing front part of longitudinal member 3480
6 1 Removing 3480
6 1 1 Cutting locations 3480
6 1 2 Replacement parts 3481
6 1 3 Welding in 3481
51 – Body – centre 3483
1 Renewing roll bar 3483
1 1 Removing 3483
1 1 1 Cutting locations 3483
1 1 2 Replacement parts 3484
1 1 3 Welding in 3484
2 Renewing windscreen frame 3486
2 1 Removing 3486
2 1 1 Cutting locations 3486
2 1 2 Replacement part 3487
3 Renewing convertible roof box 3488
3 1 Removing 3488
3 1 1 Cutting locations 3488
3 1 2 Replacement parts 3489
3 1 3 Welding in 3489
4 Renewing outer side panel 3492
4 1 Removing 3492
4 1 1 Cutting locations 3492
4 1 2 Replacement part 3493
4 1 3 Welding in 3493
5 Renewing A-pillar 3495
5 1 Includes: Side member part section 3495
5 1 1 Cutting locations 3495
5 1 2 Replacement parts 3496
5 1 3 Welding in 3496
6 Renewing A-pillar reinforcement 3499
6 1 Removing 3499
6 1 1 Cutting locations 3499
6 1 2 Replacement parts 3500
6 1 3 Welding in 3500
7 Renewing B-pillar – partial renewal 3502
7 1 Includes: Side member part section 3502
7 1 1 Cutting locations 3502
7 1 2 Replacement part 3503
7 1 3 Welding in 3503
8 Renewing outer side member 3506
8 1 Removing 3506
8 1 1 Cutting locations 3506
8 1 2 Replacement part 3507
8 1 3 Welding in 3507
9 Renewing inner side member 3508
9 1 Removing 3508
9 1 1 Cutting locations 3508
9 1 2 Replacement part 3509
9 1 3 Welding in 3509
10 Renewing floor panel – partial renewal 3510
10 1 Removing 3510
10 1 1 Cutting locations 3510
10 1 2 Replacement parts 3511
53 – Body – rear 3512
1 Renewing rear cross panel 3512
1 1 Removing 3512
1 1 1 Cutting locations 3512
1 1 2 Replacement parts 3513
1 1 3 Welding in 3513
2 Renewing cover plate 3516
2 1 Removing 3516
2 1 1 Cutting locations 3516
2 1 2 Replacement part 3517
3 Renewing luggage compartment floor – partial renewal 3518
3 1 Removing 3518
3 1 1 Cutting locations 3518
3 1 2 Replacement parts 3519
3 1 3 Welding in 3519
4 Rear longitudinal member – partial renewal 3520
4 1 Removing 3520
4 1 1 Cutting locations 3520
4 1 2 Replacement part 3521
4 1 3 Welding in 3521
5 Renewing side panel 3522
5 1 Removing 3522
5 1 1 Cutting locations 3522
5 1 2 Replacement part 3523
6 Renewing side panel – partial renewal 3525
6 1 Removing 3525
6 1 1 Cutting locations 3525
6 1 2 Replacement part 3526
6 1 3 Welding in 3526
7 Renewing side panel – partial renewal 3527
7 1 Removing 3527
7 1 1 Cutting locations 3527
7 1 2 Replacement part 3528
7 1 3 Welding in 3528
8 Renewing outer wheel housing liner 3529
8 1 Removing 3529
8 1 1 Cutting locations 3529
8 1 2 Replacement part 3530
8 1 3 Welding in 3530
D3E8049715C Wheels and Tyres Guide 3531
00 – Technical data 3539
1 General notes on wheels and tyres (passenger cars) 3539
1 1 Legislative conditions for converting wheel and tyre combinations 3540
1 2 Technical conditions for converting wheel and tyre combinations 3541
1 3 Official type designations 3541
1 3 1 Official type approval, sales or trade designation 3541
1 4 General information 3543
1 4 1 Special models 3543
1 4 2 Vehicles with Plus running gear 3543
1 4 3 Speed ratings for tyres 3544
1 4 4 “Series 80” tyres 3545
1 4 5 Wheel bolts – torque settings 3545
1 4 6 Revised wheel bolts for Sharan from model year 2001 3545
1 4 7 Wheel rims – pitch circle diameter 3546
1 4 8 Data on wheel rims 3546
1 4 9 Split rim wheels 3547
1 4 10 Alloy wheels with exchangeable trim elements 3547
2 Facts about wheels and tyres (passenger cars) 3548
2 1 Tyre wear/ mileage 3548
2 1 1 General information 3548
2 1 2 Requirements to be met by tyres 3548
2 1 3 Wear behaviour of high-speed tyres 3549
2 1 4 Factors influencing the service life of a tyre 3549
2 1 5 Driving style 3550
2 1 6 Tyre maintenance 3551
2 1 7 Evenly worn tyres 3552
2 1 8 Measuring tread depth 3552
2 1 9 One-sided wear 3553
2 1 10 Wear in middle of tyre 3555
2 1 11 Diagonal washout 3556
2 2 Tyre noise 3557
2 2 1 General notes on tyre noise 3557
2 2 2 Saw-tooth wear 3558
2 2 3 Flat spots (from locking wheels) 3559
2 3 Rough running caused by wheels/tyres 3560
2 3 1 Causes of rough running 3560
2 3 2 Balancing wheels 3560
2 3 3 Conducting a road test before balancing wheels 3560
2 3 4 Balancing wheels on stationary wheel balancing machine 3561
2 3 5 Vibration control system -VAS 6230- 3562
2 3 6 Finish balancer 3563
2 3 7 Radial and lateral runout of wheels and tyres 3564
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 3564
