Volkswagen Golf III Vento Repair Manual – PDF DOWNLOAD

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Volkswagen Golf III Vento Repair Manual – PDF DOWNLOAD

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Volkswagen Golf III Vento Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 6209
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Golf III Vento 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
00054005020 4 Cyl injection engine Mechanics (1 4 and 1 6 l engine) 756
00 – Technical data 760
1 – Technical data 760
1 1 – Technical data 760
1 2 – Engine number 760
1 3 – Engine data 760
10 – Removing and installing engine 762
1 – Removing and installing engine 762
1 1 – Removing and installing engine 762
1 2 – Notes on removing 762
1 3 – Notes on installing 763
1 4 – Tightening torques 764
1 5 – Assembly mountings 764
1 6 – Renewing engine carrier rubber mounting 765
13 – Crankshaft group 767
1 – Dismantling and assembling engine 767
1 1 – Dismantling and assembling engine 767
1 2 – Removing and installing ribbed belt 784
1 3 – Removing and installing toothed belt 785
1 4 – Checking semi-automatic toothed belt tensioning roller 788
2 – Dismantling and assembling cylinder block, crankshaft and flywheel 789
2 1 – Dismantling and assembling cylinder block, crankshaft and flywheel 789
2 2 – Renewing crankshaft oil seal – pulley end – 793
2 3 – Crankshaft dimensions 796
3 – Dismantling and assembling pistons and conrods 797
3 1 – Dismantling and assembling pistons and conrods 797
3 2 – Piston and cylinder dimensions 803
15 – Cylinder head, Valve gear 804
1 – Removing and installing cylinder head 804
1 1 – Removing and installing cylinder head 804
1 2 – Removing and installing cylinder head 810
1 3 – Checking compressions 811
2 – Servicing valve gear 812
2 1 – Servicing valve gear 812
2 2 – Reworking valve seats 819
2 3 – Removing and installing camshaft oil seal 821
2 4 – Checking hydraulic bucket tappets 822
2 5 – Removing and installing camshaft 823
2 6 – Checking valve guides 825
2 7 – Renewing valve guides 825
2 8 – Renewing valve stem seals 826
17 – Lubrication 828
1 – Removing and installing parts of the lubrication system 828
1 1 – Removing and installing parts of the lubrication system 828
1 2 – Removing and installing oil sump 842
1 3 – Removing and installing Duo-centric oil pump 844
1 4 – Checking oil pressure and oil pressure switch 847
19 – Cooling system 850
1 – Removing and installing parts of cooling system 850
1 1 – Removing and installing parts of cooling system 850
1 2 – Parts of cooling system body side 851
1 3 – Parts of cooling system – engine side 854
1 4 – Draining and filling cooling system 865
20 – Fuel supply system 867
1 – Removing and installing parts of fuel supply system 867
1 1 – Removing and installing parts of fuel supply system 867
1 2 – Removing and installing fuel tank with its attachments 868
1 3 – Safety precautions when working on the fuel supply system 873
1 4 – Rules for cleanliness 874
1 5 – Adjusting throttle cable 874
1 6 – Removing and installing fuel delivery unit 874
1 7 – Checking fuel pump 875
1 8 – Removing and installing parts of the activated charcoal filter system 881
1 9 – Checking fuel tank breather 882
26 – Exhaust system 885
1 – Removing and installing parts of exhaust system 885
1 1 – Removing and installing parts of exhaust system 885
00054005120 General body repairs 891
50 – Body – front 899
1 Body – front 899
1 1 Removing and installing lock carrier with add-on components 899
1 1 1 Assembly overview 899
1 1 2 Removing 899
1 1 3 Installing 900
1 2 Removing and installing front wing 900
1 2 1 Removing 900
1 2 2 Installing 901
55 – Bonnet, rear lid 902
1 Bonnet 902
1 1 Removing and installing bonnet lock cable 902
2 Rear lid 903
2 1 Removing gas strut 903
2 2 Removing gas strut (estate) 903
2 3 Releasing gas from gas strut 904
2 4 Adjusting lid (estate) 904
2 5 Removing and installing rear lid lock (estate) ▸ 07 95 905
2 6 Repairing push button (estate) 907
2 7 Removing and installing rear lid lock (estate) 08 95 ▸ 908
2 8 Removing and installing lock cylinder 908
57 – Front doors, door components, central locking 910
1 Front door 910
1 1 Assembly overview – front door 910
1 2 Assembly overview – front door (only for 2 and 4-door vehicles with side airbag) 911
1 3 Installing impact padding (only for 2- and 4-door vehicles with side airbag) 912
1 4 Removing and installing door 912
1 4 1 Removing 912
1 4 2 Installing 913
1 5 Adjusting door 913
1 6 Removing door window 914
1 7 Adjusting door window 915
1 8 Removing and installing window regulator 915
1 8 1 Removing 915
1 8 2 Installing 915
1 9 Repairing electric window regulators 916
1 10 Electric window regulator with convenience function (automatic opening and closing) and force limitation mechanism 917
1 10 1 Function of window regulator with ignition switched on 918
1 10 2 Function of window regulator with ignition switched off 918
1 11 Overcoming resistance with excess force limitation 918
1 12 Initialising and releasing automatic closing function 919
1 12 1 Via door lock from outside using ignition key (parallel for all windows) when (at least some) windows are open: 919
1 12 2 From inside using window operation switch (perform for each window individually) 919
1 13 Assembly overview – door lock with working parts 920
1 14 Removing and installing door lock 920
1 14 1 Removing 920
1 14 2 Installing 921
1 15 Removing inner release handle 921
1 16 Assembly overview – door handle 921
1 17 Removing and installing door handle 923
1 17 1 Removing 923
1 17 2 Installing 923
1 18 Maintaining single-key locking 923
2 Central locking 924
2 1 Assembly overview – central locking 924
2 2 New couplings and distributor elements for pipe connections 925
2 3 Removing and installing dual pressure pump 925
2 3 1 Removing 925
2 3 2 Installing 926
2 4 Removing and installing positioning element for fuel tank flap 926
2 4 1 Removing 926
2 4 2 Installing 926
2 5 Removing and installing front door positioning element 926
2 5 1 Removing 926
2 5 2 Installing 927
2 6 Removing and installing rear door lock positioning element 927
2 6 1 Removing 927
2 6 2 Installing 928
2 7 Removing and installing rear lid positioning element 929
2 7 1 Removing 929
2 7 2 Installing 929
2 8 Removing and installing rear lid positioning element (estate) 929
2 8 1 Removing 929
2 8 2 Installing 930
2 9 Functional check of central locking 930
2 9 1 Checking locking mechanism 931
2 9 2 Testing anti-theft function 931
58 – Rear doors, door components 932
1 Rear door 932
1 1 Assembly overview – rear door 932
1 2 Adjusting door window 933
60 – Sunroof 934
1 Sunroof with glass panel 934
1 1 Assembly overview – sliding/tilting roof with glass panel 934
1 2 Removing glass panel for sliding/tilting sunroof 935
1 3 Installing glass panel for sliding/tilting sunroof 936
1 4 Adjusting sunroof glass panel height 936
1 5 Adjusting panel seal 937
1 6 Checking electric drive (0 position) 937
1 7 Checking and adjusting parallel running 938
1 7 1 Checking 938
1 7 2 Adjusting 939
1 8 Removing and installing sliding headliner ▸ 08 94 939
1 8 1 Removing 939
1 8 2 Installing 940
1 9 Removing and installing sliding headliner 09 94 ▸ 940
1 9 1 Removing 940
1 9 2 Installing 941
1 10 Removing and installing carrier unit 941
1 10 1 Removing 941
1 10 2 Installing 942
1 11 Cleaning water drain hoses 943
1 11 1 Front water drain hoses 943
1 11 2 Rear water drain hoses 944
63 – Bumpers 946
1 Front bumper 946
1 1 Removing and installing front bumper 946
1 1 1 Removing and installing cover 946
2 Rear bumper 948
2 1 Removing and installing rear bumper 948
2 2 Removing and installing rear bumper (estate) 949
64 – Glazing 950
1 Flush bonded windows 950
1 1 Tools 950
1 2 Materials 952
1 3 Assembly overview – windscreen 952
1 4 Removing and installing windscreen 953
1 4 1 Removing 953
1 4 2 Installing 954
1 5 Assembly overview – rear window 954
1 6 Removing and installing rear window 955
1 6 1 Removing undamaged rear window 955
1 6 2 Removing broken rear window 956
1 6 3 Installing rear window 956
1 7 Assembly overview – side window 957
1 8 Removing and installing side window 957
1 8 1 Removing undamaged side window 957
1 8 2 Removing broken side window 958
1 8 3 Installing side window 958
1 9 Preparing old undamaged window for glazing 959
1 10 Preparing new window for glazing 959
1 11 Preparing body flange for glazing 960
1 12 Installation instructions 960
1 13 Curing time 960
1 14 Touching up paint damage 961
1 15 Cleaning off excess adhesive sealing material 961
66 – Exterior equipment 962
1 Trim 962
1 1 Removing and installing radiator grille with trim frame 962
2 Roof moulding 963
2 1 Removing and installing roof moulding 963
2 1 1 Removing 963
2 1 2 Installing 963
3 Roof railing 965
3 1 Removing and installing roof railing 965
4 Removing and installing wheel housing liner 966
5 Exterior mirror 967
6 Protective strips 968
6 1 Renewing side protective strips 968
7 Spoiler 969
7 1 Removing and installing rear spoiler (Vento) 969
7 2 Retrofitting rear spoiler (Vento) 969
8 Sill panel trim 971
8 1 Assembly overview 971
8 2 Removing and installing retaining strip 971
8 2 1 Removing 971
8 2 2 Installing 971
68 – Interior equipment 973
1 Interior mirror 973
1 1 Removing and installing interior mirror 973
1 1 1 Removing 973
1 1 2 Installing 973
1 2 Repair method using glass-to-metal adhesive 973
2 Compartments, covers and trims 975
2 1 Removing and installing centre console 975
2 1 1 Removing 975
2 1 2 Installing 975
2 2 Assembly overview – glove box 977
2 3 Removing passenger’s storage compartment 978
2 4 Removing trim for dash panel insert 978
2 5 Removing sun visor 978
3 Grab handles 979
3 1 Removing roof grab handle 979
4 Sill panel trims 980
4 1 Tools 980
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 980
4 2 Removing and installing sill panel trim 980
5 Net partition 982
5 1 Retrofitting net partition 982
5 2 Installing reinforcement plates and lashing eyes 982
5 2 1 Installing top reinforcement plates 983
5 2 2 Installing bottom, front lashing eye 983
5 3 Widening openings for cover caps in moulded headliner 984
5 4 Hooking in net partition 984
5 4 1 Hook in net partition at top 984
5 4 2 Hook in net partition to floor of luggage compartment 984
5 4 3 Hook net partition in footwell 984
5 4 4 Removing net partition 985
6 Luggage compartment cover 986
6 1 Removing and installing luggage compartment cover 986
7 Glove compartment 987
7 1 Removing and installing glove compartment on vehicles with passenger airbag 987
7 1 1 Removing 987
7 1 2 Installing 987
7 2 Removing glove compartment lock cylinder on vehicles with passenger airbag 988
69 – Passenger protection 990
1 Seat belts 990
1 1 Safety regulations for belt tensioners 990
1 2 Disposal of belt tensioner units 990
1 3 Checking belt tensioner 990
1 4 Removing and installing front seat belts with belt tensioner 990
1 5 Removing and installing belt reel with tensioner unit 991
1 5 1 Assembly overview 991
1 5 2 Removing 992
1 5 3 Installing 993
1 6 Removing and installing front seat belts without belt tensioner 994
1 7 Removing and installing belt height adjustment 995
1 8 Removing front anchorage (two-door) 995
1 9 Removing front anchorage (four-door) 996
1 10 Removing front belt buckle 996
1 11 Removing and installing rear seat belts 996
1 12 Removing and installing rear belt reel 997
1 13 Removing and installing lap belt and double buckle 998
2 Inspecting seat belts 999
2 1 Points to check 999
2 1 1 Checking belt webbing 999
2 1 2 Checking inertia reel (locking mechanism) 1000
2 1 3 Visually checking belt buckle 1001
2 1 4 Checking operation of belt buckle 1001
2 1 5 Checking belt anchors, belt guides and latch plates 1001
2 1 6 Checking securing parts and anchorage points 1001
3 Airbag 1002
3 1 Overview – installation locations 1002
3 2 Safety precautions when working on the airbag 1002
3 3 Disposal of airbag units 1003
3 4 Deactivating the airbag 1003
3 5 Renewing airbag units following an accident 1003
3 5 1 Accident involving triggering of airbag 1003
3 5 2 Accident not involving triggering of airbag 1004
3 6 Removing and installing driver airbag unit 1004
3 6 1 Assembly overview 1004
3 6 2 Removing 1005
3 6 3 Installing 1006
3 7 Removing and installing steering wheel 1006
3 7 1 Removing 1006
3 7 2 Installing 1007
3 8 Removing and installing return spring with slip ring 1007
3 9 Removing and installing front passenger airbag unit 1008
3 9 1 Removing 1008
3 9 2 Installing 1010
3 10 Removing and installing driver and front passenger side airbag 1011
3 10 1 Fitting instructions: 1011
3 11 Removing and installing sensor for driver’s/front passenger’s side airbag 1012
3 11 1 Removing 1012
3 11 2 Fitting instructions: 1013
3 12 Removing and installing airbag control unit (J 234) 1013
3 12 1 Removing 1013
3 12 2 Installing 1014
3 13 Retrofitting airbag (driver side) 1014
3 13 1 Assembly overview 1014
3 13 2 Installing airbag (retrofit kit) 1015
3 14 Adapting components 1017
70 – Trim, insulation 1018
1 Dash panel 1018
1 1 Removing and installing dash panel 1018
1 1 1 Removing 1018
1 1 2 Installing 1020
2 Door trims 1021
2 1 Tools 1021
2 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 1021
2 2 Removing and installing front door trim 1021
2 3 Removing and installing rear door trim 1023
2 4 Removing and installing window crank handle 1024
2 4 1 Removing window crank 1024
2 4 2 Installing window crank 1024
2 5 Removing and installing door insulation film 1024
2 5 1 Tools 1026
2 5 2 Removing 1027
2 5 3 Installing 1027
3 Pillar and side trims 1029
3 1 Tools 1029
3 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 1029
3 2 Removing and installing upper A-pillar trim 1029
3 3 Removing and installing B-pillar trim 1030
3 3 1 Golf 2-door 1030
3 3 2 Golf 4-door, Vento, Estate 1031
3 4 Removing and installing upper C-pillar trim (Golf) 1033
3 5 Removing and installing upper C-pillar trim (Vento) 1034
3 6 Removing and installing upper C-pillar trim (Estate) 1035
3 7 Removing and installing lower C-pillar trim (Golf 4-door, Vento) 1036
3 8 Removing and installing lower C-pillar trim (Estate) 1036
3 9 Removing and installing D-pillar trim (estate) 1038
3 10 Removing and installing side trim (Golf 2-door) 1039
4 Luggage/load compartment trim 1040
4 1 Tools 1040
4 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 1040
4 2 Removing and installing luggage compartment cover (Golf) 1040
4 3 Removing and installing rear shelf (Vento) 1042
4 4 Removing and installing side trim of luggage compartment (Vento) 1043
4 5 Removing and installing left luggage compartment trim (Estate) 1044
4 6 Removing and installing right luggage compartment trim (Estate) 1045
4 7 Removing and installing luggage compartment floor trim (Estate) 1046
4 8 Removing and installing load sill cover (Estate) 1047
5 Rear lid trim 1048
5 1 Removing and installing rear lid trim (Golf) 1048
5 2 Removing and installing rear lid trim (Estate) 1049
6 Roof trims 1050
6 1 Repairing moulded headliner (Golf, Vento) 1050
6 2 Removing and installing moulded headliner (Golf, Vento) 1050
6 2 1 Removing 1050
6 2 2 Installing 1052
6 3 Repairing moulded headliner (Estate) 1052
6 4 Removing and installing moulded headliner (estate) 1053
6 4 1 Removing 1053
6 4 2 Installing 1054
72 – Seat frames 1055
1 Front seats 1055
1 1 Tools 1055
1 2 Removing and installing seat 1055
1 2 1 Removing 1055
1 2 2 Installing 1057
1 3 Removing and installing backrest 1059
1 3 1 Assembly overview 1059
1 3 2 Removing 1059
1 3 3 Installing 1061
2 Rear seats 1062
2 1 Removing and installing (split folding) bench seat and backrest 1062
2 1 1 Removing 1062
2 1 2 Installing 1063
2 2 Removing and installing centre armrest (Vento) 1063
2 3 Removing and installing ski bag (Vento) 1065
74 – Seat – padding, covers 1066
1 Front seat covers and padding 1066
1 1 Tools 1066
1 1 1 Required special tools, workshop equipment, test and measuring devices and auxiliary items 1066
1 2 Removing and installing front seat cover and padding 1066
1 2 1 Assembly overview 1066
1 2 2 Removing 1067
1 2 3 Installing 1068
1 3 Removing and installing backrest cover and padding 1068
2 Rear seat covers and padding 1070
2 1 Removing and installing cover and padding for (one-piece) bench seat 1070
2 2 Removing and installing cover and padding for (one-piece) backrest 1071
2 3 Removing and installing covers and padding for (divided) bench seat (Golf, Vento) 1072
2 4 Removing and installing covers and padding for (divided) backrest (Golf, Vento) 1073
2 5 Removing and installing lock (backrest) (Vento) 1074
2 6 Removing and installing covers and padding for bench seat (Estate) 1075
2 7 Removing and installing covers and padding for backrest (Estate) 1076
00054005220 Electrical system 1077
01 – Self-diagnosis 1085
1 – Self-diagnosis 1085
1 1 – Self-diagnosis 1085
1 2 – Tools 1085
1 3 – Connecting fault reader 1085
2 – Self-diagnosis of immobilizer 1087
2 1 – Self-diagnosis of immobilizer 1087
2 2 – Additional information and prerequisites for work requiring the 7-digit PIN 1088
2 3 – Performing self-diagnosis of immobilizer 1089
2 4 – Reading measured value block 1096
2 5 – Adapting ignition keys 1099
2 6 – Lost key procedure 1104
2 7 – Setting when changing immobilizer control unit (coding control unit) 1104
2 8 – Procedure after changing immobilizer control unit 1105
2 9 – Procedure after changing engine control unit (Adaption) 1108
2 10 – Procedure when immobilizer control unit and engine control unit have been changed 1111
2 11 – Procedure for immobilizer malfunctions 1112
2 12 – Activating used engine control unit 1113
3 – Self-diagnosis of radio systems for Golf Convertible 05 98 > 1113
3 1 – Self-diagnosis of radio systems for Golf Convertible 05 98 > 1113
3 2 – Self-diagnosis of radio systems 1113
3 3 – Final control diagnosis 1119
3 4 – Coding radio functions 1121
3 5 – Read measured value block 1122
27 – Starter, Current supply 1124
1 – Battery 1124
1 1 – Battery 1124
1 2 – Battery handling instructions 1124
1 3 – Removing and installing battery 1124
1 4 – Visual check 1126
1 5 – Checking electrolyte level 1126
1 6 – No load voltage measurement 1128
1 7 – Checking specific gravity of all cells 1129
1 8 – Battery load test 1131
1 9 – Battery charging 1132
1 10 – Quick charging/starting boost 1133
1 11 – Checking main and auxiliary battery, only Ecomatic vehicles 1133
2 – Starter 1134
2 1 – Starter 1134
2 2 – Removing and installing starter 1134
3 – Alternator with ribbed belt 1139
3 1 – Alternator with ribbed belt 1139
3 2 – 4-Cylinder Diesel and petrol engines with power-assisted steering 1139
3 3 – Diesel engine with power-assisted steering and air conditioner compressor 1141
3 4 – 4-Cylinder injection engine with power-assisted steering and air conditioner compressor 1143
3 5 – 6-Cyl petrol engine 1145
3 6 – Belt drive 1147
3 7 – Checking and adjusting ribbed belt tension 1151
3 8 – Removing and installing ribbed belt, 4 cylinder engine 1151
3 9 – Removing and installing ribbed belt, 6-Cyl engine 1154
3 10 – Checking alternator carbon brushes 1155
3 11 – Replacing ribbed belt pulley on alternator 1156
3 12 – Removing and installing ribbed belt pulley with freewheel 1156
4 – Mechanical cruise control system (CCS) in petrol and diesel engine vehicles (not TDI and SDI) 1158
4 1 – Mechanical cruise control system (CCS) in petrol and diesel engine vehicles (not TDI and SDI) 1158
4 2 – Assembly overview: Cruise control system (CCS) 1158
4 3 – Removing positioning element 1161
4 4 – Adjusting positioning element 1161
4 5 – Removing and installing vent valve 1162
4 6 – Removing and installing CCS control unit (J213) 1162
4 7 – Removing and installing CCS vacuum pump (V18) 1163
4 8 – Checking vacuum system for leaks 1163
5 – Electronic cruise control system (CCS) in vehicles with TDI and SDI engines 1164
5 1 – Electronic cruise control system (CCS) in vehicles with TDI and SDI engines 1164
90 – Gauges, Instruments 1165
1 – Dash panel insert 1165
1 1 – Dash panel insert 1165
1 2 – Removing and installing dash panel insert 1165
1 3 – Renewing bulbs in dash panel insert 1167
1 4 – Dash panel insert connector pin assignment 1169
1 5 – Ecomatic pin assignment, from August 1995 1171
2 – Service interval display 1172
2 1 – Service interval display 1172
2 2 – Zeroing service interval display 1172
2 3 – Setting service interval display 1173
2 4 – Flexible service interval display 1174
2 5 – Zeroing flexible service interval display 1175
2 6 – Entering service interval data 1176
91 – Radio, telephone, navigation 1178
1 – Radio systems 1178
1 1 – Radio systems 1178
1 2 – Radio system overview 1178
1 3 – Radio system “alpha” 1178
1 4 – Radio system “beta” 1180
1 5 – Radio system “gamma” 1182
1 6 – Radio system “gamma” with active loudspeaker system 1186
1 7 – Removing and installing radio >1993 1190
1 8 – Removing and installing radio 1994 > 1191
1 9 – Electronic anti-theft system for radio units 1994 > 1192
1 10 – Activating electronic anti-theft system for radio units 1994 > 1193
1 11 – Removing and installing cassette storage box 1193
1 12 – Removing and installing CD changer in Golf Convertible 1194
2 – Radio systems for Golf Convertible 05 98 > 1195
2 1 – Radio systems for Golf Convertible 05 98 > 1195
2 2 – Radio system overview 1195