2 3 9 Checking radial and lateral runout on wheel 3566
2 3 10 Matching 3566
2 3 11 Flat spots caused by storage or handling 3568
2 4 Vehicle pulls to one side 3569
2 4 1 General information 3569
2 4 2 Conicity 3569
2 4 3 Remedies when vehicle pulls to one side 3571
2 4 4 Strategic rotation of wheels for non-directional tyres 3572
2 4 5 Strategic rotation of wheels having unidirectional tyres 3573
2 4 6 Tyres with a red spot 3573
2 5 Tyre damage 3574
2 5 1 General information 3574
2 5 2 Construction of a radial belted tyre 3575
2 5 3 Impact damage 3575
2 5 4 Cuts 3577
2 5 5 Damage caused by foreign bodies 3577
2 5 6 Loss of air from tyre 3578
2 5 7 Tyre pressure 3578
2 5 8 Tyre damage due to insufficient tyre pressure 3578
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 3580
2 5 10 Tyre damage due to fitting error (fitting damage) 3581
2 6 Facts about wheels and tyres 3583
2 6 1 Identification markings on the tyre sidewall 3583
2 6 2 Explanation of tyre markings 3585
2 6 3 Undulations 3586
2 6 4 The valve 3587
2 6 5 Tyre storage 3588
2 6 6 Tyre ageing 3588
2 6 7 Care and maintenance of alloy wheel rims 3589
2 6 8 Rotating wheels 3590
2 6 9 Instructions for changing or fitting wheels 3590
2 6 10 Tyres with flange protection 3591
2 6 11 Notes on use of temporary spare wheels 3592
2 6 12 M+S tyres 3593
2 6 13 Winter tyres with speed symbol “V” 3594
2 6 14 Extra Load (XL) V winter tyres 3594
2 6 15 Reinforced and Extra Load (XL) tyres 3597
2 6 16 Snow chains 3597
44 – Wheels, tyres, vehicle geometry 3598
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 3598
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 3598
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 3599
1 2 1 4 J x 14 3599
1 2 2 41/2 J x 14 3600
1 2 3 5 J x 14 3600
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 3600
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 3601
1 4 1 5 J x 14 3601
1 4 2 6 J x 14 3602
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 3604
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 3605
1 6 1 6 J x 14 3605
1 6 2 61/2 J x 15 3606
2 Lupo model year 1999 to model year 2005 3608
2 1 Lupo, type 6X model year 1999 to model year 2005 3608
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 3610
2 2 1 41/2 J x 13 3610
2 2 2 51/2 J x 13 3611
2 2 3 6 J x 14 3613
2 2 4 6 J x 15 3616
3 Fox model year 2006 3618
3 1 Fox, type 5Z model year 2006 3618
3 2 Wheel allocation for Fox, type 5Z model year 2006 3619
3 2 1 5 J x 14 3619
3 2 2 6 J x 14 3620
3 2 3 6 J x 15 3622
4 Polo model year 1995 to model year 2002 3625
4 1 Polo, type 6N up to and including 07 95 3625
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 3626
4 2 1 41/2 J x 13 3626
4 2 2 51/2 J x 13 3627
4 3 Polo, type 6N from 08 95 up to and including model year 1996 3628
4 4 Polo, type 6N from model year 1997 to model year 1999 3629
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 3631
4 5 1 41/2 J x 13 3631
4 5 2 51/2 J x 13 3632
4 5 3 6 J x 14 3633
4 5 4 6 J x 15 3635
4 6 Polo, type 6N from model year 2000 to model year 2002 3637
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 3638
4 7 1 41/2 J x 13 3638
4 7 2 51/2 J x 13 3639
4 7 3 6 J x 14 3640
4 7 4 6 J x 15 3642
5 Polo from model year 2002 3645
5 1 Polo, type 9N model year 2002 to model year 2006 3645
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 3647
5 2 1 5 J x 13 3648
5 2 2 5 J x 14 3648
5 2 3 6 J x 14 3649
5 2 4 6 J x 15 3650
5 2 5 61/2 J x 16 3652
6 Polo Fun from model year 2004 3656
6 1 Polo Fun, type 9N model year 2002 to model year 2006 3656
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 3657
6 2 1 6 J x 15 3657
6 2 2 71/2 J x 17 3658
7 Polo Classic model year 1996 to model year 2002 3659
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 3659
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 3661
7 2 1 51/2 J x 13 3661
7 2 2 6 J x 14 3662
7 2 3 6 J x 15 3664
8 Polo estate model year 1998 to model year 2002 3666
8 1 Polo estate type 6KV model year 1998 to model year 2002 3666
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 3668
8 2 1 51/2 J x 13 3668
8 2 2 6 J x 14 3669
8 2 3 6 J x 15 3671
9 Polo saloon/sedan model year 2004 to model year 2005 3673
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 3673
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 3675
9 2 1 5 J x 14 3675
9 2 2 6 J x 14 3675
9 2 3 6 J x 15 3677
9 2 4 61/2 J x 16 3679
10 Golf model year 1992 to model year 1998 3681
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3681
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 3684
10 2 1 51/2 J x 13 3685
10 2 2 6 J x 14 3686
10 2 3 6 J x 15 3690
10 2 4 61/2 J x 15 3694
10 2 5 7 J x 16 3698
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 3699
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3699
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 3702
11 2 1 6 J x 14 3702
11 2 2 6 J x 15 3703
11 2 3 51/2 J x 16 3708
11 2 4 61/2 J x 16 3709
11 2 5 7 J x 17 3715
11 2 6 71/2 J x 17 3718
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 3718
11 4 Golf R32, type 1J model year 2003 to model year 2005 3719
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 3720
11 5 1 51/2 J x 17 3720
11 5 2 71/2 J x 17 3721
11 5 3 71/2 J x 18 3722
11 6 Golf Anniversary GTI, type 1J model year 2002 3722
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 3723
11 7 1 51/2 J x 16 3723
11 7 2 61/2 J x 16 3724
11 7 3 7 J x 17 3726
11 7 4 71/2 J x 18 3728
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 3729
12 Golf from model year 2004 3731
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 3731
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 3733
12 2 1 6 J x 15 3733
12 2 2 61/2 J x 15 3734
12 2 3 6 J x 16 3735
12 2 4 61/2 J x 16 3736
12 2 5 7 J x 17 3738
12 2 6 71/2 J x 17 3741
12 2 7 71/2 J x 18 3741
12 3 Golf GTI, type 1K model year 2005 to model year 2006 3742
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 3743
12 4 1 6 J x 16 3743
12 4 2 61/2 J x 16 3744
12 4 3 6 J x 17 3745
12 4 4 7 J x 17 3746
12 4 5 71/2 J x 17 3749
12 4 6 71/2 J x 18 3749
13 Golf Plus from model year 2005 3751
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 3751
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 3753
13 2 1 6 J x 15 3753
13 2 2 61/2 J x 15 3754
13 2 3 6 J x 16 3755
13 2 4 61/2 J x 16 3756
13 2 5 7 J x 17 3758
13 2 6 71/2 J x 18 3761
14 Golf estate model year 1994 to model year 1998 3763
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 3763
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 3766
14 2 1 51/2 J x 13 3766
14 2 2 6 J x 14 3767
14 2 3 6 J x 15 3772
14 2 4 61/2 J x 15 3776
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 3777
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 3777
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 3780
15 2 1 6 J x 15 3780
15 2 2 51/2 J x 16 3784
15 2 3 61/2 J x 16 3785
15 2 4 7 J x 17 3791
15 2 5 71/2 J x 17 3794
15 3 Conditions for fitting 17″ wheels and tyres 3795
16 Golf cabriolet model year 1994 to model year 1997 3797
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 3797
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 3798
16 2 1 6 J x 14 3799
16 2 2 6 J x 15 3800
16 2 3 61/2 J x 16 3801
17 Golf cabriolet model year 1998 to model year 2002 3803
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 3803
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 3804
17 2 1 6 J x 14 3804
17 2 2 6 J x 15 3807
17 2 3 61/2 J x 16 3809
18 Vento from model year 1992 to model year 1998 3810
18 1 Vento; type 1HX0, 1H 3810
18 2 Wheel allocation for Vento; type 1HX0, 1H 3812
18 2 1 51/2 J x 13 3812
18 2 2 6 J x 14 3814
18 2 3 6 J x 15 3817
18 2 4 61/2 J x 15 3820
19 Bora model year 1999 to model year 2005 3826
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 3826
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 3829
19 2 1 6 J x 15 3829
19 2 2 51/2 J x 16 3833
19 2 3 61/2 J x 16 3834
19 2 4 7 J x 17 3840
19 2 5 71/2 J x 17 3843
19 3 Conditions for fitting 17″ wheels and tyres 3844
20 Jetta from model year 2006 3846
20 1 Jetta, type 1KM from model year 2006 3846
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 3848
20 2 1 6 J x 15 3848
20 2 2 61/2 J x 15 3849
20 2 3 6 J x 16 3849
20 2 4 61/2 J x 16 3850
20 2 5 7 J x 17 3852
21 New Beetle from model year 1999 3856
21 1 New Beetle, type 9C model year 1999 to model year 2006 3856
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 3859
21 2 1 6 J x 15 3859
21 2 2 51/2 J x 16 3862
21 2 3 61/2 J x 16 3863
21 2 4 7 J x 17 3868
21 2 5 71/2 J x 17 3871
21 3 Conditions for fitting 17″ wheels and tyres 3872
22 New Beetle Cabriolet from model year 2003 3874
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 3874
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 3876
22 2 1 6 J x 15 3876