2 3 – Radio system “BETA” 1196
2 4 – Radio system “GAMMA” 1198
2 5 – Removing and installing CD changer 1200
2 6 – Removing and installing radio 1201
2 7 – Electronic anti-theft system 1202
2 8 – Activating electronic anti-theft coding 1203
2 9 – Installing radios > 04 98 in vehicles from 05 98 > 1203
2 10 – Installing radios of radio generation 05 98 > in vehicles >04 98 1205
3 – Loudspeaker system 1207
3 1 – Loudspeaker system 1207
3 2 – Removing and installing front right treble loudspeaker 1207
3 3 – Removing and installing front left treble loudspeaker 1207
3 4 – Removing and installing rear bass loudspeakers (2-door) 1208
3 5 – Removing and installing rear treble loudspeakers (2-door) 1208
3 6 – Removing and installing rear bass loudspeakers (4-door) 1209
3 7 – Removing and installing rear treble loudspeakers (4-door) 1209
3 8 – Removing and installing front (bass) active loudspeakers 1210
3 9 – Removing and installing rear bass speakers with integrated dome type treble speakers (Golf Convertible) 1210
4 – Aerial systems 1212
4 1 – Aerial systems 1212
4 2 – Removing and installing telescopic aerial 1212
4 3 – Removing and installing short rod aerial in Golf Convertible 1214
4 4 – Removing and installing roof aerial up to Model year 1993 1216
4 5 – Removing and installing roof aerial from Model year 1994 > 1218
4 6 – Vento window aerial 1219
4 7 – Aerial amplifier 1220
4 8 – Suppression measures 1220
5 – Digital Sound System (DSP), Golf saloon 1221
5 1 – Digital Sound System (DSP), Golf saloon 1221
5 2 – Removing and installing housing with amplifier and bass loudspeaker 1225
5 3 – Removing and installing amplifier 1227
5 4 – Removing and installing operating unit in centre console 1227
6 – Digital Sound System (DSP), Golf Convertible 1229
6 1 – Digital Sound System (DSP), Golf Convertible 1229
6 2 – Removing and installing amplifier 1232
6 3 – Removing and installing operating unit in centre console 1232
6 4 – DSP system in conjunction with “GAMMA” Radio 05 98 > 1233
92 – Windscreen wipe and wash system 1234
1 – Windscreen wiper system 1234
1 1 – Windscreen wiper system 1234
1 2 – Windscreen wiper assembly overview 1234
1 3 – Adjusting wiper blade rest position 1237
1 4 – Removing and installing wiper blade rubber 1238
2 – Windscreen washer system 1239
2 1 – Windscreen washer system 1239
2 2 – Windscreen washer system assembly overview 1239
2 3 – Adjusting jets 1240
2 4 – Windscreen washer pump connection 1241
3 – Rear window wipe and wash system 1242
3 1 – Rear window wipe and wash system 1242
3 2 – Assembly overview: Rear window wipe and wash system, Golf saloon 1242
3 3 – Adjusting rear window wiper rest position 1245
4 – Headlight washer system 1246
4 1 – Headlight washer system 1246
4 2 – Assembly overview: Headlight washer system 1246
4 3 – Adjusting jets 1248
5 – Headlight washer system for Golf Convertible from March 1998 1249
5 1 – Headlight washer system for Golf Convertible from March 1998 1249
5 2 – Assembly overview: Headlight washer system 1249
5 3 – Adjusting jets 1251
5 4 – Removing and installing spray jet retainer 1252
5 5 – Removing and installing spray jet lift cylinder 1252
94 – Lights, Lamps, Switches – exterior 1254
1 – Headlight 1254
1 1 – Headlight 1254
1 2 – Assembly overview: Headlight 1254
1 3 – Adjusting headlights 1256
1 4 – Removing and installing headlights 1256
1 5 – Removing and installing main and dipped beam bulb 1257
1 6 – Removing and installing headlight range control positioning motor 1258
1 7 – Assembly overview: Double headlight 1259
1 8 – Removing and installing main and dipped beam bulbs 1261
2 – Headlight for Golf Convertible from March 1998 1262
2 1 – Headlight for Golf Convertible from March 1998 1262
2 2 – Assembly overview: Headlight 1262
2 3 – Adjusting headlights 1265
2 4 – Removing and installing headlights 1265
2 5 – Replacing headlight bulb 1266
2 6 – Servicing the upper headlight securing lugs 1269
2 7 – Removing and installing headlight range control positioning motor 1270
2 8 – Converting headlights from driving on right to driving on left and visa versa 1271
3 – Front fog lights 1272
3 1 – Front fog lights 1272
3 2 – Removing and installing front fog lights 1273
3 3 – Adjusting foglight 1273
3 4 – Removing and installing foglight bulb 1274
4 – Front turn signals 1274
4 1 – Front turn signals 1274
4 2 – Removing front turn signals 1275
4 3 – Removing and installing turn signal bulb 1275
5 – Side mounted turn signals 1276
5 1 – Side mounted turn signals 1276
5 2 – Removing and installing side mounted turn signals 1276
6 – Tail lights 1277
6 1 – Tail lights 1277
6 2 – Assembly overview: Tail lights, Golf and Golf Convertible 1277
6 3 – Removing tail light bulb holder 1278
6 4 – Removing and installing rear light 1278
6 5 – Assembly overview: Tail lights, Golf Estate 1279
6 6 – Removing tail light bulb holder 1280
6 7 – Removing and installing rear light 1280
6 8 – Assembly overview: Tail lights, Vento 1281
6 9 – Removing tail light bulb holder 1283
6 10 – Removing and installing tail light in side panel 1283
6 11 – Removing and installing tail light in tailgate 1284
7 – Number plate lights 1285
7 1 – Number plate lights 1285
7 2 – Removing and installing number plate light 1285
7 3 – Removing and installing number plate light for Golf Convertible from March 1998 1285
8 – Additional brake light 1286
8 1 – Additional brake light 1286
8 2 – Removing and installing additional brake light for Golf and Golf Estate 1286
8 3 – Removing and installing additional brake light for Golf Convertible 1287
8 4 – Removing and installing additional brake light for Vento 1289
9 – Steering column switch and ignition/starter switch 1290
9 1 – Steering column switch and ignition/starter switch 1290
9 2 – Removing cover 1293
9 3 – Removing horn plate 1293
9 4 – Horn contact ring 1293
9 5 – Removing and installing horn plate on equipment with driver’s airbag 1294
9 6 – Removing turn signal and windscreen wiper switch 1294
9 7 – Removing and installing lock cylinder 1295
9 8 – Wiring connections on steering column switch 1295
96 – Lights, Lamps, Switches – interior 1297
1 – Immobilizer 1297
1 1 – Immobilizer 1297
1 2 – Removing and installing immobilizer 1297
1 3 – Removing and installing immobilizer reading coil -D2- 1298
1 4 – Retrofitting fuel shut-off valve control unit 1299
1 5 – Installing fuel shut-off valve control unit 1300
1 6 – Removing fuel shut-off valve control unit 1302
1 7 – Adapting fuel cut-off valve control unit to immobilizer control unit 1302
1 8 – Immobilizer functional check 1305
2 – Servicing anti-theft alarm (ATA) 1306
2 1 – Servicing anti-theft alarm (ATA) 1306
2 2 – Assembly overview: Anti-theft alarm system (ATA) 1307
2 3 – Removing and installing anti-theft alarm system contact switch (F120) 1308
2 4 – Removing anti-theft system warning lamp (K 95) 1308
2 5 – Removing and installing contact switch in tailgate/anti-theft warning system lock cylinder (F 124) 1309
2 6 – Removing and installing anti-theft alarm system horn (H8) 1310
2 7 – Removing and installing anti-theft alarm system control unit (J 284) 1310
3 – Interior lights and switches 1311
3 1 – Interior lights and switches 1311
3 2 – Removing and installing sliding roof switch -E8- 1311
3 3 – Removing and installing front left door contact switch 1311
3 4 – Removing and installing luggage compartment light switch 1312
3 5 – Removing and installing luggage compartment light switch for Golf Convertible from March 1998 1313
3 6 – Removing and installing front left electric window switch -E40- 1313
3 7 – Removing and installing mirror adjustment switch -E43- with mirror adjustment change-over switch -E48- 1314
3 8 – Removing and installing light switch 1315
3 9 – Removing and installing headlight range control adjuster -E102- 1316
3 10 – Removing and installing heated rear window switch 1316
3 11 – Removing and installing heated driver’s seat regulating switch -E94- and heated front passenger’s seat regulating switch -E95- 1317
3 12 – Removing and installing interior light 1318
3 13 – Removing and installing glove box light -W6- 1319
3 14 – Removing and installing luggage compartment light -W3- 1320
3 15 – Removing and installing hazard warning light switch in Golf Convertible 10 98 > 1320
3 16 – Removing and installing hazard warning light switch additional relay in Golf Convertible 10 98 > 1321
97 – Wiring 1323
1 – Relay plate 1323
1 1 – Relay plate 1323
1 2 – Removing and installing relay plate 1323
1 3 – Removing and installing multi-pin plug behind relay plate 1323
00054005320 Heating Air conditioning 1325
01 – Self diagnosis 1329
1 – Self diagnosis of Climatronic 1329
1 1 – Self diagnosis of Climatronic 1329
1 2 – Tools 1329
1 3 – Function 1330
1 4 – Technical data of self diagnosis 1330
1 5 – Test prerequisites for self diagnosis 1330
1 6 – Connecting fault reader V A G 1551 and selecting function 1331
1 7 – Chart of functions that can be selected 1333
1 8 – Interrogating fault memory 1334
1 9 – Fault table 1334
1 10 – Final control diagnosis 1340
1 11 – Read measured value block 1342
1 12 – Erasing fault memory, ending output 1348
80 – Heating 1350
1 – Servicing heating system 1350
1 1 – Servicing heating system 1350
2 – Dismantling and assembling heater 1359
2 1 – Dismantling and assembling heater 1359
3 – Installing and adjusting cables 1363
3 1 – Installing and adjusting cables 1363
4 – Dismantling and assembling heated air and fresh air controls 1367
4 1 – Dismantling and assembling heated air and fresh air controls 1367
5 – Servicing electronic heating control – Thermotronic 1368
5 1 – Tools 1368
87 – Air conditioning 1376
1 – Safety measures for working on air conditioned vehicles and handling refrigerant – R12 1376
1 1 – Safety measures for working on air conditioned vehicles and handling refrigerant – R12 1376
1 2 – Safety precautions for working on air conditioned vehicles and handling refrigerant R12 1376
1 3 – Service work on the air conditioner which can only be carried out in specially-equipped workshops 1378
2 – Refrigerant R12 – Air conditioner with manual controls 1380
2 1 – Refrigerant R12 – Air conditioner with manual controls 1380
2 2 – Servicing air conditioning and heating – Passenger compartment 1380
2 3 – Servicing air conditioning and heating – Engine compartment 1387
2 4 – Installing and adjusting cables 1396
2 5 – Vacuum hose connection diagram 1399
2 6 – Removing and installing compressor bracket – 4 Cyl petrol engine 1402
2 7 – Removing and installing compressor bracket – 6 Cyl petrol engine 1405
3 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 1409
3 1 – Notes on repair work to vehicles with air conditioning and on handling refrigerant 1409
3 2 – Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a 1409
4 – Refrigerant R134a – Air conditioner with manual controls 1411
4 1 – Refrigerant R134a – Air conditioner with manual controls 1411
4 2 – Servicing air conditioning and heating – Passenger compartment 1411
4 3 – Servicing air conditioning and heating – Engine compartment 1419
4 4 – Installing and adjusting cables 1427
4 5 – Vacuum hose connection diagram 1430
4 6 – Removing and installing compressor bracket – 4 Cyl petrol engine 1433
4 7 – Removing and installing compressor bracket – 6 Cyl petrol engine >08 93 1436
4 8 – Removing and installing compressor bracket – 6 Cyl petrol engine 08 93 > 1440
4 9 – Removing and installing compressor bracket – Turbo Diesel engine 1444
4 10 – Removing and installing compressor bracket (“Harrison” compressor with “Diavia” bracket), Engine codes AAM, ADY, ADZ, AEK 1447
5 – Climatronic – Air conditioner with automatic regulation (R134a refrigerant) 1457
5 1 – Climatronic – Air conditioner with automatic regulation (R134a refrigerant) 1457
5 2 – Operation and function of the control and display unit 1457
5 3 – Servicing Climatronic – Passenger compartment 1458
5 4 – Servicing Climatronic – engine compartment 1473
5 5 – Checking and adjusting end position of installed temperature flap positioning motor 1481
5 6 – Vacuum hose connection diagram 1482
6 – Repair work on the refrigerant circuit which can only be carried out by properly trained mechanics (Specialist workshops for air conditioning systems) 1487
6 1 – Repair work on the refrigerant circuit which can only be carried out by properly trained mechanics (Specialist workshops for air conditioning systems) 1487
6 2 – Tools 1487
6 3 – Servicing components in the refrigerant circuit 1488
6 4 – Removing expansion valve 1501
6 5 – Servicing magnetic coupling -N25- when compressor is removed; Manufacturer Sanden 1505
6 6 – Removing and installing condenser 1513
6 7 – Dismantling and assembling evaporator housing 1516
7 – Capacities 1519
7 1 – Capacities 1519
7 2 – Refrigerant R134a 1519
7 3 – Refrigerant oil 1519
00054005420 Motronic injection and ignition system (6 Cyl engine) 1520
01 – Self-diagnosis 1524
1 – General to self-diagnosis 1524
1 1 – General to self-diagnosis 1524
1 2 – Features of self-diagnosis 1524
1 3 – Technical data of self-diagnosis 1524
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1525
2 – Fault memory 1529
2 1 – Fault memory 1529
2 2 – Interrogating and erasing fault memory 1529
2 3 – Fault table 1530
3 – Final control diagnosis 1541
3 1 – Final control diagnosis 1541
3 2 – Performing final control diagnosis 1541
4 – Measured value blocks 1545
4 1 – Measured value blocks 1545
4 2 – Safety precautions 1545
4 3 – Read measured value block 1545
4 4 – Evaluating measured value blocks 1546
24 – Mixture preparation, Injection 1556
1 – Servicing injection system 1556
1 1 – Servicing injection system 1556
1 2 – Fitting locations overview 1556
1 3 – General notes on injection 1560
1 4 – Removing and installing parts of the injection system 1561
1 5 – Dismantling and assembling air cleaner 1564
1 6 – Dismantling and assembling fuel rail with injectors 1567
1 7 – Removing and installing throttle valve control part 1570
1 8 – Safety precautions 1576
1 9 – Rules for cleanliness 1576
1 10 – Technical data 1577
2 – Checking components 1577
2 1 – Checking components 1577
2 2 – Checking Lambda probe heating 1577
2 3 – Checking air mass meter 1580
2 4 – Checking throttle valve control part 1583
2 5 – Checking throttle valve potentiometer 1591
2 6 – Checking coolant temperature sender 1592
2 7 – Checking intake manifold temperature sender 1596
2 8 – Checking engine speed sender 1599
2 9 – Checking fuel pressure regulator and holding pressure 1600
2 10 – Checking intake air system for leaks (unmetered air) 1602
2 11 – Matching engine electronic control unit to electronic immobilizer 1603
2 12 – Removing and installing injectors 1604
2 13 – Checking injectors 1605
2 14 – Checking and adjusting throttle closing damper 1609
2 15 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 1610
3 – Checking functions 1610
3 1 – Checking functions 1610
3 2 – Idling check 1610
3 3 – Checking Lambda control 1612
3 4 – Checking engine operating mode 1615
3 5 – Checking driving characteristics after a cold start 1617
4 – Engine control unit 1618
4 1 – Engine control unit 1618
4 2 – Checking control unit voltage supply 1618
4 3 – Procedure after voltage supply open circuit 1620
4 4 – Replacing engine control unit 1621
4 5 – Coding engine control unit 1621
4 6 – Matching engine control unit to throttle valve control part 1622
4 7 – Matching engine control unit to electronic immobilizer 1623
5 – Checking additional signals 1625
5 1 – Checking additional signals 1625
5 2 – Checking speed signal 1625
5 3 – Checking air conditioner compressor signal 1626
5 4 – Checking driving range signal 1628
28 – Ignition system 1630
1 – Motronic injection and ignition system with distributor-less ignition 1630
1 1 – Motronic injection and ignition system with distributor-less ignition 1630
1 2 – General notes on ignition system 1630
1 3 – Safety precautions 1634
1 4 – Test data, spark plugs 1634
1 5 – Checking Hall sender 1634
1 6 – Checking ignition transformer 1636
1 7 – Checking knock sensors 1639
2 – Motronic injection and ignition system with distributor 1641
2 1 – Motronic injection and ignition system with distributor 1641
2 2 – Servicing ignition part 1641
2 3 – Dismantling and assembling distributor 1645
2 4 – Safety precautions 1647
2 5 – Test data, spark plugs 1648
2 6 – Checking Hall sender 1648
2 7 – Checking ignition transformer 1649
2 8 – Checking ignition transformer output stage 1649
2 9 – Renewing rotor arm 1651
00054005520 6 cyl fuel injection engine Mechanics 1652
00 – Technical data 1656
1 – Technical data 1656
1 1 – Technical data 1656
1 2 – Engine number 1656
1 3 – Engine data 1657
10 – Removing and installing engine 1658
1 – Removing and installing engine 1658
1 1 – Removing and installing engine 1658
1 2 – Notes on removing 1659
1 3 – Notes on installing 1663
1 4 – Tightening torques 1664
1 5 – Assembly mountings 1665
1 6 – Aligning engine and gearbox 1666
1 7 – Renewing engine carrier rubber mounting 1667
1 8 – Additional information and removal instructions for vehicles with air conditioner 1669
13 – Crankshaft group 1670
1 – Dismantling and assembling engine 1670
1 1 – Dismantling and assembling engine 1670
1 2 – Removing and installing ribbed belt 1690
1 3 – Checking valve timing 1691
1 4 – Adjusting valve timing 1694
2 – Removing and installing sealing flanges and flywheel/drive plate 1701
2 1 – Removing and installing sealing flanges and flywheel/drive plate 1701
2 2 – Renewing crankshaft oil seal – vibration damper end – 1706
2 3 – Removing and installing drive plate 1707
3 – Removing and installing crankshaft 1709
3 1 – Removing and installing crankshaft 1709
4 – Dismantling and assembling pistons and conrods 1712
4 1 – Dismantling and assembling pistons and conrods 1712
4 2 – Piston and cylinder dimensions 1719
15 – Cylinder head, Valve gear 1720
1 – Removing and installing cylinder head 1720
1 1 – Removing and installing cylinder head 1720
1 2 – Removing and installing cylinder head cover 1727
1 3 – Installing cylinder head 1729
1 4 – Checking compressions 1730
2 – Servicing valve gear 1731
2 1 – Servicing valve gear 1731
2 2 – Reworking valve seats 1738
2 3 – Removing and installing camshafts 1739
2 4 – Checking hydraulic bucket tappets 1742
2 5 – Checking valve guides 1743
2 6 – Renewing valve guides 1743
2 7 – Renewing valve stem seals 1745
17 – Lubrication 1747
1 – Removing and installing parts of the lubrication system 1747
1 1 – Removing and installing parts of the lubrication system 1747
1 2 – Dismantling and assembling oil filter housing 1753
1 3 – Dismantling and assembling oil pump 1756
1 4 – Checking oil pressure and oil pressure switch 1759
19 – Cooling system 1761
1 – Removing and installing parts of cooling system 1761
1 1 – Removing and installing parts of cooling system 1761
1 2 – Parts of cooling system body side 1763
1 3 – Parts of cooling system engine side 1765
1 4 – Dismantling and assembling coolant thermostat housing 1769
1 5 – Draining and filling cooling system 1772
1 6 – Removing and installing radiator and radiator fan 1773
1 7 – Removing and installing coolant pump 1775
1 8 – Checking coolant continued circulation pump and radiator fan run-on 1778
20 – Fuel supply system 1780
1 – Removing and installing parts of fuel supply system 1780
1 1 – Removing and installing parts of fuel supply system 1780
1 2 – Safety precautions when working on the fuel supply system 1780
1 3 – Rules for cleanliness 1780
1 4 – Removing and installing fuel tank with its attachments and fuel filter, front wheel drive 1781
1 5 – Removing and installing fuel tank with its attachments and fuel filter, four wheel drive 1787
1 6 – Removing and installing fuel delivery unit, four wheel drive 1793
1 7 – Removing and installing fuel delivery unit 1797
1 8 – Adjusting throttle cable 1799
1 9 – Checking fuel pump 1802
1 10 – Removing and installing parts of the activated charcoal filter system 1808
1 11 – Checking fuel tank breather 1810
26 – Exhaust system 1813
1 – Removing and installing parts of exhaust system, front wheel drive 1813
1 1 – Removing and installing parts of exhaust system, front wheel drive 1813
1 2 – Removing and installing parts of exhaust system, front wheel drive 1814
1 3 – Removing and installing parts of exhaust system, four wheel drive 1819
1 4 – Exhaust manifold, front exhaust pipe and catalyst with attachments 1820
1 5 – Silencer with mountings 1822
1 6 – Removing and installing front exhaust pipe and catalyst with attachments 1824
00054005620 Diesel Injection and Glow Plug System 1825
01 – Self diagnosis 1829
1 – Self diagnosis 1829
1 1 – Self diagnosis 1829
1 2 – Function 1829
1 3 – Technical data of self diagnosis 1829
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 1829
1 5 – Interrogating fault memory 1831
1 6 – Fault table 1832
1 7 – Erasing fault memory 1834
1 8 – Final control diagnosis 1834
1 9 – Reading measured value block 1838
23 – Mixture preparation, Injection 1840
1 – Servicing fuel injection system 1840
1 1 – Servicing fuel injection system 1840
1 2 – Injection pump with two-part sprocket 1841
1 3 – Injection pump with two-part sprocket 1844
1 4 – Servicing fuel filter 1846
1 5 – Rules for cleanliness 1847
1 6 – Checking fuel system for leaks 1848
1 7 – Actuator controlled, load-dependent injection timing 1849