22 2 2 51/2 J x 16 3879
22 2 3 61/2 J x 16 3880
22 2 4 7 J x 17 3884
22 2 5 71/2 J x 17 3888
22 3 Conditions for fitting 17″ wheels and tyres 3888
23 New Beetle RSi 3890
23 1 New Beetle RSi, type 9CR from model year 2001 3890
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 3891
23 2 1 7 J x 16 3891
23 2 2 9 x 18 3892
24 Touran from model year 2003 3893
24 1 Touran, type 1T, model year 2003 to model year 2006 3893
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 3896
24 2 1 6 J x 15 3896
24 2 2 61/2 J x 15 3897
24 2 3 6 J x 16 3898
24 2 4 61/2 J x 16 3899
24 2 5 7 J x 17 3901
25 Passat model year 1994 to model year 1997 3902
25 1 Passat, type 35l model year 1994 to model year 1997 3902
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 3904
25 2 1 6 J x 14 3904
25 2 2 6 J x 15 3907
26 Passat model year 1997 to model year 2006 3912
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 3912
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 3914
26 2 1 6 J x 15 3914
26 2 2 7 J x 15 3916
26 2 3 7 J x 16 3917
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 3918
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 3920
26 4 1 6 J x 15 3920
26 4 2 7 J x 15 3921
26 4 3 6 J x 16 3923
26 4 4 7 J x 16 3924
26 4 5 7 J x 17 3926
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 3927
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 3928
26 6 1 7 J x 16 3929
26 6 2 6 J x 17 3929
26 6 3 71/2 J x 17 3930
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 3930
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 3931
26 8 1 6 J x 16 3932
26 8 2 7 J x 16 3932
27 Passat from model year 2006 3934
27 1 Passat, type 3C from model year 2006 3934
27 2 Wheel allocation for Passat, type 3C from model year 2006 3936
27 2 1 61/2 J x 16 3937
27 2 2 7 J x 16 3937
27 2 3 6 J x 17 3939
27 2 4 71/2 J x 17 3939
27 2 5 8 J x 18 3942
28 Phaeton from model year 2003 3944
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 3944
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 3946
28 2 1 71/2 J x 16 3947
28 2 2 71/2 J x 17 3947
28 2 3 71/2 J x 18 3949
28 2 4 81/2 J x 18 3949
28 2 5 81/2 J x 19 3951
28 2 6 9 J x 19 3951
29 Sharan from model year 1996 3952
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 3952
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 3955
29 2 1 6 J x 15 3955
29 2 2 7 J x 15 3955
29 2 3 7 J x 16 3956
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 3957
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 3959
29 4 1 6 J x 15 3959
29 4 2 7 J x 15 3960
29 4 3 6 J x 16 3961
29 4 4 7 J x 16 3962
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 3965
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 3967
29 6 1 6 J x 16 3967
29 6 2 7 J x 16 3968
29 6 3 7 J x 17 3971
30 Touareg from model year 2003 3972
30 1 Touareg, type 7L, model year 2003 to model year 2006 3972
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 3975
30 2 1 7 J x 16 3975
30 2 2 71/2 J x 17 3976
30 2 3 8 J x 18 3977
30 2 4 9 J x 19 3980
30 2 5 9 J x 20 3984
30 2 6 91/2 J x 20 3985
31 Breakdown set for VW Vehicles 3986
32 Temporary spare tyres and wheels for VW vehicles 3987
33 Approved makes of summer tyres for initial fitting 3990
33 1 Summer tyres for Lupo 3L from model year 1999 3990
33 2 Summer tyres for Lupo FSI from model year 1999 3990
33 3 Summer tyres for Lupo GTI from model year 1999 3990
33 4 Summer tyres for Lupo model year 1999 to model year 2005 3990
33 5 Summer tyres for Fox from model year 2006 3990
33 6 Summer tyres for Polo, model year 1995 to model year 2002 3991
33 7 Summer tyres for Polo from model year 2002 3992
33 8 Summer tyres for Polo saloon/sedan from model year 2004 3992
33 9 Summer tyres for Polo Fun from model year 2004 3993
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 3993
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 3994
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 3994
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 3995
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 3995
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 3996
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 3997
33 17 Summer tyres for Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 3998
33 18 Summer tyres for Golf R32 3998
33 19 Summer tyres for Golf Anniversary GTI 3999
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 3999
33 21 Summer tyres for New Beetle from model year 1999 4000
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 4001
33 23 Summer tyres for New Beetle RSi 4002
33 24 Summer tyres for Golf from model year 2004 4002
33 25 Summer tyres for Golf GTI from model year 2005 4003
33 26 Summer tyres for Golf Plus from model year 2005 4003
33 27 Summer tyres for Jetta from model year 2006 4004
33 28 Summer tyres for Touran from model year 2003 4004
33 29 Summer tyres for Passat model year 1994 to model year 1997 4005
33 30 Summer tyres for Passat model year 1997 to model year 2006 4005
33 31 Summer tyres for Passat W8 4006
33 32 Summer tyres for Passat Protect 4006
33 33 Summer tyres for Passat from model year 2006 4006
33 34 Summer tyres for Phaeton from model year 2003 4007
33 35 Summer tyres for Sharan from model year 1996 4007
33 36 Summer tyres for Touareg from model year 2003 4008
34 Approved makes of all-season tyres for initial fitting 4009
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 4009
34 2 All-season tyres Polo model year 1995 to model year 2002 4009
34 3 All-season tyres from model year 2002 4009
34 4 Summer tyres for Polo saloon/sedan from model year 2004 4009
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 4009
34 6 All-season tyres Golf estate model year 1994 to model year 1998 4009
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 4010
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 4010
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 4010
34 10 All-season tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 4011
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 4011
34 12 All-weather tyres New Beetle from model year 1999 4011
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 4011
34 14 All-weather tyres Golf from model year 2004 4012
34 15 All-season tyres for Golf Plus from model year 2005 4012
34 16 All-season tyres for Jetta from model year 2006 4012
34 17 All-weather tyres Touran from model year 2003 4013
34 18 All-season tyres for Passat, model year 1997 to model year 2006 4013
34 19 All-season tyres for Passat W8 4013
34 20 All-weather tyres Passat from model year 2006 4013
34 21 All-weather tyres Phaeton from model year 2003 4014
34 22 All-weather tyres Touareg from model year 2003 4014
35 Approved makes of winter tyres for initial fitting 4015
35 1 Winter tyres for Lupo 3L from model year 1999 4015
35 2 Winter tyres for Lupo FSI from model year 1999 4015
35 3 Winter tyres for Lupo GTI from model year 1999 4015
35 4 Winter tyres Lupo model year 1999 to model year 2005 4015
35 5 Winter tyres for Fox from model year 2006 4015
35 6 Winter tyres for Polo model year 1995 to model year 2002 4016
35 7 Winter tyres Polo from model year 2002 4016
35 8 Summer tyres for Polo saloon/sedan from model year 2004 4016
35 9 Summer tyres for Polo Fun from model year 2004 4017
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 4017
35 11 Winter tyres Polo estate model year 1998 to model year 2002 4017
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 4018
35 13 Winter tyres Golf estate model year 1994 to model year 1998 4018
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 4018
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 4019
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 4019
35 17 Winter tyres Golf estate, Golf estate 4Motion model year 1999 to model year 2006, Bora estate, Bora estate 4Motion model year 1999 to model year 2005 4020
35 18 Winter tyres for Golf R32 4020
35 19 Winter tyres for Golf Anniversary GTI 4020
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 4020
35 21 Winter tyres New Beetle from model year 1999 4021
35 22 Winter tyres New Beetle Cabriolet from model year 2003 4021
35 23 Winter tyres for New Beetle RSi 4022
35 24 Winter tyres Golf from model year 2004 4022
35 25 Winter tyres for Golf GTI from model year 2005 4022
35 26 Winter tyres for Golf Plus from model year 2005 4022
35 27 Winter tyres for Jetta from model year 2006 4022
35 28 Winter tyres Touran from model year 2003 4023
35 29 Winter tyres for Passat model year 1994 to model year 1997 4023
35 30 Winter tyres for Passat model year 1997 to model year 2006 4023
35 31 Winter tyres for Passat W8 4024
35 32 Winter tyres for Passat Protect 4024
35 33 Winter tyres Passat from model year 2006 4024
35 34 Winter tyres Phaeton from model year 2003 4024
35 35 Winter tyres Sharan from model year 1996 4025