1 8 – Removing and installing injection pump 1849
1 9 – Checking and adjusting injection pump timing 1856
1 10 – Checking valve timing 1860
1 11 – Adjusting idling speed, idling speed boost and engine governed speed 1862
1 12 – Load change speed 1864
1 13 – Residual volume basic setting 1865
1 14 – Idling speed boost actuator 1866
1 15 – Checking commencement of injection valve 1866
1 16 – Checking engine temperature sender 1867
1 17 – Resistance figures for engine temperature sender 1867
1 18 – Checking idling speed boost valve 1868
1 19 – Check full load stop valve, engine 1Y 1868
1 20 – Removing and installing injectors 1869
1 21 – Servicing injectors 1870
1 22 – Checking injector nozzle valve tip for damage, injection pressure and for leakage 1871
2 – Servicing injection pump 1872
2 1 – Servicing injection pump 1872
2 2 – Removing and installing throttle lever or return spring 1878
2 3 – Renewing pump cover throttle lever bush, pump cover gasket and throttle lever shaft O-ring 1881
2 4 – Renewing fuel delivery adjusting screw O-ring 1884
2 5 – Renewing idling speed boost shaft O-ring 1884
2 6 – Renewing injection timing device cover O-ring 1885
2 7 – Renewing CSA lever/cover O-ring 1885
2 8 – Sealing injection pump connections 1886
28 – Glow plug system 1888
1 – Checking glow plug system 1888
1 1 – Checking glow plug system 1888
1 2 – Checking glow plug current consumption with V A G 1315A 1888
1 3 – Checking glow plugs 1888
1 4 – Glow plugs with burned electrodes 1889
00054005720 4 Cyl diesel engine Mechanics 1890
00 – Technical data 1896
1 – Technical data 1896
1 1 – Technical data 1896
1 2 – Engine number 1896
1 3 – Engine data 1896
10 – Removing and installing engine 1898
1 – Removing and installing engine 1898
1 1 – Removing and installing engine 1898
1 2 – Notes on removing 1898
1 3 – Notes on installing 1900
1 4 – Tightening torques 1902
1 5 – Assembly mountings 1902
1 6 – Renewing engine carrier rubber mounting 1903
1 7 – Additional information and removal instructions for vehicles with air conditioner 1904
13 – Crankshaft group 1905
1 – Dismantling and assembling engine 1905
1 1 – Dismantling and assembling engine 1905
1 2 – Removing and installing ribbed belt 1919
1 3 – Removing and installing toothed belt 1922
1 4 – Checking semi-automatic toothed belt tensioning roller 1928
1 5 – Removing single part injection pump sprocket 1928
2 – Removing and installing sealing flange and pressure plate/flywheel/drive plate 1929
2 1 – Removing and installing sealing flange and pressure plate/flywheel/drive plate 1929
2 2 – Renewing crankshaft oil seal – pulley end – 1933
2 3 – Removing and installing drive plate 1934
3 – Removing and installing crankshaft 1938
3 1 – Removing and installing crankshaft 1938
3 2 – Crankshaft dimensions 1941
4 – Dismantling and assembling pistons and conrods 1942
4 1 – Dismantling and assembling pistons and conrods 1942
4 2 – Checking piston projection at TDC 1949
4 3 – Piston and cylinder dimensions 1950
15 – Cylinder head, Valve gear 1951
1 – Removing and installing cylinder head 1951
1 1 – Removing and installing cylinder head 1951
1 2 – Removing and installing cylinder head 1958
1 3 – Checking compressions 1960
2 – Servicing valve gear 1962
2 1 – Servicing valve gear 1962
2 2 – Reworking valve seats 1968
2 3 – Checking valve guides 1970
2 4 – Renewing valve guides 1971
2 5 – Renewing valve stem seals 1971
2 6 – Removing and installing camshaft 1973
2 7 – Checking hydraulic bucket tappets 1975
2 8 – Replacing swirl chambers 1976
17 – Lubrication 1977
1 – Removing and installing parts of the lubrication system 1977
1 1 – Removing and installing parts of the lubrication system 1977
1 2 – Checking oil pressure and oil pressure switch 1984
1 3 – Removing and installing oil sump cap 1985
19 – Cooling system 1986
1 – Removing and installing parts of cooling system 1986
1 1 – Removing and installing parts of cooling system 1986
1 2 – Parts of cooling system body side 1987
1 3 – Parts of cooling system – engine side 1990
1 4 – Dismantling and assembling coolant pump 1993
1 5 – Draining and filling cooling system 1994
1 6 – Removing and installing radiator and radiator fan 1996
20 – Fuel supply system 1998
1 – Removing and installing parts of fuel supply system 1998
1 1 – Removing and installing parts of fuel supply system 1998
1 2 – Removing and installing fuel tank with its attachments, front drive 1999
1 3 – Fuel tank with its attachments, four wheel drive 2002
1 4 – Safety precautions when working on the fuel supply system 2006
1 5 – Rules for cleanliness 2007
1 6 – Removing and installing fuel delivery unit, four wheel drive 2007
1 7 – Servicing accelerator mechanism 2011
1 8 – Servicing cold start accelerator (CSA) operating cable 2013
1 9 – Adjusting CSA operating cable 2014
21 – Charging 2015
1 – Charge air system with turbocharger 2015
1 1 – Charge air system with turbocharger 2015
1 2 – Removing and installing turbocharger with attachments 2015
1 3 – Removing and installing parts of charge air cooling system 2026
1 4 – Rules for cleanliness 2027
1 5 – Turbocharger hose/pipe connections 2028
1 6 – Removing and installing turbocharger 2030
1 7 – Checking turbocharger 2034
1 8 – Checking pressure unit for charge pressure regulating valve 2037
1 9 – Removing and installing pressure unit for charge pressure regulating valve 2038
26 – Exhaust system 2039
1 – Removing and installing parts of exhaust system, front wheel drive 2039
1 1 – Removing and installing parts of exhaust system, front wheel drive 2039
1 2 – Engine code 1Y 2040
1 3 – Front exhaust pipe and catalyst with attachments, engine codes 1Z, AHU, ALE 2042
1 4 – Front exhaust pipe and catalyst with attachments, engine codes AFN, AVG 2043
1 5 – Exhaust manifold, front exhaust pipe and catalyst with attachments, engine code AEY 2044
1 6 – Silencer with mountings, engine codes 1Z, AEY, AFN, AVG, AHU, ALE 2045
1 7 – Engine code AAZ 2048
2 – Removing and installing parts of exhaust system, four wheel drive 2050
2 1 – Removing and installing parts of exhaust system, four wheel drive 2050
2 2 – Front exhaust pipe and catalyst with attachments 2051
2 3 – Silencer with mountings 2053
3 – Exhaust gas recirculation system, engine codes 1Y, AEY 2055
3 1 – Exhaust gas recirculation system, engine codes 1Y, AEY 2055
3 2 – Removing and installing parts of exhaust gas recirculation system 2056
3 3 – Checking exhaust gas recirculation 2057
3 4 – Checking exhaust gas recirculation valve 2058
3 5 – Checking two-way valve 2058
4 – Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z 2059
4 1 – Exhaust gas recirculation system, engine codes AFN, AVG, AHU, ALE, 1Z 2059
4 2 – Removing and installing parts of exhaust gas recirculation system 2060
4 3 – Vacuum hose connection diagram 2063
4 4 – Checking exhaust gas recirculation valve (mechanical) 2065
5 – Exhaust gas recirculation system, engine code AAZ 2066
5 1 – Exhaust gas recirculation system, engine code AAZ 2066
5 2 – Removing and installing parts of exhaust gas recirculation system 2067
5 3 – Checking exhaust gas recirculation 2068
5 4 – Checking exhaust gas recirculation valve 2069
5 5 – Checking two-way valve 2069
00054005820 4 cylinder injection engine (2 valve) mechanics 2071
00 – Technical data 2075
1 Engine number 2075
2 Engine data 2076
10 – Removing and installing engine 2078
1 Removing and installing engine 2078
1 1 Notes on removing 2078
1 2 Notes on installing 2079
1 3 Specified torques 2081
1 4 Assembly mountings 2081
1 4 1 Specified torques 2081
1 5 Renewing engine carrier rubber mounting 2082
1 6 Additional information and assembly work for vehicles with air conditioner 2082
13 – Crankshaft group 2084
1 Crankshaft group 2084
1 1 Dismantling and assembling engine 2084
1 1 1 Part I 2085
1 1 2 Part II 2086
1 1 3 Part III 2087
1 2 Removing and installing poly V-belt 2089
1 2 1 Belt drive without tensioning roller 2089
1 2 2 Belt drive with tensioning roller 2089
1 3 Removing, installing and tensioning toothed belt (adjusting valve timing) 2090
1 3 1 Removing 2090
1 3 2 Installing 2091
1 3 3 A – Toothed belt completely removed 2091
1 3 4 B – Toothed belt only removed from camshaft pulley 2092
2 Removing and installing sealing flange and pressure plate/drive plate 2093
2 1 Renewing crankshaft oil seal – pulley end 2095
2 2 Removing and installing drive plate 2097
2 2 1 Loosening and tightening drive plate 2097
2 2 2 Installing drive plate 2098
2 3 Removing and installing crankshaft 2098
2 3 1 Crankshaft dimensions 2099
3 Dismantling and assembling pistons and conrods 2101
3 1 Piston and cylinder dimensions 2103
15 – Cylinder head, valve gear 2104
1 Removing and installing cylinder head 2104
1 1 Removing and installing cylinder head 2105
1 1 1 Removing 2106
1 1 2 Installing 2106
1 2 Checking compression 2107
2 Repairing valve gear 2108
2 1 Assembly overview – valve gear 2108
2 1 1 Checking camshaft axial clearance 2109
2 1 2 Installation position of camshaft bearing caps 2110
2 1 3 Exchange cylinder heads with camshaft bearing shells 2110
2 1 6 Valve timing at 1 mm valve lift 2112
2 2 Reworking valve seats 2112
2 3 Renewing camshaft oil seal 2114
2 4 Removing and installing camshaft 2116
2 4 1 Removing 2116
2 4 2 Installing 2117
2 5 Checking hydraulic bucket tappets 2117
2 6 Checking valve guides 2118
2 7 Renewing valve guides 2118
2 8 Renewing valve stem seals 2119
17 – Lubrication 2120
1 Lubrication 2120
1 1 Removing and installing parts of lubrication system 2120
1 1 1 Oil capacities: 2120
1 1 3 Engine oil specifications: 2120
1 1 4 Assembly overview – parts of lubrication system 2120
1 2 Checking oil pressure and oil pressure switch 2123
19 – Cooling 2124
1 Removing and installing parts of cooling system 2124
1 1 Parts of cooling system, body side 2124
1 2 Parts of cooling system, engine side 2126
1 3 Dismantling and assembling coolant pump 2127
1 4 Draining and filling with coolant 2127
1 4 1 Draining 2127
1 4 2 Filling 2128
1 4 3 With cooling system charge unit -VAS 6096- 2129
1 4 4 Without cooling system charge unit -VAS 6096- 2129
1 4 5 With or without cooling system charge unit -VAS 6096- 2129
1 5 Removing and installing radiator and fan 2129
1 5 1 Removing 2129
1 5 2 Installing 2130
1 5 3 Additional information and assembly work for vehicles with air conditioner 2130
20 – Fuel supply system 2131
1 Removing and installing parts of fuel supply system 2131
1 1 Removing and installing fuel tank with attachments and fuel filter, front-wheel drive 2131
1 2 Removing and installing fuel tank with attachments and fuel filter, four-wheel drive 2134
1 2 1 Installation position of fuel delivery unit flange 2135
1 2 2 Checking breather valve 2135
1 3 Safety precautions when working on fuel supply system 2135
1 4 Rules for cleanliness 2136
1 5 Removing and installing fuel tank, four-wheel drive 2136
1 5 1 Removing 2136
1 5 2 Installing 2139
1 6 Adjusting accelerator cable 2139
1 6 1 Vehicles with automatic gearbox 2139
1 6 2 Vehicles with automatic gearbox or manual gearbox 2139
1 7 Removing and installing fuel delivery unit 2140
1 7 1 Removing 2140
1 7 2 Installing 2140
1 8 Checking fuel pump 2141
1 8 1 Checking function and voltage supply 2141
1 8 2 Checking delivery rate 2142
1 8 3 Checking fuel pump non-return valve 2144
1 9 Removing and installing parts of activated charcoal filter system 2145
1 9 1 Removing and installing parts of activated charcoal filter system (engine codes AAM, ABS, ADZ, ANN, ANP) 2145
1 9 2 Removing and installing parts of activated charcoal filter system (engine codes 2E, ADY, AGG, AKR) 2147
26 – Exhaust system 2148
1 Removing and installing parts of exhaust system, front-wheel drive 2148
1 1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments – engine codes AAM, ABS, ADZ, ANN, ANP 2148
1 2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments – engine codes 2E, ADY, AGG, AKR 2150
1 3 Silencer with mountings – engine codes AAM, ANN 2151
1 4 Silencer with mountings – engine codes ABS, ADZ, ANP 2152
1 5 Silencer with mountings – engine codes 2E, ADY, AGG, AKR 2153
2 Removing and installing parts of exhaust system, four-wheel drive 2155
2 1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments 2155
2 2 Silencer with mountings 2156
00054005920 Digifant Injection and Ignition system (2 valve) 2158
01 – Self diagnosis, Electrical check 2162
1 – Self diagnosis 2162
1 1 – Self diagnosis 2162
1 2 – Function 2162
1 3 – Technical data of self diagnosis 2162
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2163
1 5 – Interrogating and erasing fault memory 2164
1 6 – Fault table 2165
1 7 – Final control diagnosis 2167
2 – Electrical check 2170
2 1 – Electrical check 2170
2 2 – Wiring and component check with test box V A G 1598/18 2170
24 – Mixture preparation, Injection 2175
1 – Digifant injection and ignition system 2175
1 1 – Digifant injection and ignition system 2175
1 2 – Fitting locations overview 2175
1 3 – Servicing injection part 2177
1 4 – Safety precautions 2193
1 5 – Rules for cleanliness 2194
1 6 – Technical data 2194
1 7 – Idling check 2194
1 8 – Checking Lambda probe and Lambda control 2197
1 9 – Checking acceleration/full throttle enrichment and overrun cut-off 2199
1 10 – Checking engine operating mode 2200
1 11 – Checking throttle valve potentiometer 2201
1 12 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 2203
1 13 – Checking coolant temperature sender 2203
1 14 – Checking intake air temperature sender 2204
1 15 – Checking air mass meter potentiometer 2206
1 16 – Checking control unit voltage supply 2208
1 17 – Checking fuel pressure regulator and holding pressure 2209
1 18 – Checking cold start valve 2211
1 19 – Removing and installing injectors 2213
1 20 – Checking injectors 2214
1 21 – Checking intake air system for leaks (unmetered air) 2216
1 22 – Checking intake air preheating 2217
1 23 – Basic throttle valve setting 2218
1 24 – Vacuum hose connection diagram 2219
28 – Ignition system 2223
1 – Digifant injection and ignition system 2223
1 1 – Digifant injection and ignition system 2223
1 2 – Servicing ignition part 2223
1 3 – Safety precautions 2226
1 4 – Test data, spark plugs 2227
1 5 – Installing distributor 2227
1 6 – Checking ignition timing control 2228
1 7 – Checking Hall sender 2229
1 8 – Checking ignition transformer 2230
1 9 – Checking ignition transformer output stage 2231
00054006020 Mono Motronic injection and ignition system 2233
01 – Self-diagnosis 2237
1 – Self-diagnosis 2237
1 1 – Self-diagnosis 2237
1 2 – Function 2237
1 3 – Technical data of self-diagnosis 2237
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2238
1 5 – Interrogating fault memory 2240
1 6 – Fault table 2241
1 7 – Erasing fault memory 2243
1 8 – Final control diagnosis 2244
1 9 – Coding control unit 2247
1 10 – Erasing values learnt by engine electronics control unit 2248
1 11 – Read measured value block and basic settings 2249
1 12 – Display group overview 2249
24 – Mixture preparation, Injection 2252
1 – Mono-Motronic injection and ignition system 2252
1 1 – Mono-Motronic injection and ignition system 2252
1 2 – Fitting locations overview 2252
1 3 – Servicing injection part 2255
1 4 – Servicing injection unit 2264
1 5 – Safety precautions 2270
1 6 – Rules for cleanliness 2271
1 7 – Technical data 2271
1 8 – Idling speed check 2271
1 9 – Checking Lambda probe and Lambda control 2272
1 10 – Checking Lambda probe heating 2274
1 11 – Checking engine operating mode 2275
1 12 – Checking overrun cut-off 2277
1 13 – Checking throttle valve positioner 2277
1 14 – Checking and adjusting idling switch 2279
1 15 – Checking sender for throttle valve positioner 2283
1 16 – Checking throttle valve potentiometer 2285
1 17 – Checking coolant temperature sender 2287
1 18 – Checking intake air temperature sender 2290
1 19 – Checking injector 2295
1 20 – Testing speed signal 2297
1 21 – Checking control unit voltage supply 2298
1 22 – Checking air conditioner and air conditioner compressor signals 2299
1 23 – Matching engine electronic control unit to electronic immobilizer 2301
1 24 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 2302
1 25 – Checking signal for automatic gearbox control unit 2302
1 26 – Checking fuel pressure regulator and holding pressure 2303
1 27 – Checking intake air system for leaks (unmetered air) 2306
1 28 – Checking intake air preheating 2307
28 – Ignition system 2309
1 – Mono-Motronic injection and ignition system 2309
1 1 – Mono-Motronic injection and ignition system 2309
1 2 – Servicing ignition part 2309
1 3 – Safety precautions 2312
1 4 – Adjustment data, Spark plugs 2313
1 5 – Installing distributor 2313
1 6 – Checking and adjusting ignition timing 2314
1 7 – Checking ignition timing control 2316
1 8 – Checking Hall sender 2316
1 9 – Checking ignition transformer 2318
1 10 – Checking ignition transformer output stage 2318
00054006120 Mono Motronic injection and ignition system 2321
01 – Self diagnosis 2325
1 – Self diagnosis 2325
1 1 – Self diagnosis 2325
1 2 – Function 2325
1 3 – Technical data of self diagnosis 2325
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2326
1 5 – Interrogating fault memory 2328
1 6 – Fault table 2329
1 7 – Erasing fault memory 2331
1 8 – Final control diagnosis 2332
1 9 – Erasing values learnt by engine electronics control unit 2336
1 10 – Read measured value block and basic settings 2336
1 11 – Display group overview 2337
24 – Mixture preparation, Injection 2340
1 – Mono-Motronic injection and ignition system 2340
1 1 – Mono-Motronic injection and ignition system 2340
1 2 – Fitting locations overview 2340
1 3 – Servicing injection part 2343
1 4 – Dismantling and assembling intake manifold 2350
1 5 – Dismantling and assembling wheel housing mounted air cleaner and intake elbow 2352
1 6 – Dismantling and assembling round air cleaner 2354
1 7 – Servicing injection unit 2356
1 8 – Safety precautions 2366
1 9 – Rules for cleanliness 2366
1 10 – Technical data 2367
1 11 – Idling speed check 2367
1 12 – Checking Lambda probe and Lambda control 2369
1 13 – Checking Lambda probe heating 2372
1 14 – Checking engine operating mode 2373
1 15 – Checking overrun cut-off 2374
1 16 – Checking throttle valve positioner 2375
1 17 – Checking and adjusting idling switch 2377
1 18 – Checking sender for throttle valve positioner 2382
1 19 – Checking throttle valve potentiometer 2383
1 20 – Checking coolant temperature sender 2385
1 21 – Checking intake air temperature sender 2388
1 22 – Checking injector 2392
1 23 – Checking speed signal 2395
1 24 – Checking control unit voltage supply 2396
1 25 – Matching engine electronic control unit to electronic immobilizer 2397
1 26 – Checking fuel pressure regulator and holding pressure 2398
1 27 – Adapting idling speed 2401
1 28 – Checking intake air system for leaks (unmetered air) 2402
1 29 – Checking intake air preheating 2403
1 30 – Wire routing engine wiring loom 2405
28 – Ignition system 2408
1 – Mono-Motronic injection and ignition system 2408
1 1 – Mono-Motronic injection and ignition system 2408
1 2 – Servicing ignition part 2408
1 3 – Dismantling and assembling distributor 2412
1 4 – Safety precautions 2413
1 5 – Adjustment data, Spark plugs 2413
1 6 – Checking and adjusting ignition timing 2413
1 7 – Checking ignition timing control 2415
1 8 – Checking Hall sender 2415
1 9 – Checking ignition transformer 2417
1 10 – Checking ignition transformer output stage 2417
1 11 – Checking knock sensor 2419
00054006220 Running gear 2421
00 – Technical data 2427
1 Technical data 2427
1 1 Running gear 2427
1 2 Wheels, tyres 2427
1 3 Steering 2427
1 4 Braking 2427
1 4 1 Vehicles with front brake discs ∅ 239 mm and rear brake drums 2427
1 4 2 Vehicles with front brake discs ∅ 256 mm and rear brake drums 2428
1 4 3 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 2429
1 4 4 Vehicles with front brake discs ∅ 256 mm and rear brake drums 2429
1 4 5 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 2430
1 4 6 Vehicles with front brake discs ∅ 239 mm and rear brake drums 2430
1 4 7 Vehicles with front brake discs ∅ 239 mm and rear brake drums 2430
1 4 8 Vehicles with front brake discs ∅ 256 mm and rear brake drums 2431
1 4 9 Vehicles with front brake discs ∅ 239 mm and rear brake drums 2431
1 4 10 Vehicles with front brake discs ∅ 256 mm and rear brake drums 2431
1 4 11 Vehicles with front brake discs ∅ 256 mm and rear brake discs ∅ 226 mm 2432
1 4 12 Vehicles with front brake discs ∅ 239 mm and rear brake drums 2432
1 4 13 Vehicles with front brake discs ∅ 256 mm and rear brake drums 2433
1 4 14 Vehicles with front brake discs ∅ 288 mm and rear brake discs ∅ 239 mm 2433
1 4 15 Vehicles with Plus running gear 2433
1 4 16 Vehicles with front brake discs ∅ 280 mm and rear brake discs ∅ 226 mm 2433
1 4 17 Vehicles with Plus running gear 2434
1 4 18 Vehicles with front brake discs ∅ 288 mm and rear brake discs ∅ 226 mm 2434
40 – Front suspension 2435
1 Repairing front suspension (basic running gear) 2435
1 1 Removing and installing subframe, anti-roll bar and suspension link (basic running gear) 2436
1 1 1 Modified bonded rubber bush in suspension link 2439
1 2 Allocation of anti-roll bar to Golf/Vento basic running gear 2439
1 3 Checking swivel joint 2440
1 3 1 Checking axial play 2440
1 3 2 Checking radial play 2440