35 36 Winter tyres Touareg from model year 2003 4025
36 Approved makes of offroad tyres for initial fitting 4026
36 1 Offroad tyres for Touareg from model year 2003 4026
D4B807E3B5B Body Repairs General Body Repairs 4027
1 Safety instructions 4031
1 1 Part removal 4031
1 2 Battery and welding operation 4031
1 3 Electronic control unit 4031
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 4031
1 4 Paint, glass, soft pad and trim 4032
1 5 Fuel tank or fuel delivery pipeline 4032
1 6 Air conditioner 4032
1 6 1 Remedial measures: 4032
1 7 Airbag System 4033
1 8 Check the seat belts 4033
1 8 1 Belt body 4034
1 8 2 Automatic retractor (locking function) 4034
1 8 3 Visual inspection of the seat belt buckle 4035
1 8 4 Seat belt buckle function 4035
1 8 5 Seat belt guide member and tongue 4036
1 8 6 Fixing piece and fixing point 4036
1 9 Safety specifications for the seat belt tensioner 4036
1 10 Body repair on a vehicle equipped with the seat belt tensioners 4037
1 10 1 The following vehicles have been equipped with: 4037
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 4038
1 12 Remove the front seats with a side airbag 4038
2 Basic instruction 4039
2 1 Diagnosis of the accident vehicle 4039
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 4039
2 3 Correction 4039
2 4 Cutting 4039
2 5 Body-cut part and part section 4039
2 6 Original connection 4040
2 7 Galvanized body parts 4040
2 8 Remove the rest part 4040
2 9 New parts 4040
2 10 Parts 4040
2 11 Molded foam plastic pads 4041
3 Symbolic interpretation 4042
3 1 Symbolic interpretation for welding 4042
3 2 Symbolic interpretation for the operation method 4042
3 2 1 Grinding 4043
3 2 2 Thinning 4043
3 2 3 Punching 4043
3 2 4 Drilling 4044
3 2 5 Polishing 4044
3 2 6 Cavity corrosion protection 4044
3 2 7 Bonding 4045
3 2 8 Precise sealing 4045
4 Body repair tools 4046
4 1 Flaring tool -V A G 1317- 4046
4 2 Punching pliers -V A G 1329- 4046
4 3 Basic equipment -V A G 1366/3- 4046
4 4 Bottom protection layer spray gun -V A G 1379- 4047
4 5 Electric blower -V A G 1416- 4047
4 6 Door tensioner -V A G 1438- 4047
4 7 Body equipment component -V A G 1439- 4048
4 8 Pneumatic cutting knife -V A G 1523 A- 4048
4 9 Air chisel -V A G 1577- 4048
4 10 Edge closing iron block -V A G 1585- 4049
4 11 Welding fume ventilator -V A G 1586- 4049
4 12 Welding spot releasing device -V A G 1731- 4049
4 13 Pneumatic spray gun -V A G 1761/1- 4050
4 14 Pneumatic punching and thinning pliers -VAS 1996- 4050
4 15 Pneumatic adhesive spray gun -V A G 2005- 4050
4 16 Door hinge correction tool 4051
4 17 Hose kit 5023 for the inert gas protection welding 4051
4 18 Angle grinder -VAS 5174- 4051
4 19 Angle grinder -VAS 5175- 4052
4 20 Wire brush -VAS 5182- 4052
5 Body bonding 4053
5 1 Transporter 1991 → 4053
5 1 1 Separation process: 4053
5 1 2 Bonding process: 4053
5 2 Bonding types 4053
5 2 1 Bonding-strong 4053
5 2 2 Bonding-spot welding 4054
5 3 Repair method for replacing the parts 4054
5 3 1 Spot welding and bonding 4054
5 3 2 Plug welding and bonding (if spot welding is impossible) 4054
5 3 3 Welding fume ventilator 4055
5 3 4 Preparations 4055
5 3 5 Trimming 4055
6 Corrosion protection measures 4056
6 1 Corrosion protection 4056
7 Waste disposal instructions 4057
7 1 Waste disposal 4057
7 2 Air pressure tappet exhaust 4057
7 3 Airbag 4058
7 3 1 Waste disposal 4058
8 Contact corrosion protection 4059
8 1 Connection of aluminum alloy/magnesium alloy with steel 4059
9 Steel plate repair 4060
9 1 High-strength body plate 4060
9 2 Galvanized body parts 4060
9 2 1 Preparations 4060
9 2 2 Part cutting 4061
9 2 3 Connection process 4061
9 3 Welding on the galvanized body steel plate 4061
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 4061
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 4062
9 3 3 Welding transformer 4062
9 3 4 Welding clamp 4062
9 4 Tearing test 4062
10 Aluminum repair 4063
10 1 Painting 4063
10 2 Surface treatment 4063
10 3 Leveling 4064
10 4 Temperature control for heating 4064
11 Plastic repair method 4065
11 1 Material 4065
11 2 Repairing the pit 4066
11 3 Repairing the scratch 4067
11 4 Repair the crack 4069
11 5 Repairing the small hole (the diameter is more than 30 mm) 4070
11 6 Plastic repair (glass fibre material) 4071
11 7 Repair process 4072
11 7 1 Repairing the breakage position 4072
11 7 2 Repairing the surface damage 4074
12 Glass repair 4075
12 1 Repairing the windshield 4075