1 4 Reworking cap nut in longitudinal member 2440
1 5 Removing and installing wheel bearing, suspension strut, drive shaft (basic running gear) 2441
1 6 Removing and installing drive shaft, vehicles with automatic gearbox 2445
1 6 1 Removing right drive shaft 2445
1 6 2 Removing left drive shaft: 2445
1 6 3 Installing 2446
1 7 Repairing front suspension strut (basic running gear) 2446
1 8 Allocation of suspension strut mounting to vehicle 2448
2 Repairing front suspension (Plus running gear) 2449
2 1 Removing and installing subframe, anti-roll bar and suspension link (Plus running gear) 2450
2 2 Removing and installing swivel joint 2452
2 2 1 Removing 2452
2 2 2 Installing 2453
2 3 Allocation of anti-roll bar to Golf/Vento Plus running gear 2453
2 4 Removing and installing wheel bearing, suspension strut (Plus running gear) 2453
2 5 Repairing front suspension strut (Plus running gear) 2457
2 6 Modified suspension strut from 06 93, vehicles with Plus running gear 2458
2 6 1 Determining the part number on coil springs 2459
2 7 Removing and installing drive shaft (Plus running gear), vehicles with bonded drive shaft 2459
2 7 1 Removing 2459
2 7 2 Installing 2460
2 7 3 Specified torques: 2460
2 8 Removing and installing drive shaft with triple roller joint 2461
2 8 1 Removing right drive shaft 2461
2 8 2 Removing left drive shaft: 2461
2 8 3 Installing 2462
2 9 Wheel hubs with compressed splines, vehicles with Plus running gear 2462
2 10 Removing and installing drive shafts on vehicles with compressed splines in the wheel hub 2463
2 10 1 Removing 2463
2 10 2 Installing 2463
2 10 3 Specified torque: 2464
3 Repairing drive shaft 2465
3 1 Checking outer constant velocity joint 2470
3 1 1 Removing 2470
3 1 2 Installing 2471
3 2 Checking inner constant velocity joint 2471
3 2 1 Installing 2472
3 2 2 Checking function of constant velocity joint 2473
3 3 Repairing drive shaft with triple roller joint 2473
3 4 Dismantling and assembling triple roller joint 2474
3 4 1 Dismantling 2474
3 4 2 Assembling 2476
42 – Rear suspension 2478
1 Repairing rear axle (front-wheel drive vehicles) 2478
1 1 Repairing rear axle 2478
1 2 Removing and installing bonded rubber bush 2480
1 2 1 Removing 2480
1 2 2 Installing 2482
1 3 Track width change on Golf/Vento from 08 93 – model year 1994 2484
1 4 Modified weld studs on rear axle 2485
1 4 1 Rear axle for Golf/Vento up to July 1994 2485
1 4 2 Rear axle for Golf/Vento from August 1994 2486
1 5 Reworking cap nut in longitudinal member, vehicles with front-wheel drive 2486
1 6 Allocation of rear axle assembly and anti-roll bar 2487
1 7 Dismantling and assembling suspension strut 2487
1 8 Removing and installing rear axle, Golf Variant 2489
1 8 1 Removing 2489
1 8 2 Installing 2490
1 9 Assembly overview: Rear axle, Golf Variant 2490
1 10 Removing and installing bonded rubber bush 2492
1 10 1 Removing 2493
1 10 2 Installing 2495
1 11 Modified weld studs on rear axle, Golf Variant 2497
1 11 1 Rear axle for Golf Variant up to July 1994 2497
1 11 2 Rear axle for Golf Variant from August 1994 2498
1 12 Modified rear axle for Golf Variant 2499
1 13 Removing and installing rear shock absorber, Golf Variant 2500
1 13 1 Removing 2500
1 13 2 Installing 2500
1 14 Dismantling and assembling shock absorber, Golf Variant 2501
2 Repairing rear axle (vehicles with four-wheel drive) 2503
2 1 Assembly overview – rear axle, vehicles with four-wheel drive 2503
2 2 I – Assembly overview – rear axle assembly 2504
2 3 II – Assembly overview – suspension link 2507
2 4 Removing and installing rear axle 2509
2 4 1 Removing 2509
2 4 2 Installing 2511
2 5 Determining installation position with bonded rubber bush removed 2511
2 6 Reworking cap nut in longitudinal member, vehicles with four-wheel drive 2511
3 Repairing wheel bearing 2513
3 1 Repairing wheel bearing, vehicles with front-wheel drive – drum brakes 2513
3 2 Repairing wheel bearing, vehicles with front-wheel drive – disc brakes 2516
3 3 Repairing wheel bearings, vehicles with four-wheel drive – drum brakes 2520
3 4 Repairing wheel bearing, vehicles with four-wheel drive – disc brakes 2523
44 – Wheels, tyres, vehicle geometry 2527
1 Wheel alignment 2527
1 1 Test prerequisites: 2527
1 2 Specifications for wheel alignment, vehicles with front and four-wheel drive 2527
1 3 Adjusting front wheel camber 2529
1 4 Calculating the direction of travel: 2529
45 – Anti-lock brake system 2530
1 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL) Teves 04 2530
1 1 Notes for repairs on ABS, ABS/EDL 2530
1 2 Removing and installing control unit 2531
1 2 1 Location 2531
1 2 2 Removing 2531
1 2 3 Installing 2531
1 3 Removing and installing speed sensor and speed sensor rotor 2531
1 3 1 Speed sensor 2531
1 3 2 Rotors 2531
1 3 3 Front axle 2531
1 3 4 Rear axle 2531
2 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04 – LHD 2533
2 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, LHD 2533
2 2 Modified Teves 04 ABS/EDL units 2534
2 3 Removing and installing hydraulic unit, LHD 2535
2 3 1 Removing 2535
2 3 2 Installing 2535
2 4 Removing and installing brake pedal position sender, LHD 2536
2 4 1 Removing 2536
2 4 2 Installing 2537
3 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 04, RHD 2538
3 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, RHD 2538
3 2 Removing and installing hydraulic unit, RHD 2541
3 2 1 Removing 2541
3 2 2 Installing 2541
3 3 Removing and installing brake pedal position sender, RHD 2542
3 3 1 Removing 2542
3 3 2 Installing 2542
4 Anti-lock brake system (ABS) and anti-lock brake system with electronic differential lock (ABS/EDL), Teves 20 GI 2544
4 1 General information on this ABS 2544
4 2 Notes for repairs on ABS, ABS/EDL 2544
4 3 Removing and installing control unit and hydraulic unit 2545
4 3 3 Removing 2546
4 3 4 Installing 2547
5 Assembly overview – hydraulic unit, brake servo/brake master cylinder Teves 20 GI – LHD 2548
5 1 Assembly overview – hydraulic unit, brake servo/brake master cylinder, LHD 2548
6 Assembly overview – hydraulic unit Teves 20 Gl, RHD 2549
6 1 Assembly overview – hydraulic unit Teves 20 Gl, RHD 2549
7 Initiating basic setting, vehicles with ABS/EDL 2551
46 – Brakes – mechanism 2552
1 Repairing front brakes 2552
1 1 Repairing front brakes, brake caliper VW II 2552
1 2 Removing and installing brake pads/brake calipers 2554
1 2 1 Removing 2554
1 2 2 Installing 2554
1 3 Removing and installing brake pads/brake calipers as of model year 1996 (T) 2555
1 3 1 Removing 2555
1 3 2 Installing 2555
1 4 Repairing front brakes, Girling brake caliper 2556
1 5 Removing and installing brake pads or linings 2558
1 5 1 Removing 2558
1 5 2 Installing 2559
1 6 Repairing front brakes, Teves/ATE 2559
1 7 Removing and installing brake pads or linings 2561
1 7 1 Removing 2561
1 7 2 Installing 2562
2 Repairing rear brakes (drum brakes) 2564
2 1 Removing and installing rear brakes 2564
2 2 Removing and installing impulse rotor 2565
2 2 1 Removing 2565
2 2 2 Installing 2565
2 3 Repairing rear brakes 2565
2 4 Removing and installing brake shoes 2567
2 4 1 Removing 2567
2 4 2 Installing 2568
2 5 Adjusting handbrake 2568
3 Repairing rear brakes (disc brakes) 2570
3 1 Repairing rear brakes (disc brakes) 2570
3 2 Modified brake caliper 2572
3 3 Removing and installing brake pads or linings 2572
3 3 1 Removing 2572
3 3 2 Installing 2573
3 4 Adjusting handbrake 2574
4 Assembly overview – handbrake lever 2575
47 – Brakes – hydraulics 2576
1 Assembly overview – brake servo/brake master cylinder 2576
1 1 Ecomatic vacuum supply 2577
1 2 Assembly overview: pedal cluster, brake pedal 2578
1 3 Separating brake pedal from, and clipping to, brake servo 2579
1 3 1 Separating brake pedal from brake servo 2579
1 3 2 Clipping brake pedal to brake servo 2580
1 4 Removing and installing brake pedal 2580
1 4 1 Removing 2580
1 4 2 Installing 2580
2 Removing and installing brake servo/brake master cylinder, RHD 2581
2 1 Removing and installing brake servo/brake master cylinder, RHD 2581
2 1 1 Removing 2581
2 1 2 Installing 2581
3 Repairing front brake caliper, brake caliper VW II 2582
3 1 Removing and installing front brake caliper piston 2583
3 1 1 Removing 2583
3 1 2 Installing 2583
4 Repairing Girling front brake calipers 2585
4 1 Assembly overview – Girling front brake calipers 2585
4 2 Removing and installing front brake caliper piston 2586
4 2 1 Removing 2586
4 2 2 Installing 2586
5 Repairing rear brake caliper 2588
5 1 Removing and installing rear brake caliper piston 2589
5 1 1 Removing: 2589
5 1 2 Reworking wedge -V A G 1474/5- 2589
5 1 3 Installing: 2590
5 1 4 Pre-bleeding brake caliper 2590
6 Checking and adjusting brake pressure regulator 2591
6 1 Checking and adjusting brake pressure regulator, load-dependent 2591
6 2 Specifications for load dependent brake pressure regulator 2591
6 2 1 Adjusting regulator 2592
6 3 Checking brake pressure regulator, pressure-dependent 2592
7 Bleeding brake system on vehicles with and without ABS or ABS/EDL 2594
7 1 Bleeding brake system 2594
7 1 1 Notes 2594
7 1 2 Bleeding brake system with brake filling and bleeding unit -VW 1238/1- or -V A G 1238 B- 2594
7 2 Bleeding brake system without brake filling and bleeding unit 2595
48 – Steering 2596
1 Assembly overview: steering column, column tube, steering wheel and airbag steering wheel 2596
1 1 Modified teeth on steering rack steering pinion and steering column drive shaft 2598
1 2 Assembly overview: Steering wheel with airbag 2599
1 3 Removing and installing airbag module 2600
1 3 1 Removing 2600
1 3 2 Installing 2601
1 4 Removing and installing steering wheel with airbag 2601
1 4 1 Removing 2601
1 4 2 Installing steering wheel 2602
1 5 Removing and installing coil connector with slip ring 2602
1 6 Removing and installing column tube for height adjustable steering wheel 2603
2 Assembly overview: mechanical steering rack 2604
2 1 Adjusting steering rack 2605
2 2 Removing and installing mechanical (manual) steering rack 2606
2 2 1 Removing 2606
2 2 2 Installing 2606
2 3 Bolting track rod onto steering rack 2607
2 3 1 Checking track rod length and adjusting if necessary 2608
3 Repairing power steering 2609
3 1 Checking pump delivery pressure 2609
3 2 Checking function of steering hydraulics pump -V119-, Ecomatic 2610
3 3 Checking delivery pressure of steering hydraulics pump -V119-, Ecomatic 2610
3 4 Removing and installing steering hydraulics pump -V119-, Ecomatic 2611
3 4 1 Removing 2611
3 4 2 Installing 2612
3 4 3 Filling steering system with hydraulic fluid 2612
3 5 Removing and installing power steering rack 2612
3 5 1 Removing 2613
3 5 2 Installing 2613
3 6 Assembly overview – power steering rack (TRW) 2614
3 7 Modified teeth on steering rack steering pinion and steering column drive shaft 2616
3 8 Modified track rod ball joint for Golf Variant, Golf convertible 2616
3 9 Removing and installing track rod (TRW and ZF power steering rack) 2617
3 9 1 Removing 2617
3 9 2 Installing 2618
3 10 Checking and/or adjusting left-hand track rod length 2618
3 10 1 Installing boots 2618
3 11 Repairing TRW power steering 2619
3 12 Dismantling and assembling power steering rack (TRW) 2622
3 12 1 Assembling 2625
3 13 Adjusting power steering rack when installed 2631
3 14 Adjusting power steering rack with new steering rack (TRW) 2632
3 15 Assembly overview – power steering rack (ZF) 2633
3 16 Repairing ZF power assisted steering rack 2636
3 17 Dismantling and assembling power assisted steering rack (ZF) 2638
3 17 1 Dismantling 2638
3 17 2 Assembling 2642
3 18 Adjusting power steering rack (ZF) 2648
4 Assembly overview: vane pump, reservoir and hydraulic lines 2649
4 1 Assembly overview: steering hydraulics pump -V119-, hydraulic lines, Ecomatic 2650
4 2 Removing and installing power steering vane pump, vehicles with 1 4 l engine 2653
4 3 Removing and installing poly-V belt 2654
4 4 Removing and installing power steering vane pump, vehicles with 1 8l, 1 9l, 2 0l engine 2655
4 5 Installing vane pump 2656
4 6 Tensioning V-belt 2657
4 7 Removing and installing power-assisted steering vane pump, vehicles with 128 kW engine 2658
00054006620 4 and 5 speed manual gearbox 020 02K 2660
00 – Technical data 2664
1 Identification of gearbox 2664
1 1 Location on gearbox 2664
1 2 Code letters, allocation, ratios, capacities 2665
2 Overview – power transmission 2675
3 Calculating overall gear ratio “i” 2677
4 General repair instructions 2678
4 1 Components 2678
4 1 1 Gearbox 2678
4 1 2 Gaskets and seals 2678
4 1 3 Locking devices 2679
4 1 4 Nuts and bolts 2679
4 1 5 Bearings 2679
4 1 6 Shims 2679
4 1 7 Synchro-rings 2679
4 1 8 Gear wheels 2680
30 – Clutch 2681
1 Repairing clutch mechanism 2681
1 1 Repairing clutch mechanism in Ecomatic vehicles 2681
1 2 Assembly overview – pedals – hydraulic and mechanical clutch mechanism 2682
1 3 Removing and installing over-centre spring 2683
1 3 1 Removing 2683
1 3 2 Installing 2684
1 4 Removing and installing clutch pedal 2684
1 4 1 Removing from vehicles with hydraulic clutch mechanism 2685
1 4 2 Removing from vehicles with mechanical clutch mechanism 2685
1 4 3 Installing in vehicles with hydraulic clutch mechanism 2685
1 4 4 Installing in vehicles with mechanical clutch mechanism 2686
1 5 Assembly overview – hydraulic system 2686
1 6 Removing and installing master cylinder 2688
1 6 1 Removing 2689
1 6 2 Installing 2690
1 7 Bleeding clutch system 2690
1 8 Assembly overview – mechanics 2691
1 9 Removing and installing clutch cable 2692
1 10 Checking function of clutch cable 2693
1 10 1 Returning adjustment mechanism of clutch cable to functional condition 2694
2 Repairing clutch mechanism – Ecomatic 2696
2 1 Assembly overview – Ecomatic 2696
2 2 Removing and installing clutch actuator 2698
2 2 1 Removing 2698
2 2 2 Installing 2700
2 3 Clutch mechanism/servo-assistance vacuum system 2701
2 3 1 Removing clutch system pressure switch -F210- 2702
2 3 2 Removing vacuum reservoir 2703
2 4 Checking clutch mechanism/servo-assistance vacuum system for leaks 2703
2 4 1 Checking overall system – vehicles ► March 94: 2704
2 4 2 Checking overall system – vehicles March 94 ► 2707
3 Repairing clutch 2709
3 1 Removing and installing clutch 2710
3 1 1 Removing 2711
3 1 2 Installing 2712
34 – Controls, housing 2714
1 Repairing selector mechanism 2714
1 1 Installation position of selector mechanism 2714
1 2 Assembly overview – selector housing and gear lever 2716
1 2 1 Installing selector lever gaiter 2717
1 2 2 Retaining plate installation position 2718
1 3 Removing and installing gear shift switch -F191- 2718
1 3 1 Removing 2719
1 3 2 Installing 2719
1 4 Assembly overview – gear selector relay points on gearbox 2719
1 5 Adjusting selector mechanism 2722
1 5 1 Adjusting 2722
1 5 2 Function 2723
1 5 3 Fine adjustment 2723
1 6 Removing and installing selector lever and selector rod 2724
1 6 1 Removing 2724
1 6 2 Installing 2725
2 Removing and installing gearbox 2726
2 1 Removing gearbox 2726
2 1 1 Transporting gearbox 2732
2 2 Install gearbox 2732
2 2 1 Specified torques 2733
3 Checking or topping up gear oil 2736
3 1 Checking gear oil 2736
4 Dismantling and assembling gearbox 2737
4 1 Overview – gearbox 2737
4 2 Assembly overview 2738
4 3 Part I – Removing and installing cover for gearbox housing and 5th gear 2739
4 4 Part II – Dismantling and assembling gearbox housing and selector mechanism 2740
4 5 Part III – Removing and installing input shaft, output shaft, differential and selector forks 2741
4 6 Assembly sequence 2743
4 6 1 Removing and installing cover, gearbox housing, selector shaft, input shaft, output shaft, differential, selector forks 2743
5 Repairing clutch housing 2760
6 Repairing gearbox housing and selector shaft 2766
7 Repairing gearbox housing cover 2771
35 – Gears, shafts 2777
1 Dismantling and assembling input shaft 2777
2 Dismantling and assembling output shaft 2785
2 1 Allocation/output shafts 2792
3 Output shaft 2793
3 1 Adjusting output shaft 2793
3 1 1 Determining thickness of shim 2795
3 1 2 Checking friction torque 2795
39 – Final drive – rear differential 2797
1 Removing and installing drive flange seals (gearbox installed) 2797
1 1 Removing 2798
1 2 Installing 2799
2 Differential 2800
2 1 Dismantling and assembling differential 2800
2 1 1 Adjustment overview 2807
2 2 Adjusting differential 2807
2 2 1 Determining shim S1 thickness 2809
00054006720 Automatic gearbox 096 2811
00 – Technical data 2815
1 Gearbox identification 2815
1 1 Identification codes, engine allocation, ratios, equipment 2815
1 1 1 Gearboxes for vehicles with program switch -E122- 2815
1 1 2 Gearboxes for vehicles with electronic program switch 2817
2 Capacities 2821
2 1 Planetary gearbox 2821
2 1 1 Final drive 2821
3 Repair instructions 2822
3 1 Special tools 2822
3 2 Gearbox 2822
3 2 1 Seals and sealing rings 2822
3 2 2 Locking devices 2822
3 2 4 Bearings 2823
3 2 5 Shims 2823
3 2 6 Clutches 2823
3 2 7 Self-diagnosis 2823
01 – Self-diagnosis, electrical checks 2824
1 Self-diagnosis function 2824
1 1 Functions of gearbox control unit 2824
1 1 1 Safety functions of gearbox control unit 2824
1 1 2 Faults which may lead to emergency running 2824
1 1 3 Gearbox control unit fault detection 2825
1 2 Technical data of self-diagnosis 2825
1 3 Self-diagnosis guide 2825
1 3 1 Fault finding with fault reader -V A G 1551- on „automatic gearbox“ 2825
2 Electrical and electronic components and their locations 2827
3 Performing self-diagnosis 2833
3 1 Connecting fault reader -V A G 1551- and selecting functions 2833
3 1 1 Test conditions 2833
3 1 2 Vehicles ► 07 93 2833
3 1 3 Vehicles 08 93 ► 2834
3 1 4 Control unit identification 2834
3 2 Overview of selectable functions 2835
3 3 Read fault memory 2836
3 4 Fault table 2836
3 5 Clear fault memory 2842
3 5 1 Requirement: 2842
3 6 Initiating basic setting 2843
3 7 Read measured value block 2844
3 7 1 List of selectable display group numbers 2844
3 8 Test table 2845
3 8 1 Reading measured value block; Display group number 04; „Checking solenoid valves whilst driving“ 2849
3 8 2 Checking solenoid valves whilst driving, gearboxes ► 12 92 2850
3 8 3 Checking solenoid valves during road test, gearboxes 01 93 ► 2851
4 Gearbox: Electrical check 2856
4 1 Test conditions 2856
4 2 Electrical check of 38-pin connectors 2856
4 2 1 Multi-pin connection (38-pin connector) of automatic gearbox control unit -J217- (sockets on text box -V A G 1598-) 2857
4 2 2 List of test steps (38-pin connector) 2858
4 3 Test table 2859
4 4 Electrical check of 68-pin connectors 2868
4 4 1 Multi-pin connection (68-pin connector) of automatic gearbox control unit -J217- (sockets on test box -V A G 1598/18-) 2869
4 4 2 List of test steps (68-pin connector) 2870
4 5 Test table 2871
32 – Torque converter 2879
1 Torque converter 2879
1 1 Identification of torque converter 2879
1 2 Draining torque converter 2879
1 3 Removing and installing torque converter oil seal 2880
37 – Controls, housing 2881
1 Repairing selector mechanism 2881
1 1 Checking selector mechanism 2881
1 2 Checking and adjusting selector lever cable 2881
1 2 1 Checking 2881
1 2 2 Adjusting 2882
1 3 Checking ignition key withdrawal lock (vehicles with ignition key withdrawal lock) 2882
1 4 Dismantling and assembling shift mechanism 2882
1 5 Dismantling and assembling selector mechanism (vehicles with ignition key withdrawal lock) 2887
1 6 Dismantling and assembling selector lever (vehicles with ignition key withdrawal lock) 2891
1 7 Removing and installing locking cable (vehicles with ignition key withdrawal lock) 2894
1 8 Adjusting locking cable (vehicles with ignition key withdrawal lock) 2895
2 Checking gearbox 2897
3 Removing and installing gearbox 2898
4 Checking ATF level and topping up 2903
4 1 Checking ATF level 2903
4 2 Topping up ATF 2903
5 Gearbox with selector elements ► 12 92 2904
5 1 Positions of selector elements in gearboxes through 12 92 2905
5 2 Gearbox with selector elements 01 93 ► 2906
5 3 Positions of selector elements in gearboxes from 01 93 2907
6 Dismantling and assembling gearbox 2908
6 1 Removing and installing ATF cooler and ATF filler tube 2908
6 2 Overview – dismantling and assembling planetary gearbox 2909
6 3 I – Removing and installing ATF pump to support tube 2909
6 4 II – Removing and installing reverse clutch -K2- to small sun gear 2911
6 5 III – Removing and installing freewheel and reverse gear brake -B1- 2912
6 6 IV – Planet carrier and gearbox housing with input gear and cover 2913
6 7 Dismantling and assembling planetary gearbox 2915
6 7 1 Dismantling 2915
6 7 2 Assembling 2918
6 8 Overview – all planetary gearbox adjustments 2924
6 9 Adjusting planet carrier 2925
6 9 2 Table of „shims“: 2927
6 9 3 Example: 2927
6 9 4 Checking dimensions of planet carrier 2928
6 10 Adjusting reverse gear brake -B1- 2928
6 10 2 Calculating I: 2929
6 10 3 Determining m: 2930
6 10 4 Table of „shims“: 2930
6 10 5 Checking dimensions for reverse gear brake -B1- 2930
6 11 Adjusting clutch play between -K1- and -K2- 2931
6 11 2 Calculating a: 2932
6 11 3 Calculating b: 2933
6 11 4 Table of „shims“: 2933
6 11 5 Checking dimension for clutch play 2933
6 12 Adjusting 2nd and 4th gear brake -B2- 2933
6 12 2 Calculating a: 2935
6 12 3 Calculating b: 2935
6 12 4 Table of „outer plates“: 2935
38 – Gears, control 2937
1 Dismantling and assembling ATF pump 2937