12 1 1 Premises 4075
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 4076
12 1 3 Repair description 4077
D4B8038DB0A 4 cylinder injection engine (crossflow cylinder head) mechanics 4081
00 – Technical data 4085
1 Technical data 4085
1 1 Engine number 4085
1 2 Engine data 4085
10 – Removing and installing engine 4087
1 Removing and installing engine 4087
1 1 Notes on removing 4087
1 2 Notes on installing 4089
1 3 Specified torques 4090
1 4 Assembly mountings 4091
1 5 Renewing engine carrier rubber mounting 4092
13 – Crankshaft group 4095
1 Dismantling and assembling engine 4095
1 1 Assembly overview 4095
1 1 1 Part I 4096
1 1 2 Part II – engine codes AEK, ATU, AWF, AWG 4098
1 1 3 Part Il – engine codes AFT, AKS 4099
1 1 4 Part III 4100
1 2 Removing and installing poly V-belt 4102
1 3 Removing, installing and tensioning toothed belt 4104
2 Removing and installing sealing flange and pressure plate/drive plate 4108
2 1 Assembly overview – sealing flanges 4108
2 2 Renewing crankshaft oil seal – pulley end 4110
2 3 Removing and installing drive plate 4112
3 Crankshaft 4114
3 1 Assembly overview – crankshaft 4114
3 2 Crankshaft dimensions 4115
4 Dismantling and assembling pistons and conrods 4116
4 1 Assembly overview – pistons and conrods 4116
4 2 Checking pistons, piston rings and cylinder bores 4117
4 3 Piston and cylinder dimensions 4119
15 – Cylinder head, valve gear 4120
1 Cylinder head 4120
1 1 Assembly overview – cylinder head 4120
1 1 1 Engine codes AEK, ATU, AWF, AWG 4120
1 1 2 Engine codes AFT, AKS 4123
1 2 Removing and installing cylinder head 4124
1 3 Checking compression 4126
2 Valve gear 4128
2 1 Assembly overview – valve gear 4128
2 2 Reworking valve seats 4132
2 3 Removing and installing camshaft oil seal 4133
2 4 Removing and installing camshaft 4135
2 5 Checking hydraulic bucket tappets 4137
2 6 Checking valve guides 4138
2 7 Renewing valve guides 4138
2 7 1 Vehicles ► 10 94 4138
2 7 2 Vehicles 11 94 ► 4139
2 8 Renewing valve stem seals 4140
17 – Lubrication 4143
1 Parts of lubrication system 4143
1 1 Engine oil 4143
1 2 Assembly overview – parts of lubrication system 4143
1 3 Checking oil pressure and oil pressure switch 4146
19 – Cooling 4148
1 Removing and installing parts of cooling system 4148
1 1 Parts of cooling system, body side 4148
1 1 1 Engine codes AEK, AFT, AKS 4148
1 1 2 Engine codes ATU, AWF, AWG 4150
1 2 Parts of cooling system – engine side 4151
1 2 1 Engine codes AEK, AFT, AKS 4152
1 2 2 Engine codes ATU, AWF, AWG 4153
1 3 Dismantling and assembling coolant pump 4155
1 4 Draining and filling coolant 4155
1 5 Removing and installing radiator and fan 4158
20 – Fuel supply system 4160
1 Removing and installing parts of fuel supply system 4160
1 1 Safety precautions when working on fuel supply system 4160
1 2 Rules for cleanliness 4161
1 3 Assembly overview – fuel tank with attachments and fuel filter 4161
1 4 Adjusting accelerator cable 4164
1 4 1 Vehicles with manual gearbox 4164
1 4 2 Vehicles with automatic gearbox 4165
1 5 Removing and installing fuel delivery unit 4166
1 6 Checking fuel pump 4168
1 6 1 Checking function and voltage supply 4170
1 6 2 Checking fuel delivery rate 4170
1 6 3 Checking non-return valve for fuel pump 4172
1 7 Crash fuel shut-off 4172
2 Activated charcoal filter system 4173
2 1 Function 4173
2 2 Assembly overview – activated charcoal filter system 4174
2 2 1 Engine code AEK 4174
2 2 2 Engine codes AFT, AKS 4175
2 2 3 Engine codes ATU, AWF, AWG 4176
2 3 Test solenoid valve 1 for activated charcoal filter 4176
2 4 Checking fuel tank breather 4178
26 – Exhaust system 4180
1 Removing and installing parts of exhaust system 4180
1 1 Exhaust manifold, front exhaust pipe with catalytic converter and add-on parts 4180
1 2 Silencer with mountings 4183
1 3 Checking catalytic converter 4184
2 Secondary air system 4187
2 1 Function 4187
2 2 Removing and installing components of secondary air system 4187
2 3 Checking combination valve 4189
2 3 1 Vehicles ► 05 00 4189
2 3 2 Vehicles 05 00 ► 4190
2 4 Checking secondary air pump motor 4190
2 5 Checking secondary air inlet valve 4191
K0059101320 Electrical system General information 4193
27 – Starter, current supply, CCS 4199
1 Battery 4199
1 1 Fundamentals for batteries 4199
1 2 Battery load test 4199
1 2 1 Battery with »standard« colour indicator 4200
1 2 2 Battery with »enhanced« colour indicator 4200