2 Dismantling and assembling freewheel with -B1- piston 2939
3 Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft for gearboxes ► 12 92 2941
3 1 Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft for gearboxes 01 93 ► 2944
3 2 Dismantling and assembling reverse gear clutch -K2- 2947
4 Dismantling and assembling 3rd and 4th gear clutch -K3- with pump shaft for gearboxes ► 12 92 2950
4 1 Dismantling and assembling 4th gear clutch -K3- with pump shaft for gearboxes 01 93 2951
4 2 Removing and installing valve body 2953
4 3 Removing and installing gearbox oil temperature sender -G93- 2956
4 4 Dismantling and assembling parking lock 2957
39 – Final drive – differential 2961
1 Checking gear oil in final drive 2961
1 1 Removing and installing drive flange seal 2961
1 1 1 When replacing oil seal on right: 2961
1 1 2 When replacing left oil seal 2961
1 2 Dismantling and assembling final drive 2962
1 2 1 Overview – final drive repair 2962
1 3 Removing and installing input gear 2963
1 4 Removing and installing pinion shaft 2966
1 5 Removing and installing differential 2970
1 6 Dismantling and assembling differential 2974
1 7 Adjusting final drive 2977
1 7 1 Overview of adjustments 2977
1 7 2 Adjustments to be completed after renewing individual components 2978
1 8 Adjusting pinion shaft 2978
1 8 1 Determining shims 2979
1 8 2 Table of „shims“ for pinion shaft and input gear 2979
1 9 Adjusting input gear 2980
1 9 1 Determining thickness of shim 2981
1 10 Adjusting differential 2982
00054006920 Digifant injection and ignition system (4 valve) 2983
01 – Self diagnosis 2987
1 – Self diagnosis 2987
1 1 – Self diagnosis 2987
1 2 – Function 2987
1 3 – Technical data of self diagnosis 2987
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 2988
1 5 – Interrogating and erasing fault memory 2990
1 6 – Fault table Digifant 3 0 2991
1 7 – Fault table Digifant 3 2 2993
1 8 – Final control diagnosis 2996
1 9 – Read measured value block and basic settings 2999
1 10 – Display group overview Digifant 3 0 2999
1 11 – Display group overview Digifant 3 2 3001
24 – Mixture preparation, Injection 3003
1 – Digifant injection and ignition system 3003
1 1 – Digifant injection and ignition system 3003
1 2 – Fitting locations overview 3003
1 3 – Servicing injection part 3006
1 4 – Dismantling and assembling intake manifold upper part 3013
1 5 – Dismantling and assembling intake manifold lower part 3016
1 6 – Dismantling and assembling air cleaner 3018
1 7 – Safety precautions 3020
1 8 – Rules for cleanliness 3020
1 9 – Technical data 3021
1 10 – Performing basic setting 3021
1 11 – Checking Lambda probe and Lambda control 3023
1 12 – Checking Lambda probe heating 3026
1 13 – Checking idling stabilization 3028
1 14 – Checking acceleration/full throttle enrichment and overrun cut-off 3029
1 15 – Checking engine operating mode 3030
1 16 – Checking throttle valve potentiometer 3031
1 17 – Checking coolant temperature sender 3034
1 18 – Checking intake air temperature sender 3036
1 19 – Checking engine speed sender 3039
1 20 – Checking idling switch 3041
1 21 – Replacing and adjusting idling switch 3044
1 22 – Checking control unit voltage supply 3045
1 23 – Matching engine electronic control unit to electronic immobilizer 3046
1 24 – Checking starter signal 3047
1 25 – Checking injectors 3048
1 26 – Checking fuel pressure regulator and holding pressure 3050
1 27 – Checking intake air system for leaks (unmetered air) 3052
1 28 – Checking intake air preheating 3053
28 – Ignition system 3055
1 – Digifant injection and ignition system 3055
1 1 – Digifant injection and ignition system 3055
1 2 – Servicing ignition part 3055
1 3 – Dismantling and assembling distributor 3059
1 4 – Safety precautions 3060
1 5 – Test data, spark plugs 3061
1 6 – Checking ignition timing control 3061
1 7 – Checking No 1 Cyl recognition sender/Hall sender 3062
1 8 – Checking ignition transformer 3063
1 9 – Checking ignition transformer output stage 3063
1 10 – Checking knock sensors 3066
1 11 – Renewing rotor arm 3067
00054007120 5 Speed manual gearbox 02C four wheel drive 3068
00 – Technical data 3074
1 – Gearbox identification 3074
1 1 – Gearbox identification 3074
1 2 – Code letters, assembly allocation, ratios, capacities 3075
2 – Rear final drive identification 3076
2 1 – Rear final drive identification 3076
2 2 – Code letters, assembly allocation, ratios, capacities 3077
3 – Transmission layout 3078
3 1 – Transmission layout 3078
4 – Calculating overall ratio (i) 3080
4 1 – Calculating overall ratio (i) 3080
4 2 – Notes on brake and performance tests and towing 3080
5 – General repair instructions 3080
5 1 – General repair instructions 3080
30 – Clutch 3082
1 – Servicing clutch control 3082
1 1 – Servicing clutch control 3082
1 2 – Assembly overview – pedal cluster 3083
1 3 – Removing and installing over-centre spring 3087
1 4 – Removing and installing clutch pedal 3088
1 5 – Assembly overview – hydraulic system 3090
1 6 – Removing and installing master cylinder 3093
1 7 – Bleeding clutch system 3095
2 – Servicing clutch release mechanism 3097
2 1 – Servicing clutch release mechanism 3097
3 – Servicing clutch 3100
3 1 – Servicing clutch 3100
34 – Controls, Housing 3105
1 – Servicing gear selector mechanism 3105
1 1 – Servicing gear selector mechanism 3105
1 2 – Installation position of gear selector mechanism 3105
1 3 – Removing and installing gear selector cables 3108
1 4 – Removing and installing gear stick housing 3114
1 5 – Servicing gear stick 3116
1 6 – Adjusting gear selector mechanism 3119
2 – Removing and installing gearbox 3121
2 1 – Removing and installing gearbox 3121
2 2 – Removing and installing gearbox and bevel box (Vehicles with 4 cylinder engine) 3121
2 3 – Removing and installing gearbox and bevel box (Vehicles with 6 cylinder fuel injection engine) 3132
3 – Removing and installing bevel box 3143
3 1 – Removing and installing bevel box 3143
3 2 – Removing and installing bevel box (Vehicles with 4-cylinder engine) 3143
3 3 – Removing and installing bevel box (Vehicles with 6-cylinder injection engine) 3148
4 – Checking oil in manual gearbox with bevel box 3153
4 1 – Checking oil in manual gearbox with bevel box 3153
5 – Dismantling and assembling gearbox 3155
5 1 – Dismantling and assembling gearbox 3155
5 2 – Removing and installing cover for gearbox housing and 5th gear 3156
5 3 – Removing and installing gearbox housing and selector mechanism 3159
5 4 – Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks 3161
5 5 – Dismantling and assembling sequence 3163
6 – Servicing gearbox housing and clutch housing 3180
6 1 – Servicing gearbox housing and clutch housing 3180
7 – Dismantling and assembling gearbox selector mechanism 3189
7 1 – Dismantling and assembling gearbox selector mechanism 3189
8 – Dismantling and assembling selector forks 3194
8 1 – Dismantling and assembling selector forks 3194
35 – Gears, Shafts 3200
1 – Dismantling and assembling input shaft 3200
1 1 – Dismantling and assembling input shaft 3200
2 – Adjusting input shaft 3211
2 1 – Adjusting input shaft 3211
2 2 – Table of adjustment shims 3212
2 3 – Carrying out check measurement 3214
3 – Dismantling and assembling output shaft (pinion shaft) 3215
3 1 – Dismantling and assembling output shaft (pinion shaft) 3215
4 – Adjusting output shaft 3239
4 1 – Adjusting output shaft 3239
5 – Dismantling and assembling reverse shaft 3242
5 1 – Dismantling and assembling reverse shaft 3242
39 – Final drive, Differential rear 3246
1 – Renewing left-hand flange shaft or right-hand drive flange oil seals (gearbox installed) 3246
1 1 – Renewing left-hand flange shaft or right-hand drive flange oil seals (gearbox installed) 3246
1 2 – Renewing left-hand flange shaft oil seal 3246
1 3 – Renewing right-hand drive flange oil seal 3247
2 – Renewing bevel box output flange oil seal (bevel box removed) 3248
2 1 – Renewing bevel box output flange oil seal (bevel box removed) 3248
3 – Dismantling and assembling differential 3250
3 1 – Dismantling and assembling differential 3250
4 – Adjustment overview 3262
4 1 – Adjustment overview 3262
5 – Adjusting differential 3262
5 1 – Adjusting differential 3262
6 – Dismantling and assembling bevel box 3264
6 1 – Dismantling and assembling bevel box 3264
6 2 – Assembly overview 3265
6 3 – Dismantling and assembling sequence 3274
7 – Adjusting shaft bevel gear and bevel gear (gear set) 3285
7 1 – Adjusting shaft bevel gear and bevel gear (gear set) 3285
7 2 – General notes 3285
7 3 – Adjusting and marking of gear sets 3285
7 4 – Position of shims 3286
7 5 – Adjustment overview (bevel box) 3286
7 6 – Recommended sequence for adjusting gear set 3287
7 7 – Determining shim “S4” thickness when replacing output flange 3287
7 8 – Adjusting shaft bevel gear 3288
7 9 – Adjusting bevel gear 3294
8 – Removing and installing propshaft 3297
8 1 – Removing and installing propshaft 3297
9 – Servicing propshaft 3301
9 1 – Servicing propshaft 3301
10 – Checking function of viscous coupling 3309
10 1 – Checking function of viscous coupling 3309
11 – Removing and installing viscous coupling 3309
11 1 – Removing and installing viscous coupling 3309
12 – Removing and installing viscous coupling seal 3311
12 1 – Removing and installing viscous coupling seal 3311
13 – Removing and installing drive flange oil seal (rear final drive) 3311
13 1 – Removing and installing drive flange oil seal (rear final drive) 3311
14 – Functional check of free-wheel 3313
14 1 – Functional check of free-wheel 3313
15 – Functional check of free-wheel lock 3313
15 1 – Functional check of free-wheel lock 3313
16 – Removing and installing rear final drive 3314
16 1 – Removing and installing rear final drive 3314
17 – Checking rear final drive oil 3317
17 1 – Checking rear final drive oil 3317
18 – Dismantling and assembling rear final drive 3318
18 1 – Dismantling and assembling rear final drive 3318
18 2 – Removing viscous coupling and rear axle housing from bevel gear housing 3330
18 3 – Servicing shaft bevel gear bearings 3332
18 4 – Pressing bevel gear off and on input shaft 3336
18 5 – Servicing bevel gear/input shaft bearings 3337
18 6 – Servicing differential bearings 3341
18 7 – Installing rear axle housing on bevel gear housing and building on viscous coupling 3343
19 – Dismantling and assembling differential and freewheel (assembly overview) 3348
19 1 – Dismantling and assembling differential and freewheel (assembly overview) 3348
20 – Dismantling and assembling differential (sequence) 3352
20 1 – Dismantling and assembling differential (sequence) 3352
21 – Removing and installing freewheel (sequence) 3353
21 1 – Removing and installing freewheel (sequence) 3353
22 – Dismantling and assembling freewheel (sequence) 3354
22 1 – Dismantling and assembling freewheel (sequence) 3354
23 – Adjusting bevel gear and shaft bevel gear (gear set) 3355
23 1 – Adjusting bevel gear and shaft bevel gear (gear set) 3355
23 2 – General notes 3355
23 3 – Adjusting and marking of gear sets 3356
23 4 – Position of shims 3357
23 5 – Adjustment overview (rear final drive) 3357
23 6 – Recommended sequence for adjusting gear set 3358
23 7 – Adjusting shaft bevel gear 3358
23 8 – Adjusting bevel gear 3362
00054007220 Running gear self diagnosis for ABS 3366
01 – Self-diagnosis, Electrical check 3370
1 – Self-diagnosis function, ITT Mark 04 3370
1 1 – Self-diagnosis function, ITT Mark 04 3370
1 2 – Function 3370
1 3 – Distinguishing features of ABS and the ABS/EDL, ITT Mark 04 3371
1 4 – Technical data of self-diagnosis 3373
1 5 – Safety precautions and fundamental points regarding fault finding 3373
1 6 – Fault finding with fault reader V A G 1551 on ABS, ITT Mark 04 and ABS/EDL ITT Mark 04 (flow chart) 3374
2 – Electrical/electronic components and fitting locations 3375
2 1 – Electrical/electronic components and fitting locations 3375
3 – Executing self diagnosis 3380
3 1 – Executing self diagnosis 3380
3 2 – Test prerequisites for self-diagnosis 3381
3 3 – Connecting fault reader V A G 1551 and selecting function 3381
3 4 – List of selectable functions 3384
3 5 – Interrogating fault memory 3384
3 6 – Fault table 3385
3 7 – Erasing fault memory, ending output 3390
4 – Electrical check of the ABS and ABS/EDL ITT Mark 04 3391
4 1 – Electrical check of the ABS and ABS/EDL ITT Mark 04 3391
4 2 – Test prerequisites 3391
4 3 – Contact assignment of multi-pin connector 3392
4 4 – Fault table 3395
4 5 – Removing and installing control unit 3408
4 6 – Adjusting brake light switch 3409
5 – Self-diagnosis function ITT Mark 20 GI 3409
5 1 – Self-diagnosis function ITT Mark 20 GI 3409
5 2 – Function 3409
5 3 – Distinguishing features of ABS ITT Mark 20 GI and the ABS/EDL ITT Mark 20 GI 3410
5 4 – Technical data of self-diagnosis 3412
5 5 – Safety precautions and fundamental points regarding fault finding 3412
5 6 – Fault finding with fault reader V A G 1551 on ABS and ABS/EDL ITT Mark 20 (flow chart) 3413
6 – Electrical/electronic components and fitting locations 3414
6 1 – Electrical/electronic components and fitting locations 3414
7 – Faults displayed by warning lamps K47 and K118 3418
7 1 – Faults displayed by warning lamps K47 and K118 3418
7 2 – Vehicle with ABS/EDL has no EDL function 3419
8 – Executing self diagnosis 3419
8 1 – Executing self diagnosis 3419
8 2 – Test prerequisites for self-diagnosis 3419
8 3 – List of selectable functions 3419
8 4 – Connecting fault reader V A G 1551 and selecting functions 3420
8 5 – Interrogating fault memory 3422
8 6 – Fault table 3423
8 7 – Erasing fault memory, ending output 3425
8 8 – Coding control unit 3426
8 9 – Read measured value block 3427
8 10 – Final control diagnosis 3430
8 11 – Initiating basic setting 3437
9 – Electrical check of the ABS and ABS/ EDL ITT Mark 20 GI 3442
9 1 – Electrical check of the ABS and ABS/ EDL ITT Mark 20 GI 3442
9 2 – Test prerequisites 3442
9 3 – Multi-pin connector with contact assignment 3443
9 4 – Test table 3444
9 5 – Adjusting brake light switch 3448
00054007320 4 Cyl injection engine (cross flow cylinder head) Mechanics 3450
00 – Technical data 3454
1 – Technical data 3454
1 1 – Technical data 3454
1 2 – Engine number 3454
1 3 – Engine data 3454
10 – Removing and installing engine 3456
1 – Removing and installing engine 3456
1 1 – Removing and installing engine 3456
1 2 – Notes on removing 3457
1 3 – Notes on installing 3459
1 4 – Tightening torques 3460
1 5 – Assembly mountings 3461
1 6 – Replacing engine carrier rubber mounting 3463
1 7 – Additional information and removal instructions for vehicles with air conditioner 3464
13 – Crankshaft group 3466
1 – Dismantling and assembling engine 3466
1 1 – Dismantling and assembling engine 3466
1 2 – Removing and installing ribbed belt 3481
1 3 – Removing and installing toothed belt 3484
2 – Removing and installing sealing flange and pressure plate/drive plate 3488
2 1 – Removing and installing sealing flange and pressure plate/drive plate 3488
2 2 – Renewing crankshaft oil seal -pulley side- 3492
2 3 – Removing and installing drive plate 3495
3 – Removing and installing crankshaft 3498
3 1 – Removing and installing crankshaft 3498
3 2 – Crankshaft dimensions 3500
4 – Dismantling and assembling pistons and conrods 3501
4 1 – Dismantling and assembling pistons and conrods 3501
4 2 – Piston and cylinder dimensions 3507
15 – Cylinder head, Valve gear 3508
1 – Removing and installing cylinder head 3508
1 1 – Removing and installing cylinder head 3508
1 2 – Removing and installing cylinder head 3515
1 3 – Checking compressions 3517
2 – Servicing valve gear 3519
2 1 – Servicing valve gear 3519
2 2 – Reworking valve seats 3525
2 3 – Removing and installing camshaft oil seal 3528
2 4 – Removing and installing camshaft 3530
2 5 – Checking hydraulic bucket tappets 3532
2 6 – Checking valve guides 3533
2 7 – Renewing valve guides 3534
2 8 – Renewing valve stem seals 3536
17 – Lubrication 3539
1 – Removing and installing parts of the lubrication system 3539
1 1 – Removing and installing parts of the lubrication system 3539
1 2 – Checking oil pressure and oil pressure switch 3546
19 – Cooling system 3548
1 – Removing and installing parts of cooling system 3548
1 1 – Removing and installing parts of cooling system 3548
1 2 – Parts of cooling system body side 3549
1 3 – Parts of cooling system – engine side 3555
1 4 – Dismantling and assembling coolant pump 3562
1 5 – Draining and filling cooling system 3564
1 6 – Removing and installing radiator and radiator fan 3566
20 – Fuel supply system 3568
1 – Removing and installing parts of fuel supply system 3568
1 1 – Removing and installing parts of fuel supply system 3568
1 2 – Removing and installing fuel tank with its attachments and fuel filter 3569
1 3 – Safety precautions when working on the fuel supply system 3574
1 4 – Rules for cleanliness 3575
1 5 – Adjusting throttle cable 3575
1 6 – Removing and installing fuel delivery unit 3578
1 7 – Checking fuel pump 3580
1 8 – Crash fuel shut-off 3581
2 – Activated charcoal filter system 3585
2 1 – Activated charcoal filter system 3585
2 2 – Function 3585
2 3 – Servicing parts of the activated charcoal filter system 3587
2 4 – Checking activated charcoal filter solenoid valve 1 3592
2 5 – Checking fuel tank breather 3594
26 – Exhaust system 3597
1 – Removing and installing parts of exhaust system 3597
1 1 – Removing and installing parts of exhaust system 3597
1 2 – Exhaust manifold, front exhaust pipe and catalyst with attachments 3597
1 3 – Silencer with mountings 3601
1 4 – Checking catalyst 3603
2 – Secondary air system 3605
2 1 – Secondary air system 3605
2 2 – Function 3605
2 3 – Removing and installing parts of the secondary air system 3606
2 4 – Checking combi-valve 3609
2 5 – Checking secondary air pump motor 3611
2 6 – Checking secondary air inlet valve 3612
00054007420 Motronic injection and ignition system (4 Cyl engine) 3614
01 – Self diagnosis, Electrical check 3618
1 – Self diagnosis 3618
1 1 – Self diagnosis 3618
1 2 – Function 3618
1 3 – Technical data of self diagnosis 3618
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 3619
1 5 – Interrogating fault memory 3620
1 6 – Fault table 3620
1 7 – Erasing fault memory 3626
1 8 – Final control diagnosis 3627
1 9 – Reading measuring value block 3630
1 10 – Display group overview 3630
2 – Electrical check 3632
2 1 – Electrical check 3632
2 2 – Wiring and component check with test box V A G 1598/18 3632
24 – Mixture preparation, Injection 3639
1 – Motronic injection and ignition system 3639
1 1 – Motronic injection and ignition system 3639
1 2 – Fitting locations overview 3639
1 3 – Servicing injection part 3642
1 4 – Dismantling and assembling intake manifold – upper part 3650
1 5 – Dismantling and assembling intake manifold – lower part 3653
1 6 – Dismantling and assembling air cleaner 3654
1 7 – Safety precautions 3655
1 8 – Rules for cleanliness 3656
1 9 – Technical data 3656
1 10 – Idling check 3656
1 11 – Checking idling stabilization 3657
1 12 – Checking Lambda probe and Lambda control 3659
1 13 – Checking engine operation 3661
1 14 – Checking throttle valve potentiometer 3662
1 15 – Matching automatic gearbox control unit and throttle valve potentiometer to one another 3663
1 16 – Checking intake manifold temperature sender 3664
1 17 – Checking coolant temperature sender 3665
1 18 – Checking speed signal 3666
1 19 – Matching engine electronic control unit to electronic immobilizer 3667
1 20 – Checking fuel pressure regulator and holding pressure 3668
1 21 – Checking injectors 3670
1 22 – Checking intake air system for leaks (outside air) 3672
1 23 – Checking intake air preheating 3673
28 – Ignition system 3675
1 – Motronic injection and ignition system 3675
1 1 – Motronic injection and ignition system 3675
1 2 – Servicing ignition part 3675
1 3 – Safety precautions 3679
1 4 – Test data, spark plugs 3679
1 5 – Installing distributor 3679
1 6 – Checking ignition transformer 3681
1 7 – Checking ignition transformer output stage 3682
1 8 – Checking Hall sender 3683
00054007520 General body repairs – Cabriolet 3685
01 – Self-diagnosis 3693
1 Self-diagnosis 3693
1 1 Tools 3693
1 2 Connecting fault reader 3694
2 Self-diagnosis of airbag system ▸ 08 94 3696
2 1 Function 3696
2 2 Starting self-diagnosis of airbag 3696
2 3 Overview of the selectable functions 3697
2 4 Interrogating control unit version 3697
2 5 Interrogating fault memory 3698
2 6 Fault table 3699
2 7 Erasing fault memory 3700
2 7 1 Prerequisites: 3700
2 8 End output 3701
3 Self-diagnosis of airbag system 09 94 ▸ 3702
3 1 Function 3702
3 2 Starting self-diagnosis of airbag 3702
3 3 Overview of the selectable functions 3703
3 4 Interrogating control unit version 3704
3 4 1 Control unit -VW 3-(example) 3704
3 4 2 Control unit -VW 3-(example) 3704
3 5 Interrogating fault memory 3704
3 6 Erasing fault memory 3705
3 7 End output 3706
3 8 Fault table 3706
3 9 Coding airbag control unit using fault reader -V A G 1551- 3717
3 10 Read measured value block 3719
3 10 1 Display group 001 3720
3 10 2 Evaluating display group number 001 3720
3 10 3 Display group 003 3721
3 10 4 Evaluating display group number 003 3722
3 10 5 Display group 005 3722
3 10 6 Evaluating display group number 005 3723
3 11 Deactivating and activating front passenger’s airbag unit (matching) 09 94 ▸ 3723
3 11 1 Deactivating front passenger’s airbag 3723
3 11 2 Activating front passenger’s airbag 3726
3 12 Auxiliary airbag tester -VAS 5056- 3729
3 12 1 Connecting auxiliary airbag tester -VAS 5056- with driver’s airbag components 3729
3 12 2 Connecting auxiliary airbag tester -VAS 5056- with passenger’s airbag components 3730
3 13 Final control diagnosis 3730
4 Self-diagnosis of central locking remote control 3733
4 1 Functional description 3733
4 2 Initiating self-diagnosis of central locking remote control 3733
4 3 Overview of the selectable functions 3734
4 4 Interrogating control unit version 3734
4 5 Interrogating fault memory 3735
4 6 Final control diagnosis 3735
4 6 1 Tools 3736
4 6 2 Procedure 3736
4 7 Erasing fault memory 3736
4 8 End output 3737
4 9 Fault table 3737
4 10 Read measured value block 3739
4 10 1 Tools 3739
4 10 2 Procedure 3739
4 11 Display group overview 3740
4 11 1 Breakdown of display content for display group number 001 3740
4 11 2 Evaluating display group number 001 3740
4 11 3 Breakdown of display content for display group number 002 3741
4 11 4 Evaluating display group number 002 3741
4 11 5 Breakdown of display content for display group number 003 3741
4 11 6 Evaluating display group number 003 3742
4 12 Adapting ignition keys to remote control 3743
4 13 Adapting a new, additional key 3745
4 13 1 With fault reader -V A G 1551- 3745
4 13 2 Without fault reader -V A G 1551- 3746
4 14 Synchronising ignition keys to remote control 3747
4 15 Removing and installing batteries for the main key with radio wave remote control 3747
4 15 1 Removing 3748
4 15 2 Installing 3748
4 16 Removing and installing batteries for hinged main key with remote control system 3749
4 16 2 Removing 3749
4 16 3 Installing 3750
50 – Body – front 3751
1 Body – front 3751
1 1 Repairing lock carrier with attachments 3751
1 2 Removing and installing front wing 3752
1 2 1 Removing 3752
1 2 2 Installing 3753
55 – Bonnet, rear lid 3754
1 Bonnet 3754
1 1 Removing and installing bonnet lock cable 3754
1 2 Assembly overview – bonnet 03 98 ▸ 3755
1 3 Removing gas strut 3756
2 Rear lid ▸ 02 98 3757
2 1 Removing gas strut 3757
2 2 Releasing gas from gas strut 3757
2 3 Removing and installing rear lid lock 3757
2 4 Adjusting pull rod 3758
2 5 Removing the push button 3759
2 6 Repairing push button 3759
2 7 Maintaining single-key locking 3760
3 Rear lid 03 98 ▸ 3761
3 1 Assembly overview 3761
3 2 Assembly overview – lock components 3762
3 3 Removing and installing rear lid lock 3763
3 3 1 Removing 3763
3 3 2 Installing 3763
3 4 Assembly overview – handle and lock cylinder housing 3764
3 5 Removing and installing lock cylinder housing 3765
3 5 1 Removing 3765
3 5 2 Installing 3768
3 6 Removing and installing handle 3769
3 6 1 Removing 3769
3 6 2 Installing 3769
57 – Front doors, door components, central locking 3770
1 Front door 3770
1 1 Tools 3770
1 2 Assembly overview – front door 3770
1 3 Removing and installing door 3772
1 3 1 Removing 3772
1 3 2 Installing 3772
1 4 Removing and installing door window 3772
1 4 1 Removing 3772
1 4 2 Installing 3772
1 5 Adjusting door window 3772
1 5 1 Aligning door window to the front window channel 3773
1 5 2 Adjusting window regulator 3773
1 5 3 Adjusting the height of the door window 3773
1 5 4 Aligning door window to B pillar 3774
1 5 5 Adjusting the height of the front window 3775
1 5 6 Adjusting window position on B pillar 3776
1 5 7 Adjusting preload on the door window 3776
1 6 Removing and installing window regulator 3778
1 6 1 Removing 3778
1 6 2 Installing 3778
1 7 Repairing door lock with actuating components 3778
1 8 Removing and installing door lock 3779
1 8 1 Removing 3779
1 8 2 Installing 3780
1 9 Assembly overview – door handle 3780
1 10 Removing and installing door handle 3782
1 10 1 Removing 3782
1 10 2 Installing 3783
1 11 Maintaining single-key locking 3783
1 12 Assembly overview – door handle with interior profile key 3783
1 13 Removing and installing lock cylinder with interior profile key 3784
1 13 1 Removing 3784
1 13 2 Installing 3785
1 14 Removing inner release handle 3788
2 Repairing central locking system 3789
2 1 Assembly overview 3789
2 2 New couplings and distributor elements for pipe connections 3790
2 3 Removing and installing dual pressure pump 3790
2 3 1 Removing 3790
2 3 2 Installing 3791
2 4 Removing and installing positioning element for fuel tank flap 3791
2 4 1 Removing 3791
2 4 2 Installing 3791
2 5 Removing and installing door lock positioning element 3791
2 5 1 Removing 3791
2 6 Removing and installing rear lid positioning element 3792
2 6 1 Removing 3792
2 6 2 Installing 3793
2 7 Functional check of central locking 3794
2 8 Activating separate opening of doors with central locking 3795
61 – Convertible roof, hardtop, canopy 3796
1 Convertible top 3796
1 1 Tools 3796
1 2 Assembly overview ▸ 09 00 3796
1 3 Assembly overview 10 00 ▸ 3798
1 4 Adjusting top 3799
1 5 Removing and installing convertible top 3799
1 5 1 Removing 3799
1 5 2 Installing 3801
1 6 Renewing top cover ▸ 09 00 3802
1 6 1 Removing 3802
1 6 2 Installing 3804
1 7 Renewing top cover 10 00 ▸ 3807
1 7 1 Removing 3807
1 7 2 Installing 3810
1 8 Renewing padding ▸ 08 98 3812
1 8 1 Removing 3812
1 8 2 Installing 3813
1 9 Renewing padding 09 98 ▸ 3815
1 9 1 Removing 3815
1 9 2 Installing 3816
1 10 Renewing top liner 3820
1 10 1 Removing 3820
1 10 2 Installing 3821
2 Electrical/hydraulic top 3822
2 1 Assembly overview 3822
2 2 Filling and bleeding the hydraulic system 3823
2 2 1 Filling the hydraulic system 3823
2 2 2 Bleeding the hydraulic system 3824
2 3 Removing and installing hydraulic pump 3824
2 3 1 Removing 3824
2 3 2 Installing 3825
2 4 Assembly overview – impeller for hydraulic pump 3825
2 5 Removing and installing impeller for hydraulic pump 3826
2 5 1 Removing 3826
2 5 2 Installing 3827
2 6 Assembly overview – oil reservoir, electrical/hydraulic top 3829
2 7 Removing and installing oil reservoir 3829
2 7 1 Removing 3829
2 7 2 Installing 3831
2 8 Removing and installing the hydraulic cylinder 3832
2 8 1 Removing 3832
2 8 2 Installing 3832
2 9 Removing and installing hydraulic hose 3833
2 9 1 Removing 3833
2 9 2 Installing 3833
3 Windscreen frame 3834
3 1 Removing and installing windscreen frame seal 3834
3 1 1 Removing 3834
3 1 2 Installing 3835
63 – Bumpers 3836
1 Front bumper ▸ 02 98 3836
1 1 Removing front bumper 3836
1 2 Removing and installing cover 3836
1 2 1 Removing 3836
1 2 2 Installing 3837
2 Front bumper 03 98 ▸ 3838
2 1 Assembly overview – bumper cover 3838
2 2 Assembly overview – bumper carrier 3840
3 Rear bumper ▸02 98 3841
3 1 Assembly overview 3841
3 2 Removing and installing rear bumper 3842
3 2 1 Removing 3842
3 2 2 Installing 3842
4 Rear bumper 03 98 ▸ 3843
4 1 Assembly overview – bumper cover 3843
4 2 Assembly overview – bumper carrier 3844
64 – Glazing 3845
1 Flush bonded windows 3845
1 1 Tools 3845
1 2 Materials 3847
1 3 Assembly overview – windscreen 3847
1 4 Removing and installing windscreen 3848
1 4 1 Removing 3848
1 4 2 Installing 3849
1 5 Removing and installing water deflector strips 3849
1 5 1 Removing 3849
1 5 2 Installing 3850
1 6 Preparing old undamaged window for glazing 3851
1 7 Preparing new window for glazing 3851
1 8 Preparing body flange for glazing 3852
1 9 Installation instructions 3853
1 10 Curing time 3853
1 11 Touching up paint damage 3853
1 12 Cleaning off excess adhesive sealing material 3854
2 Side window 3855
2 1 Assembly overview – side window 3855
2 2 Removing outer B-pillar trim 3855
2 3 Removing side window 3856
2 4 Adjusting side window 3856
2 4 1 Adjusting window guide 3856
2 4 2 Adjusting window position on B pillar 3857
2 4 3 Adjusting the height of the side window 3858
2 5 Removing and installing electrical window regulator 3859
2 5 1 Removing 3859
2 5 2 Installing 3859
66 – Exterior equipment 3860
1 Trim 3860
1 1 Removing and installing radiator grille ▸ 02 98 3860
1 1 1 Removing 3860
1 1 2 Installing 3861
1 2 Removing and installing radiator grille 03 98 ▸ 3861
1 2 1 Removing 3861
1 2 2 Installing 3862
2 Removing and installing wheel housing liner 3863
2 1 Front wheel housing liner 3863
2 1 1 Removing 3863
2 1 2 Installing 3863
3 Exterior mirror 3864
3 1 Removing and installing exterior mirror 3864
68 – Interior equipment 3865
1 Interior mirror 3865
1 1 Removing and installing interior mirror 3865
1 1 1 Removing 3865
1 1 2 Installing 3865
1 2 Repair method using glass-to-metal adhesive 3865
1 2 1 Materials 3865
2 Compartments, covers and trims 3867
2 1 Removing and installing centre console 3867
2 1 1 Removing 3867
2 1 2 Installing 3868
3 Windbreak 3869
3 1 Assembly overview – windbreak 3869
3 2 Retrofitting windbreak 3869
69 – Passenger protection 3871
1 Removing and installing seat belts 3871
1 1 Assembly overview – seat belts 3871
1 2 Removing and installing belt height adjustment 3871
1 3 Removing and installing front belt reel and anchor rail 3872
1 4 Safety regulations for belt tensioners 3873
1 5 Disposal of belt tensioner units 3874
1 6 Checking belt tensioner 3874
1 7 Removing and installing front seat belt with belt tensioner 3874
1 8 Assembly overview – belt reel with tensioner unit 3876
1 9 Removing and installing belt reel with tensioner unit 3876
1 9 1 Removing 3876
1 9 2 Installing 3877
1 10 Removing and installing rear belt reel 3877
1 11 Removing and installing rear belt buckle 3878
1 11 1 Removing 3878
1 11 2 Installing 3878
1 12 Removing and installing front belt buckle 3879
1 12 1 Removing 3879
1 12 2 Installing 3879
2 Inspecting seat belts 3880
2 1 Points to check 3880
2 1 1 Checking belt webbing 3880
2 1 2 Checking inertia reel (locking mechanism) 3881
2 1 3 Visually checking belt buckle 3882
2 1 4 Checking operation of belt buckle 3882
2 1 5 Checking belt anchors, belt guides and latch plates 3882
2 1 6 Checking securing parts and anchorage points 3882
3 Airbag 3884
3 1 Overview – installation locations 3884
3 2 Safety precautions when working on the airbag 3884
3 3 Disposal of airbag units 3885
3 4 Deactivating the airbag 3885
3 5 Renewing airbag units following an accident 3885
3 5 1 Accident involving triggering of airbag 3885
3 5 2 Accident not involving triggering of airbag 3886
3 6 Assembly overview – driver airbag unit ▸ 02 98 3886
3 7 Removing and installing driver’s airbag unit ▸ 02 98 3887
3 7 1 Removing 3888
3 7 2 Installing 3889
3 8 Assembly overview – driver airbag unit 03 98 ▸ 3889
3 9 Removing and installing driver’s airbag unit 03 98 ▸ 3890
3 9 1 Removing 3890
3 9 2 Installing 3893
3 10 Removing and installing steering wheel 3893
3 10 1 Removing 3894
3 10 2 Installing 3895
3 11 Removing and installing return spring with slip ring 3895
3 11 1 Removing 3895
3 11 2 Installing 3895
3 12 Removing and installing front passenger airbag unit 3895
3 12 1 Removing 3896
3 12 2 Installing 3897
3 13 Removing and installing driver and front passenger side airbag 3897
3 13 1 Removing 3897
3 13 2 Installing 3898
3 14 Assembly overview – driver/front passenger side airbag sensor 3899
3 15 Removing and installing sensor for driver’s/front passenger’s side airbag 3899
3 15 1 Removing 3900
3 15 2 Installing 3900
3 16 Removing and installing airbag control unit (J 234) 3901
3 16 1 Removing 3901
3 16 2 Installing 3901
70 – Trim, insulation 3903
1 Dash panel 3903
1 1 Removing and installing centre console 3903
1 1 1 Removing 3903
1 1 2 Installing 3904
1 2 Removing and installing dash panel 3904
1 2 1 Removing 3904
1 2 2 Installing 3906
1 3 Removing and installing cover for relay plate 3906
1 3 1 Removing 3906
1 3 2 Installing 3906
1 4 Removing and installing driver side storage compartment 3906
1 4 1 Removing 3906
1 4 2 Installing 3906
1 5 Removing and installing passenger side storage compartment 3907
1 5 1 Removing 3907
1 5 2 Installing 3907
1 6 Removing and installing heating controls 3907
1 6 1 Removing 3907
1 6 2 Installing 3907
1 7 Removing and installing instrument panel 3908
1 7 1 Removing 3908
1 7 2 Installing 3908
1 8 Repairing glove box 3908
2 Door trims 3910
2 1 Removing trim 3910
2 1 1 Removing window crank 3911
2 1 3 Removing door stowage compartment with loudspeaker mount 3911
2 2 Renewing insulation film 3911
3 Pillar and side trims 3913
3 1 Removing and installing windscreen frame trim 3913
3 1 1 Removing 3913
3 1 2 Installing 3913
3 2 Removing and installing A-pillar trim 3913
3 2 1 Removing 3913
3 3 Removing and installing B-pillar trim 3914
3 3 1 Removing 3914
3 3 2 Installing 3914
3 4 Removing and installing side trim 3915
3 4 1 Removing 3915
3 4 2 Installing 3915
3 5 Removing and installing roll bar trim 3916
3 5 1 Removing 3916
3 5 2 Installing 3916
4 Rear lid trim 3917
4 1 Removing and installing rear lid trim 3917
4 1 1 Removing 3917
4 1 2 Installing 3917
72 – Seat frames 3918
1 Front seats 3918
1 1 Tools 3918
1 2 Removing and installing front seat 3918
1 2 1 Removing 3918
1 2 2 Installing 3921
1 3 Assembly overview – backrest 3922
1 4 Removing and installing backrest 3922
1 4 1 Removing 3922
1 4 2 Installing 3923
2 Rear seats 3924
2 1 Removing and installing lower part of backrest 3924
2 1 1 Removing 3924
2 1 2 Installing 3924
2 2 Removing and installing upper part of backrest 3924
2 2 1 Removing 3924
2 2 2 Installing 3925
2 3 Removing and installing rear seat 3926
2 3 1 Removing 3926
2 3 2 Installing 3926
74 – Seat – padding, covers 3927
1 Front seat covers and padding 3927
1 1 Removing and installing seat cover and padding 3927
1 2 Removing and installing backrest cover and padding 3928
2 Seat heater elements 3929
2 1 Removing and installing seat heater element 3929
2 1 1 Removing 3929
2 1 2 Installing 3929
2 2 Removing and installing heater element for backrest 3929
2 2 1 Removing 3929
3 Rear seat covers and padding 3931
3 1 Removing and installing cover and padding for rear seat bench 3931
3 2 Removing and installing backrest cover and padding 3932
3 2 1 Upper part of backrest 3932
3 2 2 Lower part of backrest 3932
00054007620 Diesel direct injection and glow plug system 3933
01 – Self-diagnosis 3937
1 – Self-diagnosis 3937
1 1 – Self-diagnosis 3937
1 2 – Features of self-diagnosis 3937
1 3 – Technical data of self-diagnosis 3937
1 4 – Connecting fault reader V A G 1551 and selecting engine control unit 3938
2 – Fault memory 3939
2 1 – Fault memory 3939
2 2 – Interrogating fault memory 3939
2 3 – Fault table 3940
2 4 – Erasing fault memory 3947
3 – Final control diagnosis 3948
3 1 – Final control diagnosis 3948
3 2 – Performing final control diagnosis 3948
4 – Measured value blocks 3952
4 1 – Measured value blocks 3952
4 2 – Safety precautions 3952
4 3 – Reading measured value block 3952
4 4 – Display group overview engine codes AFN, AVG, AHU, ALE, 1Z 3953
4 5 – Evaluating measured value blocks, engine codes AHU, 1Z 3956
4 6 – Evaluating measured value blocks, engine codes AFN, AVG 3968
4 7 – Evaluating measured value blocks, engine code ALE 3978
4 8 – Display group overview engine code AEY 3989
4 9 – Evaluating measured value blocks, engine code AEY 3991
23 – Mixture preparation, Injection 4001
1 – Servicing Diesel direct injection system 4001
1 1 – Servicing Diesel direct injection system 4001
1 2 – Safety precautions 4001
1 3 – Rules for cleanliness 4001
1 4 – Fitting locations overview 4002
1 5 – Servicing injection pump 4009
1 6 – Servicing fuel filter 4013
1 7 – Servicing accelerator linkage 4015
1 8 – Setting engine to TDC number 1 cylinder, engine removed 4017
1 9 – Removing, installing and adjusting accelerator position sender 4017
1 10 – Checking sender adjustment 4019
1 11 – Checking throttle valve positioner housing 4020
1 12 – Removing and installing injection pump 4021
1 13 – Dynamically checking and adjusting commencement of injection 4024
1 14 – Checking valve timing 4026
1 15 – Removing and installing injectors 4027
1 16 – Servicing injectors 4028
1 17 – Renewing injection timing device cover O-ring 4029
2 – Checking components and functions 4030
2 1 – Checking components and functions 4030
2 2 – Wiring and component check with test box V A G 1598/18 4030
2 3 – Checking engine speed sender 4030
2 4 – Checking intake manifold pressure sender and elevation sender 4032
2 5 – Checking coolant temperature sender 4033
2 6 – Checking brake light switch and brake pedal switch 4035
2 7 – Checking clutch pedal switch 4037
2 8 – Checking intake manifold temperature sender 4039
2 9 – Checking intake air temperature sender 4041
2 10 – Checking Diesel direct injection system voltage supply 4043
2 11 – Checking fuel temperature sender 4043
2 12 – Checking modulating piston movement sender and quantity adjuster 4045
2 13 – Checking needle lift sender 4048
2 14 – Checking injection timing control range 4049
2 15 – Checking charge pressure control 4053
2 16 – Hose connection diagram for charge pressure control, engine codes AFN, AVG 4059
2 17 – Checking valve for throttle butterfly 4060
2 18 – Checking exhaust gas recirculation and air mass meter function 4062
2 19 – Checking speedometer sender 4070
2 20 – Checking accelerator position sender 4071
3 – Replacing, coding and matching engine control unit 4073
3 1 – Replacing, coding and matching engine control unit 4073
3 2 – Replacing engine control unit 4073
3 3 – Coding engine control unit 4073
3 4 – Matching engine electronic control unit to electronic immobilizer 4075
28 – Glow plug system 4077
1 – Checking glow plug system 4077
1 1 – Checking glow plug system 4077
1 2 – Checking glow plugs 4077
00054007720 Ecomatic Self diagnosis 4079
01 – Self diagnosis, Electrical check 4083
1 – Performing self-diagnosis 4083
1 1 – Performing self-diagnosis 4083
1 2 – Technical data of self-diagnosis 4084
1 3 – Electronic components 4084
1 4 – Connecting fault reader V A G 1551 and selecting functions 4108
1 5 – List of selectable functions 4110
1 6 – Interrogating fault memory 4110
1 7 – Fault table 4111
1 8 – Erasing fault memory 4117
1 9 – Initiating basic setting 4118
1 10 – Read measured value block 4119
1 11 – Test table 4121
2 – Gearbox: Electrical test 4129
2 1 – Gearbox: Electrical test 4129
2 2 – Test table 4130
00054007820 Simos injection and ignition system 4132
01 – Self-diagnosis 4136
1 – Self-diagnosis 4136
1 1 – Self-diagnosis 4136
1 2 – Function 4136
1 3 – Technical data of self-diagnosis 4136
1 4 – Connecting fault reader V A G 1551 and selecting engine electronics control unit 4137
1 5 – Coding Simos control unit 4138
1 6 – Interrogating and erasing fault memory 4139
1 7 – Fault table 4141
1 8 – Final control diagnosis 4147
1 9 – Read measured value block 4151
1 10 – Display group overview, engine codes ADY, AGG, AKR 4152
1 11 – Display group overview, engine codes AFT, AKS 4155
24 – Mixture preparation, Injection 4160
1 – Simos injection and ignition system 4160
1 1 – Simos injection and ignition system 4160
1 2 – Fitting locations overview 4160
1 3 – Servicing injection part 4166
1 4 – Dismantling and assembling intake manifold, engine codes ADY, AGG, AKR 4180
1 5 – Dismantling and assembling intake manifold upper part, engine codes AFT, AKS 4183
1 6 – Dismantling and assembling intake manifold lower part, engine codes AFT, AKS 4186
1 7 – Dismantling and assembling air cleaner 4187
1 8 – Safety precautions 4190
1 9 – Rules for cleanliness 4190
1 10 – Technical data 4191
1 11 – Idling check 4191
1 12 – Performing basic setting 4192
1 13 – Checking Lambda probe and Lambda control 4193
1 14 – Checking Lambda probe heating 4197
1 15 – Checking engine operating mode 4199
1 16 – Checking intake manifold change-over valve 4200
1 17 – Checking air mass meter 4201
1 18 – Checking throttle valve control part 4203
1 19 – Checking coolant temperature sender 4210
1 20 – Checking intake air temperature sender 4212
1 21 – Checking engine speed sender 4216
1 22 – Testing speed signal 4217
1 23 – Checking control unit voltage supply 4219
1 24 – Matching engine electronic control unit to electronic immobilizer 4221
1 25 – Checking air conditioner and air conditioner compressor signals 4222
1 26 – Checking starter signal 4223
1 27 – Checking injectors 4223
1 28 – Checking fuel pressure regulator and holding pressure 4227
1 29 – Checking intake air system for leaks (unmetered air) 4229
28 – Ignition system 4231
1 – Simos injection and ignition system 4231
1 1 – Simos injection and ignition system 4231
1 2 – Servicing ignition part 4231
1 3 – Safety precautions 4235
1 4 – Test data, spark plugs 4235
1 5 – Checking position of distributor 4235
1 6 – Removing and installing distributor 4236
1 7 – Checking ignition timing control 4240
1 8 – Checking Hall sender 4240
1 9 – Checking knock sensor 4242
1 10 – Checking ignition transformer 4244
1 11 – Checking ignition transformer output stage 4244
00054007920 Automatic gearbox 01M from 01 95 4247
00 – Technical data 4251
1 – Identification of gearbox 4251
1 1 – Identification of gearbox 4251
2 – Information on “Automatic gearbox 01M” 4252
2 1 – Information on “Automatic gearbox 01M” 4252
3 – Code letters, gearbox allocation, ratios, equipment 4252
3 1 – Code letters, gearbox allocation, ratios, equipment 4252
4 – Capacities 4259
4 1 – Capacities 4259
5 – Repair instructions 4260
5 1 – Repair instructions 4260
32 – Torque converter 4263
1 – Torque converter 4263
1 1 – Torque converter 4263
1 2 – Identification of torque converter 4263
1 3 – Torque converter allocation 4264
1 4 – Removing and installing torque converter oil seal 4266