1 2 3 Absorbent glass mat battery 4201
1 2 4 Lithium ion battery 4201
1 3 Warning notices and safety regulations 4201
1 3 1 Dangers when handling vehicle batteries 4201
1 3 2 Safety markings on battery 4202
1 3 3 Working on airbag system 4203
1 4 Battery load test 4203
2 Checking battery 4205
2 1 Checking the various types of batteries 4205
2 1 1 Checking a battery with colour indicator 4205
2 1 2 Absorbent glass mat battery 4205
2 2 Visual inspection 4206
2 3 Information about battery replacement and battery gas venting 4207
2 4 Checking colour indicator in battery cover 4208
2 4 1 Checking colour indicator, “3-colour” 4208
2 4 2 Checking colour indicator, “2-colour” 4209
2 5 Current draw test 4210
3 Charging the battery 4212
3 1 Totally discharged batteries 4212
4 Cruise control system (CCS) 4214
4 1 Activating and deactivating cruise control system (CCS) 4214
90 – Gauges, instruments 4215
92 – Windscreen wash/wipe system 4216
1 Washer fluid line hose couplings 4216
1 1 Windscreen and rear window washer system 4216
1 2 Headlight washer system 4217
2 Hose repair 4218
2 1 General description 4218
2 2 Repairing smooth pipe 4218
2 3 Repairing corrugated pipe 4218
3 Distinguishing features of jointless wiper blades 4221
94 – Lights, bulbs, switches – exterior 4222
1 Operation and safety notes for gas discharge lamps 4222
96 – Lights, bulbs, switches – interior 4225
1 12 V socket 4225
1 1 Removing and installing 12 V socket 4225
1 2 Removing and installing socket illumination bulb -L42- 4225
2 Cigarette lighter -U1- 4226
2 1 General description 4226
2 2 Assembly overview 4227
2 3 Removing and installing cigarette lighter socket 4228
2 4 Removing and installing cigarette lighter illumination bulb -L28- 4231
97 – Wiring 4233
1 Vehicle diagnostic, testing and information systems 4233
1 1 Connecting vehicle diagnostic tester 4233
1 2 Connecting vehicle diagnostic tester Golf Model Year 1998 – 2003 4235
2 Repairs to wiring harnesses and connectors 4236
2 1 General notes concerning repairs to vehicle electrical system 4236
2 2 Wiring harness repair set 4238
2 2 1 Wiring harness repair set -VAS 1978- 4238
2 2 2 Upgrade kit -VAS 1978/50- 4238
2 2 3 Wiring harness repair set -VAS 1978A- 4239
2 2 4 Release tool set -VAS 1978/35- 4239
2 3 Tool descriptions 4240
2 3 1 Special pliers with insert 4240
2 3 2 Release tools for contacts 4241
2 3 3 Assembly tools for single wire seals 4241
2 3 4 Wire stripper -VAS 1978/3- 4241
2 3 5 Hot air blower 220 V/50 Hz -VAS 1978/14- 4243
2 3 6 Crimping pliers -VAS 1978/1A- 4243
2 4 Repairing wiring harnesses 4245
2 4 1 Repairs to airbag and belt tensioner wiring 4245
2 4 2 Repairing CAN bus wiring 4247
2 4 3 Repair of Flexray wires with sheath 4248
2 4 4 Repair of Flexray wires without sheath 4249
2 4 5 Renewal of aerial wiring 4250
2 4 6 Repairing 0 13 mm2/0 35 mm2/0 5 mm2 wire 4252
2 4 7 Repair of 10 mm2 or 16 mm2 wire with single butt connector 4257
2 4 8 Repair of 2 5 mm2, 4 mm2 or 6 mm2 aluminium wire with single butt connector 4264
2 4 9 Wiring open circuit with one repair position 4270
2 4 10 Wiring open circuit with two repair positions 4273
2 5 Repairing fibre optic cables 4275
2 5 1 Preparing fibre optic cable 4276
2 5 2 Detaching fibre optic cable from cable harness connector 4283
2 6 Repair of aerial wires 4284
2 6 1 Repair set, aerial cable VAS 6720 4284
2 7 Repairs to contact housings and connectors 4296
2 7 1 Notes on repairs to contact housings and connectors 4296
2 7 2 Repairs to contacts in contact housings 4296
2 7 3 Fitting single wire seals 4298
2 7 4 Repairs to contact housings using cut-and-clamp method 4301
2 8 Releasing and dismantling contact housings 4302
2 8 1 Notes on releasing and dismantling contact housings 4302
2 8 2 Secondary locking element 4302
2 8 3 Primary locking element 4303
2 8 4 Round connector systems 4304
2 8 5 Flat connector systems 4305
2 8 6 Special connector systems 4307
3 Contact surface cleaning set -VAS 6410- 4310
3 1 Using contact surface cleaning set -VAS 6410- 4310
3 1 1 Servicing ring terminals 4310
3 1 2 Servicing screw connections 4312
3 1 3 Cleaning battery clamp and battery terminal 4314
3 1 4 Anti-corrosion treatment 4316
4 Renewing lambda probe 4318
4 1 Renewing LSF Lambda probe (4-pin) 4318
4 2 Renewing LSU Lambda probe (6-pin) 4319
4 3 Types of protective tube on universal lambda probes 4320
5 Exhaust gas temperature sensor 4322

S.V 26/01/2025