1 5 – Draining torque converter 4267
37 – Controls, Housing 4269
1 – Servicing shift mechanism 4269
1 1 – Servicing shift mechanism 4269
1 2 – Checking shift mechanism 4269
1 3 – Checking and adjusting selector lever cable 4269
1 4 – Checking ignition key removal lock (vehicles with ignition key removal lock) 4270
1 5 – Dismantling and assembling selector mechanism 4270
1 6 – Dismantling and assembling shift mechanism (vehicles with ignition key removal lock) 4279
1 7 – Dismantling and assembling selector lever (vehicles with ignition key removal lock) 4287
1 8 – Removing and installing locking cable (vehicles with ignition key removal lock) 4293
1 9 – Adjusting locking cable (vehicles with ignition key removal lock) 4296
2 – Checking gearbox 4296
2 1 – Checking gearbox 4296
2 2 – Checking shift points 4297
2 3 – Checking stall speed 4297
2 4 – Measuring main pressure 4297
2 5 – Fault finding table for “4-speed automatic gearbox” 4297
3 – Removing and installing gearbox 4297
3 1 – Removing and installing gearbox 4297
3 2 – Removing and installing starter bush 4303
4 – Checking and topping up ATF level 4305
4 1 – Checking and topping up ATF level 4305
4 2 – Checking ATF level 4306
4 3 – Topping up ATF 4308
4 4 – Renewing ATF 4309
5 – Gearbox with selector elements 4310
5 1 – Gearbox with selector elements 4310
5 2 – Position of selector elements 4311
6 – Dismantling and assembling gearbox 4313
6 1 – Dismantling and assembling gearbox 4313
6 2 – Removing and installing ATF cooler and ATF filler tube 4313
6 3 – Dismantling and assembling planetary gearbox -Overview- 4315
6 4 – I – Removing and installing ATF pump to supporting tube 4316
6 5 – II – Removing and installing reverse gear clutch -K2- to large sun wheel 4320
6 6 – III – Removing and installing freewheel and reverse gear brake -B1- 4323
6 7 – IV – Planet carrier and gearbox housing with input gear and cover 4325
6 8 – Dismantling and assembling planetary gearbox 4327
6 9 – Overview of all planetary gearbox adjustments 4344
6 10 – Adjusting planet carrier 4345
6 11 – Adjusting reverse gear brake -B1- 4351
6 12 – Adjusting clutch play between -K1- and -K2- 4356
6 13 – Adjusting 2nd and 4th gear brake -B2- 4361
38 – Gears, Hydraulic controls 4374
1 – Dismantling and assembling ATF pump 4374
1 1 – Dismantling and assembling ATF pump 4374
2 – Dismantling and assembling freewheel with -B1- piston 4377
2 1 – Dismantling and assembling freewheel with -B1- piston 4377
3 – Dismantling and assembling 1st to 3rd gear clutch -K1- 4379
3 1 – Dismantling and assembling 1st to 3rd gear clutch -K1- 4379
4 – Dismantling and assembling reverse gear clutch -K2- 4384
4 1 – Dismantling and assembling reverse gear clutch -K2- 4384
5 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 4387
5 1 – Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 4387
6 – Removing and installing valve chest 4391
6 1 – Removing and installing valve chest 4391
7 – Dismantling and assembling parking lock 4400
7 1 – Dismantling and assembling parking lock 4400
39 – Final drive, Differential 4407
1 – Checking oil in final drive 4407
1 1 – Checking oil in final drive 4407
2 – Removing and installing oil seal for drive flange 4407
2 1 – Removing and installing oil seal for drive flange 4407
3 – Dismantling and assembling final drive 4410
3 1 – Dismantling and assembling final drive 4410
3 2 – Repair overview of final drive 4410
3 3 – Removing and installing input gear 4412
3 4 – Removing and installing drive pinion 4416
3 5 – Removing and installing differential 4423
3 6 – Dismantling and assembling differential 4431
4 – Adjusting final drive 4437
4 1 – Adjusting final drive 4437
4 2 – Overview of adjustments 4437
4 3 – Adjustments to be completed after replacing individual components 4438
4 4 – Adjusting drive pinion 4439
4 5 – Adjusting input gear 4441
4 6 – Adjusting differential 4442
00054008220 1AV fuel injection and ignition system 4443
01 – Self-diagnosis 4447
1 – Self diagnosis 4447
1 1 – Self diagnosis 4447
1 2 – Features of self-diagnosis 4447
1 3 – Technical data of self diagnosis 4447
1 4 – Connecting fault reader V A G 1551 and selecting engine control unit 4448
1 5 – Interrogating and erasing fault memory 4449
1 6 – Fault table 4451
1 7 – Final control diagnosis 4455
1 8 – Read measured value block and basic settings 4458
1 9 – Display group overview 4459
24 – Mixture preparation, Injection 4462
1 – Servicing injection system 4462
1 1 – Servicing injection system 4462
1 2 – Fitting locations overview 4462
1 3 – General notes on injection 4465
1 4 – Removing and installing parts of the injection system 4466
1 5 – Dismantling and assembling fuel manifold with injectors 4472
1 6 – Dismantling and assembling intake manifold 4473
1 7 – Dismantling and assembling air cleaner 4475
1 8 – Safety precautions 4478
1 9 – Rules for cleanliness 4478
1 10 – Technical data 4478
1 11 – Performing basic setting 4479
1 12 – Checking Lambda probe and Lambda control 4480
1 13 – Checking Lambda probe heating 4482
1 14 – Checking engine operating mode 4483
1 15 – Checking throttle valve control part 4485
1 16 – Checking intake manifold pressure sender 4491
1 17 – Checking speed signal 4493
1 18 – Checking coolant temperature sender 4495
1 19 – Checking intake air temperature sender 4498
1 20 – Checking control unit voltage supply 4500
1 21 – Matching engine control unit to electronic immobilizer 4502
1 22 – Checking injectors 4503
1 23 – Checking fuel pressure regulator and holding pressure 4505
1 24 – Checking intake air system for leaks (unmetered air) 4508
1 25 – Checking intake air preheating 4508
1 26 – Wire routing engine wiring loom 4510
28 – Ignition system 4512
1 – Servicing ignition system 4512
1 1 – Servicing ignition system 4512
1 2 – General notes to ignition system 4512
1 3 – Removing and installing parts of the ignition system 4513
1 4 – Dismantling and assembling distributor 4516
1 5 – Safety precautions 4517
1 6 – Adjustment data, Spark plugs 4517
1 7 – Checking and adjusting ignition timing 4517
1 8 – Checking Hall sender 4519
1 9 – Checking ignition transformer 4520
1 10 – Checking ignition transformer output stage 4520
1 11 – Checking knock sensor 4522
00054008320 Motronic injection and ignition system 4525
01 – Self-diagnosis 4529
1 – Self-diagnosis 4529
1 1 – Self-diagnosis 4529
1 2 – Features of self-diagnosis 4529
1 3 – Technical data of self-diagnosis 4529
1 4 – Connecting fault reader V A G 1551 and selecting engine control unit 4530
1 5 – Interrogating and erasing fault memory 4531
1 6 – Fault table 4533
1 7 – Final control diagnosis 4538
1 8 – Read measured value block and basic settings 4540
1 9 – Display group overview 4540
24 – Mixture preparation, Injection 4544
1 – Servicing injection system 4544
1 1 – Servicing injection system 4544
1 2 – Fitting locations overview 4544
1 3 – General notes on injection 4547
1 4 – Removing and installing parts of the injection system 4548
1 5 – Dismantling and assembling fuel rail with injectors 4554
1 6 – Dismantling and assembling intake manifold 4555
1 7 – Dismantling and assembling air cleaner 4557
1 8 – Safety precautions 4559
1 9 – Rules for cleanliness 4560
1 10 – Technical data 4560
1 11 – Performing basic setting 4560
1 12 – Checking Lambda probe and Lambda control 4561
1 13 – Checking Lambda probe heating 4563
1 14 – Checking engine operating mode 4565
1 15 – Checking throttle valve control part 4566
1 16 – Checking intake manifold pressure sender 4572
1 17 – Testing speed signal 4573
1 18 – Checking coolant temperature sender 4575
1 19 – Checking intake air temperature sender 4577
1 20 – Checking control unit voltage supply 4580
1 21 – Matching engine control unit to electronic immobilizer 4581
1 22 – Checking injectors 4582
1 23 – Checking fuel pressure regulator and holding pressure 4585
1 24 – Checking intake air system for leaks (unmetered air) 4587
1 25 – Checking intake air preheating 4588
1 26 – Wire routing engine wiring loom 4589
28 – Ignition system 4591
1 – Servicing ignition system 4591
1 1 – Servicing ignition system 4591
1 2 – General notes to ignition system 4591
1 3 – Removing and installing parts of the ignition system 4592
1 4 – Dismantling and assembling distributor 4595
1 5 – Safety precautions 4596
1 6 – Adjustment data, Spark plugs 4596
1 7 – Checking and adjusting ignition timing 4596
1 8 – Checking Hall sender 4598
1 9 – Checking ignition transformer 4599
1 10 – Checking ignition transformer output stage 4599
1 11 – Checking knock sensor 4601
00054008420 4 Cyl injection engine (4 valve) Mechanics 4603
00 – Technical data 4607
1 – Technical data 4607
1 1 – Technical data 4607
1 2 – Engine number 4607
1 3 – Engine data 4607
10 – Removing and installing engine 4608
1 – Removing and installing engine 4608
1 1 – Removing and installing engine 4608
1 2 – Notes on removing 4608
1 3 – Notes on installing 4609
1 4 – Tightening torques 4610
1 5 – Assembly mountings 4611
1 6 – Renewing engine carrier rubber mounting 4612
1 7 – Additional information and removal instructions for vehicles with air conditioner 4613
13 – Crankshaft group 4614
1 – Dismantling and assembling engine 4614
1 1 – Dismantling and assembling engine 4614
1 2 – Removing and installing ribbed belt 4624
1 3 – Removing and installing toothed belt 4625
1 4 – Checking semi-automatic toothed belt tensioning roller 4627
2 – Removing and installing sealing flange and flywheel 4628
2 1 – Removing and installing sealing flange and flywheel 4628
2 2 – Renewing crankshaft oil seal – pulley end – 4630
3 – Removing and installing crankshaft 4632
3 1 – Removing and installing crankshaft 4632
3 2 – Crankshaft dimensions 4634
4 – Dismantling and assembling pistons and conrods 4635
4 1 – Dismantling and assembling pistons and conrods 4635
4 2 – Piston and cylinder dimensions 4640
15 – Cylinder head, Valve gear 4641
1 – Removing and installing cylinder head 4641
1 1 – Removing and installing cylinder head 4641
1 2 – Removing and installing cylinder head 4644
1 3 – Checking compressions 4646
2 – Servicing valve gear 4647
2 1 – Servicing valve gear 4647
2 2 – Reworking valve seats 4652
2 3 – Removing and installing camshaft oil seal 4654
2 4 – Checking hydraulic bucket tappets 4655
2 5 – Removing and installing camshaft 4656
2 6 – Checking valve guides 4658
2 7 – Renewing valve guides 4658
2 8 – Renewing valve stem seals 4660
17 – Lubrication 4662
1 – Removing and installing parts of the lubrication system 4662
1 1 – Removing and installing parts of the lubrication system 4662
1 2 – Checking oil pressure and oil pressure switch 4669
19 – Cooling system 4671
1 – Removing and installing parts of cooling system 4671
1 1 – Removing and installing parts of cooling system 4671
1 2 – Parts of cooling system body side 4672
1 3 – Parts of cooling system – engine side 4675
1 4 – Dismantling and assembling coolant pump 4678
1 5 – Draining and filling cooling system 4679
1 6 – Removing and installing radiator and radiator fan 4681
20 – Fuel supply system 4683
1 – Removing and installing parts of fuel supply system 4683
1 1 – Removing and installing parts of fuel supply system 4683
1 2 – Removing and installing fuel tank with its attachments 4684
1 3 – Safety precautions when working on the fuel supply system 4690
1 4 – Rules for cleanliness 4690
1 5 – Adjusting throttle cable 4691
1 6 – Removing and installing fuel delivery unit 4691
1 7 – Checking fuel pump 4692
1 8 – Removing and installing parts of the activated charcoal filter system 4697
1 9 – Checking fuel tank breather 4698
26 – Exhaust system 4701
1 – Removing and installing parts of exhaust system 4701
1 1 – Removing and installing parts of exhaust system 4701
00054008520 Body self diagnosis 4708
01 – Self-diagnosis 4712
1 Self-diagnosis of airbag system ▸ 08 94 4712
1 1 Function 4712
1 1 1 Connecting fault reader -V A G 1551- and selecting function (reading out control unit version) 4712
1 1 2 Reading fault memory 4715
1 1 3 Fault table 4716
1 1 4 Erasing fault memory 4717
1 1 5 Ending output 4718
1 2 Deactivating and activating driver side airbag unit ▸ 08 84 4718
1 2 1 Deactivating front passenger airbag 4718
1 2 2 Activating front passenger airbag 4719
2 Airbag system self-diagnosis 09 94 ▸ 4721
2 1 Tools 4721
2 2 Function 4721
2 2 1 Connecting fault reader -V A G 1551- and selecting function (reading out control unit version) 4722
2 2 2 Reading control unit version 4723
2 2 3 Overview of the selectable functions 4724
2 2 4 Reading fault memory 4724
2 2 5 Erasing fault memory 4725
2 2 6 Ending output 4726
2 2 7 Fault table 4726
2 3 Coding airbag control unit -J234- with fault reader -V A G 1551- 4729
2 4 Reading measured value block 4731
2 4 1 Display group 001 4732
2 4 2 Interpreting display group number 001 4732
2 4 3 Display group 003 4733
2 4 4 Interpreting display group number 003 4734
2 4 5 Display group 005 4734
2 4 6 Interpreting display group number 005 4734
2 5 Deactivating and activating front passenger airbag unit (adapting) 09 94 ▸ 4735
2 5 1 Deactivating front passenger airbag 4735
2 5 2 Activating front passenger airbag 4738
2 6 Auxiliary airbag tester -VAS 5056- 4741
2 6 1 Connecting auxiliary airbag tester -VAS 5056- to driver airbag components 4742
2 6 2 Connecting auxiliary airbag tester -VAS 5056- to passenger airbag components 4742
00054008620 Automatic gearbox self diagnosis 01M from 01 95 4744
01 – Self-diagnosis, Electrical check 4748
1 – Self-diagnosis function 4748
1 1 – Self-diagnosis function 4748
1 2 – Technical data of self-diagnosis 4749
1 3 – Self-diagnosis – Guide 4750
2 – Locations of electrical/electronic components 4751
2 1 – Locations of electrical/electronic components 4751
3 – Performing self-diagnosis 4763
3 1 – Performing self-diagnosis 4763
3 2 – Connecting fault reader V A G 1551 and selecting functions 4763
3 3 – List of selectable functions 4765
3 4 – Interrogating fault memory 4765
3 5 – Fault table 4766
3 6 – Erasing fault memory 4771
3 7 – Initiating basic setting 4772
3 8 – Read measured value block 4773
3 9 – Test table 4774
4 – Gearbox: Electrical test 4782
4 1 – Gearbox: Electrical test 4782
4 2 – Electrical check 4783
4 3 – Test table 4785
00054008720 5 speed manual gearbox 02J 4790
00 – Technical data 4794
1 – Gearbox identification 4794
1 1 – Gearbox identification 4794
1 2 – Code letters, gearbox allocation, ratios, capacities 4795
2 – Transmission layout 4797
2 1 – Transmission layout 4797
3 – Calculating overall ratio “i” 4799
3 1 – Calculating overall ratio “i” 4799
4 – General repair instructions 4799
4 1 – General repair instructions 4799
30 – Clutch 4801
1 – Servicing clutch control 4801
1 1 – Servicing clutch control 4801
1 2 – Assembly overview – pedal cluster 4802
1 3 – Removing and installing over-centre spring 4806
1 4 – Removing and installing clutch pedal 4807
1 5 – Assembly overview – Hydraulic system 4809
1 6 – Removing and installing master cylinder 4812
1 7 – Bleeding clutch system 4815
2 – Servicing clutch release mechanism 4815
2 1 – Servicing clutch release mechanism 4815
3 – Servicing clutch 4818
3 1 – Servicing clutch 4818
34 – Controls, Housing 4823
1 – Servicing gear selector mechanism 4823
1 1 – Servicing gear selector mechanism 4823
1 2 – Installation position of gear selector mechanism 4823
1 3 – Assembly overview – removing and installing selector cables 4825
1 4 – Removing and installing gear selector mechanism 4830
1 5 – Servicing gear stick housing 4832
1 6 – Servicing gear stick 4835
1 7 – Adjusting selector mechanism 4839
2 – Removing and installing gearbox 4843
2 1 – Removing and installing gearbox 4843
3 – Checking gear oil 4857
3 1 – Checking gear oil 4857
4 – Dismantling and assembling gearbox 4859
4 1 – Dismantling and assembling gearbox 4859
4 2 – Overview 4859
4 3 – Assembly overview 4861
4 4 – Removing and installing cover for gearbox housing and 5th gear 4862
4 5 – Removing and installing gearbox housing and selector mechanism 4865
4 6 – Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks 4867
4 7 – Assembly sequence 4870
5 – Servicing gearbox housing and clutch housing 4888
5 1 – Servicing gearbox housing and clutch housing 4888
6 – Dismantling and assembling gearbox selector mechanism 4898
6 1 – Dismantling and assembling gearbox selector mechanism 4898
7 – Dismantling and assembling selector forks 4903
7 1 – Dismantling and assembling selector forks 4903
35 – Gears, Shafts 4910
1 – Dismantling and assembling input shaft 4910
1 1 – Dismantling and assembling input shaft 4910
2 – Adjusting input shaft 4923
2 1 – Adjusting input shaft 4923
2 2 – Table of adjustment shims 4925
2 3 – Performing measurement check 4927
3 – Dismantling and assembling output shaft 4928
3 1 – Dismantling and assembling output shaft 4928
3 2 – From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified 4954
4 – Adjusting output shaft 4958
4 1 – Adjusting output shaft 4958
5 – Dismantling and assembling reverse shaft 4961
5 1 – Dismantling and assembling reverse shaft 4961
39 – Final drive, Differential 4966
1 – Renewing flanged shaft oil seals (gearbox installed) 4966
1 1 – Renewing flanged shaft oil seals (gearbox installed) 4966
2 – Dismantling and assembling differential 4969
2 1 – Dismantling and assembling differential 4969
3 – Adjustment overview 4982
3 1 – Adjustment overview 4982
4 – Adjusting differential 4983
4 1 – Adjusting differential 4983
00054008920 Motronic injection and ignition system (4 cyl engine) 4987
01 – Self-diagnosis 4991
1 – General to self-diagnosis 4991
1 1 – General to self-diagnosis 4991
1 2 – Features of self-diagnosis 4991
1 3 – Technical data of self-diagnosis 4991
1 4 – Significance of exhaust emissions warning lamp 4993
1 5 – Connecting fault reader V A G 1551 and selecting engine control unit 4994
1 6 – Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit 4996
2 – Fault memory 4998
2 1 – Fault memory 4998
2 2 – Interrogating and erasing fault memory 4998
2 3 – Automatic test sequence 4999
3 – Fault table: SAE P0 codes 5000
3 1 – Fault table: SAE P0 codes 5000
4 – Fault table: SAE P1 codes 5004
4 1 – Fault table: SAE P1 codes 5004
5 – Final control diagnosis 5007
5 1 – Final control diagnosis 5007
5 2 – Performing final control diagnosis 5007
6 – Readiness code 5013
6 1 – Readiness code 5013
6 2 – Reading readiness code 5013
6 3 – Generating readiness code 5014
7 – Measured value blocks 5020
7 1 – Measured value blocks 5020
7 2 – Safety precautions 5020
7 3 – Read measured value block 5020
8 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 5021
8 1 – Evaluating measured value blocks, display groups 0 9 -Basic functions- 5021
9 – Evaluating measured value blocks, display groups 10 29, 212 -Ignition- 5025
9 1 – Evaluating measured value blocks, display groups 10 29, 212 -Ignition- 5025
10 – Evaluating measured value blocks, display grps 30 49, 99 -Lambda regulation- 5028
10 1 – Evaluating measured value blocks, display grps 30 49, 99 -Lambda regulation- 5028
11 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 5033
11 1 – Evaluating measured value blocks, display groups 50 69 -Speed regulation- 5033
12 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 5035
12 1 – Evaluating measured value blocks, display groups 70 79 -Reducing emissions- 5035
13 – Evaluating measured value blocks, display groups 80 100 -Readiness code- 5036
13 1 – Evaluating measured value blocks, display groups 80 100 -Readiness code- 5036
24 – Mixture preparation, Injection 5038
1 – Servicing injection system 5038
1 1 – Servicing injection system 5038
1 2 – Fitting locations overview 5038
1 3 – General notes on injection 5042
1 4 – Removing and installing parts of the injection system 5044
1 5 – Dismantling and assembling intake manifold – Upper part 5053
1 6 – Dismantling and assembling intake manifold – lower part 5055
1 7 – Dismantling and assembling air cleaner 5056
1 8 – Safety precautions 5057
1 9 – Rules for cleanliness 5058
1 10 – Technical data 5058
2 – Checking components 5059
2 1 – Checking components 5059
2 2 – Checking Lambda probe heating for Lambda probe before catalyst 5059
2 3 – Checking Lambda probe heating for Lambda probe after catalyst 5061
2 4 – Checking air mass meter 5064
2 5 – Checking throttle valve control part 5066
2 6 – Checking coolant temperature sender 5073
2 7 – Checking intake air temperature sender 5077
2 8 – Checking engine speed sender 5080
2 9 – Checking injectors 5082
2 10 – Checking fuel pressure regulator and holding pressure 5086
2 11 – Checking intake air system for leaks (unmetered air) 5089
3 – Checking functions 5090
3 1 – Checking functions 5090
3 2 – Idling check 5090
3 3 – Adapting idling speed 5091
3 4 – Checking Lambda probe and Lambda regulation before catalyst 5093
3 5 – Checking Lambda probe and Lambda regulation after catalyst 5096
3 6 – Checking Lambda probe ageing Lambda probe 1 5101
3 7 – Checking engine operating mode 5102
3 8 – Checking intake air preheating 5103
4 – Engine control unit 5105
4 1 – Engine control unit 5105
4 2 – Checking control unit voltage supply 5105
4 3 – Procedure after voltage supply open circuit 5106
4 4 – Replacing engine control unit 5107
4 5 – Coding engine control unit 5107
4 6 – Adapting engine control unit to throttle valve control part 5109
5 – Checking additional signals 5110
5 1 – Checking additional signals 5110
5 2 – Checking speed signal 5110
5 3 – Checking signal from/to air conditioning system 5112
5 4 – Checking driving range signal 5113
5 5 – Checking data bus 5114
28 – Ignition system 5116
1 – Servicing ignition system 5116
1 1 – Servicing ignition system 5116
1 2 – General notes on ignition system 5116
1 3 – Removing and installing parts of the ignition system 5117
1 4 – Safety precautions 5120
1 5 – Test data, spark plugs 5121
1 6 – Installing distributor 5121
1 7 – Checking and adjusting distributor basic setting 5123
1 8 – Checking Hall sender 5124
1 9 – Checking ignition transformer and output stage 5125
1 10 – Checking knock sensor 5128
1 11 – Check misfiring recognition 5130
D3E8049715C Wheels and Tyres Guide 5132
00 – Technical data 5140
1 General notes on wheels and tyres (passenger cars) 5140
1 1 Legislative conditions for converting wheel and tyre combinations 5141
1 2 Technical conditions for converting wheel and tyre combinations 5142
1 3 Official type designations 5142
1 3 1 Official type approval, sales or trade designation 5142
1 4 General information 5144
1 4 1 Special models 5144
1 4 2 Vehicles with Plus running gear 5144
1 4 3 Speed ratings for tyres 5145
1 4 4 “Series 80” tyres 5146
1 4 5 Wheel bolts – torque settings 5146
1 4 6 Revised wheel bolts for Sharan from model year 2001 5146
1 4 7 Wheel rims – pitch circle diameter 5147
1 4 8 Data on wheel rims 5147
1 4 9 Split rim wheels 5148
1 4 10 Alloy wheels with exchangeable trim elements 5148
2 Facts about wheels and tyres (passenger cars) 5149
2 1 Tyre wear/ mileage 5149
2 1 1 General information 5149
2 1 2 Requirements to be met by tyres 5149
2 1 3 Wear behaviour of high-speed tyres 5150
2 1 4 Factors influencing the service life of a tyre 5150
2 1 5 Driving style 5151
2 1 6 Tyre maintenance 5152
2 1 7 Evenly worn tyres 5153
2 1 8 Measuring tread depth 5153
2 1 9 One-sided wear 5154
2 1 10 Wear in middle of tyre 5156
2 1 11 Diagonal washout 5157
2 2 Tyre noise 5158
2 2 1 General notes on tyre noise 5158
2 2 2 Saw-tooth wear 5159
2 2 3 Flat spots (from locking wheels) 5160
2 3 Rough running caused by wheels/tyres 5161
2 3 1 Causes of rough running 5161
2 3 2 Balancing wheels 5161
2 3 3 Conducting a road test before balancing wheels 5161
2 3 4 Balancing wheels on stationary wheel balancing machine 5162
2 3 5 Vibration control system -VAS 6230- 5163
2 3 6 Finish balancer 5164
2 3 7 Radial and lateral runout of wheels and tyres 5165
2 3 8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V A G 1435- 5165
2 3 9 Checking radial and lateral runout on wheel 5167
2 3 10 Matching 5167
2 3 11 Flat spots caused by storage or handling 5169
2 4 Vehicle pulls to one side 5170
2 4 1 General information 5170
2 4 2 Conicity 5170
2 4 3 Remedies when vehicle pulls to one side 5172
2 4 4 Strategic rotation of wheels for non-directional tyres 5173
2 4 5 Strategic rotation of wheels having unidirectional tyres 5174
2 4 6 Tyres with a red spot 5174
2 5 Tyre damage 5175
2 5 1 General information 5175
2 5 2 Construction of a radial belted tyre 5176
2 5 3 Impact damage 5176
2 5 4 Cuts 5178
2 5 5 Damage caused by foreign bodies 5178
2 5 6 Loss of air from tyre 5179
2 5 7 Tyre pressure 5179
2 5 8 Tyre damage due to insufficient tyre pressure 5179
2 5 9 Rising tyre temperature caused by insufficient inflation pressure 5181
2 5 10 Tyre damage due to fitting error (fitting damage) 5182
2 6 Facts about wheels and tyres 5184
2 6 1 Identification markings on the tyre sidewall 5184
2 6 2 Explanation of tyre markings 5186
2 6 3 Undulations 5187
2 6 4 The valve 5188
2 6 5 Tyre storage 5189
2 6 6 Tyre ageing 5189
2 6 7 Care and maintenance of alloy wheel rims 5190
2 6 8 Rotating wheels 5191
2 6 9 Instructions for changing or fitting wheels 5191
2 6 10 Tyres with flange protection 5192
2 6 11 Notes on use of temporary spare wheels 5193
2 6 12 M+S tyres 5194
2 6 13 Winter tyres with speed symbol “V” 5195
2 6 14 Extra Load (XL) V winter tyres 5195
2 6 15 Reinforced and Extra Load (XL) tyres 5198
2 6 16 Snow chains 5198
44 – Wheels, tyres, vehicle geometry 5199
1 Lupo 3L, Lupo FSI, Lupo GTI from model year 1999 5199
1 1 Lupo 3L, type 6E model year 1999 to model year 2006 5199
1 2 Wheel allocation for Lupo 3L, type 6E model year 1999 to model year 2006 5200
1 2 1 4 J x 14 5200
1 2 2 41/2 J x 14 5201
1 2 3 5 J x 14 5201
1 3 Lupo FSI, type 6E model year 2001 to model year 2006 5201
1 4 Wheel allocation for Lupo FSI, type 6E model year 2001 to model year 2006 5202
1 4 1 5 J x 14 5202
1 4 2 6 J x 14 5203
1 5 Lupo GTI, type 6ES model year 2001 to model year 2006 5205
1 6 Wheel allocation for Lupo GTI, type 6ES model year 2001 to model year 2006 5206
1 6 1 6 J x 14 5206
1 6 2 61/2 J x 15 5207
2 Lupo model year 1999 to model year 2005 5209
2 1 Lupo, type 6X model year 1999 to model year 2005 5209
2 2 Wheel allocation for Lupo, type 6X model year 1999 to model year 2005 5211
2 2 1 41/2 J x 13 5211
2 2 2 51/2 J x 13 5212
2 2 3 6 J x 14 5214
2 2 4 6 J x 15 5217
3 Fox model year 2006 5219
3 1 Fox, type 5Z model year 2006 5219
3 2 Wheel allocation for Fox, type 5Z model year 2006 5220
3 2 1 5 J x 14 5220
3 2 2 6 J x 14 5221
3 2 3 6 J x 15 5223
4 Polo model year 1995 to model year 2002 5226
4 1 Polo, type 6N up to and including 07 95 5226
4 2 Wheel allocation for Polo, type 6N up to and including 07 95 5227
4 2 1 41/2 J x 13 5227
4 2 2 51/2 J x 13 5228
4 3 Polo, type 6N from 08 95 up to and including model year 1996 5229
4 4 Polo, type 6N from model year 1997 to model year 1999 5230
4 5 Wheel allocation for Polo, type 6N from 08 95 to model year 1999 5232
4 5 1 41/2 J x 13 5232
4 5 2 51/2 J x 13 5233
4 5 3 6 J x 14 5234
4 5 4 6 J x 15 5236
4 6 Polo, type 6N from model year 2000 to model year 2002 5238
4 7 Wheel allocation for Polo, type 6N from model year 2000 to model year 2002 5239
4 7 1 41/2 J x 13 5239
4 7 2 51/2 J x 13 5240
4 7 3 6 J x 14 5241
4 7 4 6 J x 15 5243
5 Polo from model year 2002 5246
5 1 Polo, type 9N model year 2002 to model year 2006 5246
5 2 Wheel allocation for Polo, type 9N model year 2002 to model year 2006 5248
5 2 1 5 J x 13 5249
5 2 2 5 J x 14 5249
5 2 3 6 J x 14 5250
5 2 4 6 J x 15 5251
5 2 5 61/2 J x 16 5253
6 Polo Fun from model year 2004 5257
6 1 Polo Fun, type 9N model year 2002 to model year 2006 5257
6 2 Wheel allocation for Polo Fun, type 9N model year 2004 to model year 2006 5258
6 2 1 6 J x 15 5258
6 2 2 71/2 J x 17 5259
7 Polo Classic model year 1996 to model year 2002 5260
7 1 Polo Classic, type 6KV model year 1996 to model year 2002 5260
7 2 Wheel allocation for Polo Classic, type 6KV model year 1996 to model year 2002 5262
7 2 1 51/2 J x 13 5262
7 2 2 6 J x 14 5263
7 2 3 6 J x 15 5265
8 Polo estate model year 1998 to model year 2002 5267
8 1 Polo estate type 6KV model year 1998 to model year 2002 5267
8 2 Wheel allocation for Polo estate type 6KV model year 1998 to model year 2002 5269
8 2 1 51/2 J x 13 5269
8 2 2 6 J x 14 5270
8 2 3 6 J x 15 5272
9 Polo saloon/sedan model year 2004 to model year 2005 5274
9 1 Polo saloon/sedan, type 9N model year 2004 to model year 2005 5274
9 2 Wheel allocation for Polo saloon/sedan, type 9N model year 2004 to model year 2005 5276
9 2 1 5 J x 14 5276
9 2 2 6 J x 14 5276
9 2 3 6 J x 15 5278
9 2 4 61/2 J x 16 5280
10 Golf model year 1992 to model year 1998 5282
10 1 Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 5282
10 2 Wheel allocation for Golf type 1HX0, Golf Syncro 1HX1, Golf type 1H 5285
10 2 1 51/2 J x 13 5286
10 2 2 6 J x 14 5287
10 2 3 6 J x 15 5291
10 2 4 61/2 J x 15 5295
10 2 5 7 J x 16 5299
11 Golf model year 1998 to model year 2004, Golf R32, Golf Anniversary GTI 5300
11 1 Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 5300
11 2 Wheel allocation for Golf, Golf 4Motion, type 1J model year 1998 to model year 2004 5303
11 2 1 6 J x 14 5303
11 2 2 6 J x 15 5304
11 2 3 51/2 J x 16 5309
11 2 4 61/2 J x 16 5310
11 2 5 7 J x 17 5316
11 2 6 71/2 J x 17 5319
11 3 Conditions for fitting 17″ wheels and tyres to Golf model year 1998 to model year 2004 5319
11 4 Golf R32, type 1J model year 2003 to model year 2005 5320
11 5 Wheel allocation for Golf R32, type 1J model year 2003 to model year 2005 5321
11 5 1 51/2 J x 17 5321
11 5 2 71/2 J x 17 5322
11 5 3 71/2 J x 18 5323
11 6 Golf Anniversary GTI, type 1J model year 2002 5323
11 7 Wheel allocation for Golf Anniversary GTI, type 1J model year 2002 5324
11 7 1 51/2 J x 16 5324
11 7 2 61/2 J x 16 5325
11 7 3 7 J x 17 5327
11 7 4 71/2 J x 18 5329
11 8 Conditions for fitting 17″ and 18″ wheels and tyres of Golf Anniversary GTI 5330
12 Golf from model year 2004 5332
12 1 Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 5332
12 2 Wheel allocation for Golf, Golf 4Motion, type 1K model year 2004 to model year 2006 5334
12 2 1 6 J x 15 5334
12 2 2 61/2 J x 15 5335
12 2 3 6 J x 16 5336
12 2 4 61/2 J x 16 5337
12 2 5 7 J x 17 5339
12 2 6 71/2 J x 17 5342
12 2 7 71/2 J x 18 5342
12 3 Golf GTI, type 1K model year 2005 to model year 2006 5343
12 4 Wheel allocation for Golf GTI, type 1K model year 2005 to model year 2006 5344
12 4 1 6 J x 16 5344
12 4 2 61/2 J x 16 5345
12 4 3 6 J x 17 5346
12 4 4 7 J x 17 5347
12 4 5 71/2 J x 17 5350
12 4 6 71/2 J x 18 5350
13 Golf Plus from model year 2005 5352
13 1 Golf Plus, type 1KP model year 2005 to model year 2006 5352
13 2 Wheel allocation for Golf Plus, type 1KP model year 2005 to model year 2006 5354
13 2 1 6 J x 15 5354
13 2 2 61/2 J x 15 5355
13 2 3 6 J x 16 5356
13 2 4 61/2 J x 16 5357
13 2 5 7 J x 17 5359
13 2 6 71/2 J x 18 5362
14 Golf estate model year 1994 to model year 1998 5364
14 1 Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 5364
14 2 Wheel allocation for Golf estate type 1HX0, Golf estate Syncro type 1HX1, Golf estate type 1H 5367
14 2 1 51/2 J x 13 5367
14 2 2 6 J x 14 5368
14 2 3 6 J x 15 5373
14 2 4 61/2 J x 15 5377
15 Golf estate model year 1999 to model year 2006, Bora estate model year 1999 to model year 2005 5378
15 1 Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 5378
15 2 Wheel allocation for Golf estate, Golf estate 4Motion, Bora estate, Bora estate 4Motion, type 1J 5381
15 2 1 6 J x 15 5381
15 2 2 51/2 J x 16 5385
15 2 3 61/2 J x 16 5386
15 2 4 7 J x 17 5392
15 2 5 71/2 J x 17 5395
15 3 Conditions for fitting 17″ wheels and tyres 5396
16 Golf cabriolet model year 1994 to model year 1997 5398
16 1 Golf cabriolet type 1EX0 model year 1994 to model year 1997 5398
16 2 Wheel allocation for Golf cabriolet, type 1EX0 from model year 1994 to model year 1997 5399
16 2 1 6 J x 14 5400
16 2 2 6 J x 15 5401
16 2 3 61/2 J x 16 5402
17 Golf cabriolet model year 1998 to model year 2002 5404
17 1 Golf cabriolet; type 1E from model year 1998 to model year 2002 5404
17 2 Wheel allocation for Golf cabriolet; type 1E from model year 1998 to model year 2002 5405
17 2 1 6 J x 14 5405
17 2 2 6 J x 15 5408
17 2 3 61/2 J x 16 5410
18 Vento from model year 1992 to model year 1998 5411
18 1 Vento; type 1HX0, 1H 5411
18 2 Wheel allocation for Vento; type 1HX0, 1H 5413
18 2 1 51/2 J x 13 5413
18 2 2 6 J x 14 5415
18 2 3 6 J x 15 5418
18 2 4 61/2 J x 15 5421
19 Bora model year 1999 to model year 2005 5427
19 1 Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 5427
19 2 Wheel allocation for Bora, Bora 4Motion, type 1J model year 1999 to model year 2005 5430
19 2 1 6 J x 15 5430
19 2 2 51/2 J x 16 5434
19 2 3 61/2 J x 16 5435
19 2 4 7 J x 17 5441
19 2 5 71/2 J x 17 5444
19 3 Conditions for fitting 17″ wheels and tyres 5445
20 Jetta from model year 2006 5447
20 1 Jetta, type 1KM from model year 2006 5447
20 2 Wheel allocation for Jetta, type 1KM from model year 2006 5449
20 2 1 6 J x 15 5449
20 2 2 61/2 J x 15 5450
20 2 3 6 J x 16 5450
20 2 4 61/2 J x 16 5451
20 2 5 7 J x 17 5453
21 New Beetle from model year 1999 5457
21 1 New Beetle, type 9C model year 1999 to model year 2006 5457
21 2 Wheel allocation for New Beetle, type 9C model year 1999 to model year 2006 5460
21 2 1 6 J x 15 5460
21 2 2 51/2 J x 16 5463
21 2 3 61/2 J x 16 5464
21 2 4 7 J x 17 5469
21 2 5 71/2 J x 17 5472
21 3 Conditions for fitting 17″ wheels and tyres 5473
22 New Beetle Cabriolet from model year 2003 5475
22 1 New Beetle Cabriolet, type 1Y, model year 2003 to model year 2006 5475
22 2 Wheel allocation for New Beetle Cabriolet, type 1Y model year 2003 to model year 2006 5477
22 2 1 6 J x 15 5477
22 2 2 51/2 J x 16 5480
22 2 3 61/2 J x 16 5481
22 2 4 7 J x 17 5485
22 2 5 71/2 J x 17 5489
22 3 Conditions for fitting 17″ wheels and tyres 5489
23 New Beetle RSi 5491
23 1 New Beetle RSi, type 9CR from model year 2001 5491
23 2 Wheel allocation for New Beetle RSi, type 9CR from model year 2001 5492
23 2 1 7 J x 16 5492
23 2 2 9 x 18 5493
24 Touran from model year 2003 5494
24 1 Touran, type 1T, model year 2003 to model year 2006 5494
24 2 Wheel allocation for Touran, type 1T model year 2003 to model year 2006 5497
24 2 1 6 J x 15 5497
24 2 2 61/2 J x 15 5498
24 2 3 6 J x 16 5499
24 2 4 61/2 J x 16 5500
24 2 5 7 J x 17 5502
25 Passat model year 1994 to model year 1997 5503
25 1 Passat, type 35l model year 1994 to model year 1997 5503
25 2 Wheel allocation for Passat, type 35l model year 1994 to model year 1997 5505
25 2 1 6 J x 14 5505
25 2 2 6 J x 15 5508
26 Passat model year 1997 to model year 2006 5513
26 1 Passat, Passat estate, type 3B model year 1997 to model year 2000 5513
26 2 Passat, Passat estate, type 3B model year 1997 to model year 2000 5515
26 2 1 6 J x 15 5515
26 2 2 7 J x 15 5517
26 2 3 7 J x 16 5518
26 3 Passat, Passat estate, type 3BG model year 2001 to model year 2006 5519
26 4 Wheel allocation for Passat, Passat estate, type 3BG model year 2001 to model year 2006 5521
26 4 1 6 J x 15 5521
26 4 2 7 J x 15 5522
26 4 3 6 J x 16 5524
26 4 4 7 J x 16 5525
26 4 5 7 J x 17 5527
26 5 Passat W8 4Motion, type 3BS model year 2002 to model year 2005 5528
26 6 Wheel allocation for Passat W8 4Motion, type 3BS model year 2002 to model year 2005 5529
26 6 1 7 J x 16 5530
26 6 2 6 J x 17 5530
26 6 3 71/2 J x 17 5531
26 7 Passat Protect, type 3BL model year 2002 to model year 2005 5531
26 8 Wheel allocation for Passat Protect, type 3BL model year 2002 to model year 2005 5532
26 8 1 6 J x 16 5533
26 8 2 7 J x 16 5533
27 Passat from model year 2006 5535
27 1 Passat, type 3C from model year 2006 5535
27 2 Wheel allocation for Passat, type 3C from model year 2006 5537
27 2 1 61/2 J x 16 5538
27 2 2 7 J x 16 5538
27 2 3 6 J x 17 5540
27 2 4 71/2 J x 17 5540
27 2 5 8 J x 18 5543
28 Phaeton from model year 2003 5545
28 1 Phaeton, type 3D, model year 2003 to model year 2006 – short and long wheelbase 5545
28 2 Wheel allocation for Phaeton, type 3D model year 2003 to model year 2006 – short and long wheelbase 5547
28 2 1 71/2 J x 16 5548
28 2 2 71/2 J x 17 5548
28 2 3 71/2 J x 18 5550
28 2 4 81/2 J x 18 5550
28 2 5 81/2 J x 19 5552
28 2 6 9 J x 19 5552
29 Sharan from model year 1996 5553
29 1 Sharan, Sharan Syncro, type 7M model year 1996 to model year 2000 5553
29 2 Wheel allocation for Sharan, Sharan Syncro Type 7M model year 1996 to model year 2000 5556
29 2 1 6 J x 15 5556
29 2 2 7 J x 15 5556
29 2 3 7 J x 16 5557
29 3 Sharan, Sharan 4Motion, type 7M model year 2001 5558
29 4 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2001 5560
29 4 1 6 J x 15 5560
29 4 2 7 J x 15 5561
29 4 3 6 J x 16 5562
29 4 4 7 J x 16 5563
29 5 Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 5566
29 6 Wheel allocation for Sharan, Sharan 4Motion, type 7M model year 2002 to model year 2006 5568
29 6 1 6 J x 16 5568
29 6 2 7 J x 16 5569
29 6 3 7 J x 17 5572
30 Touareg from model year 2003 5573
30 1 Touareg, type 7L, model year 2003 to model year 2006 5573
30 2 Wheel allocation for Touareg, type 7L model year 2003 to model year 2006 5576
30 2 1 7 J x 16 5576
30 2 2 71/2 J x 17 5577
30 2 3 8 J x 18 5578
30 2 4 9 J x 19 5581
30 2 5 9 J x 20 5585
30 2 6 91/2 J x 20 5586
31 Breakdown set for VW Vehicles 5587
32 Temporary spare tyres and wheels for VW vehicles 5588
33 Approved makes of summer tyres for initial fitting 5591
33 1 Summer tyres for Lupo 3L from model year 1999 5591
33 2 Summer tyres for Lupo FSI from model year 1999 5591
33 3 Summer tyres for Lupo GTI from model year 1999 5591
33 4 Summer tyres for Lupo model year 1999 to model year 2005 5591
33 5 Summer tyres for Fox from model year 2006 5591
33 6 Summer tyres for Polo, model year 1995 to model year 2002 5592
33 7 Summer tyres for Polo from model year 2002 5593
33 8 Summer tyres for Polo saloon/sedan from model year 2004 5593
33 9 Summer tyres for Polo Fun from model year 2004 5594
33 10 Summer tyres for Polo Classic model year 1996 to model year 2002 5594
33 11 Summer tyres for Polo estate model year 1998 to model year 2002 5595
33 12 Summer tyres for Golf, Vento model year 1992 to model year 1998 5595
33 13 Summer tyres for Golf estate model year 1994 to model year 1998 5596
33 14 Summer tyres for Golf cabriolet model year 1994 to model year 1997 5596
33 15 Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004 5597
33 16 Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005 5598
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 5599
33 18 Summer tyres for Golf R32 5599
33 19 Summer tyres for Golf Anniversary GTI 5600
33 20 Summer tyres for Golf Cabriolet, model year 1998 to model year 2002 5600
33 21 Summer tyres for New Beetle from model year 1999 5601
33 22 Summer tyres for New Beetle Cabriolet from model year 2003 5602
33 23 Summer tyres for New Beetle RSi 5603
33 24 Summer tyres for Golf from model year 2004 5603
33 25 Summer tyres for Golf GTI from model year 2005 5604
33 26 Summer tyres for Golf Plus from model year 2005 5604
33 27 Summer tyres for Jetta from model year 2006 5605
33 28 Summer tyres for Touran from model year 2003 5605
33 29 Summer tyres for Passat model year 1994 to model year 1997 5606
33 30 Summer tyres for Passat model year 1997 to model year 2006 5606
33 31 Summer tyres for Passat W8 5607
33 32 Summer tyres for Passat Protect 5607
33 33 Summer tyres for Passat from model year 2006 5607
33 34 Summer tyres for Phaeton from model year 2003 5608
33 35 Summer tyres for Sharan from model year 1996 5608
33 36 Summer tyres for Touareg from model year 2003 5609
34 Approved makes of all-season tyres for initial fitting 5610
34 1 All-season tyres for Lupo, model year 1999 to model year 2005 5610
34 2 All-season tyres Polo model year 1995 to model year 2002 5610
34 3 All-season tyres from model year 2002 5610
34 4 Summer tyres for Polo saloon/sedan from model year 2004 5610
34 5 All-season tyres Golf, Vento model year 1992 to model year 1998 5610
34 6 All-season tyres Golf estate model year 1994 to model year 1998 5610
34 7 All-season tyres Golf cabriolet model year 1994 to model year 1997 5611
34 8 All-season tyres Golf, Golf 4Motion model year 1998 to model year 2004 5611
34 9 All-season tyres Bora, Bora 4Motion model year 1999 to model year 2005 5611
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 5612
34 11 All-season tyres Golf cabriolet model year 1998 to model year 2002 5612
34 12 All-weather tyres New Beetle from model year 1999 5612
34 13 All-weather tyres New Beetle Cabriolet from model year 2003 5612
34 14 All-weather tyres Golf from model year 2004 5613
34 15 All-season tyres for Golf Plus from model year 2005 5613
34 16 All-season tyres for Jetta from model year 2006 5613
34 17 All-weather tyres Touran from model year 2003 5614
34 18 All-season tyres for Passat, model year 1997 to model year 2006 5614
34 19 All-season tyres for Passat W8 5614
34 20 All-weather tyres Passat from model year 2006 5614
34 21 All-weather tyres Phaeton from model year 2003 5615
34 22 All-weather tyres Touareg from model year 2003 5615
35 Approved makes of winter tyres for initial fitting 5616
35 1 Winter tyres for Lupo 3L from model year 1999 5616
35 2 Winter tyres for Lupo FSI from model year 1999 5616
35 3 Winter tyres for Lupo GTI from model year 1999 5616
35 4 Winter tyres Lupo model year 1999 to model year 2005 5616
35 5 Winter tyres for Fox from model year 2006 5616
35 6 Winter tyres for Polo model year 1995 to model year 2002 5617
35 7 Winter tyres Polo from model year 2002 5617
35 8 Summer tyres for Polo saloon/sedan from model year 2004 5617
35 9 Summer tyres for Polo Fun from model year 2004 5618
35 10 Winter tyres Polo Classic model year 1996 to model year 2002 5618
35 11 Winter tyres Polo estate model year 1998 to model year 2002 5618
35 12 Winter tyres Golf, Vento model year 1992 to model year 1998 5619
35 13 Winter tyres Golf estate model year 1994 to model year 1998 5619
35 14 Winter tyres Golf cabriolet model year 1994 to model year 1997 5619
35 15 Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004 5620
35 16 Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005 5620
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 5621
35 18 Winter tyres for Golf R32 5621
35 19 Winter tyres for Golf Anniversary GTI 5621
35 20 Winter tyres Golf cabriolet model year 1998 to model year 2002 5621
35 21 Winter tyres New Beetle from model year 1999 5622
35 22 Winter tyres New Beetle Cabriolet from model year 2003 5622
35 23 Winter tyres for New Beetle RSi 5623
35 24 Winter tyres Golf from model year 2004 5623
35 25 Winter tyres for Golf GTI from model year 2005 5623
35 26 Winter tyres for Golf Plus from model year 2005 5623
35 27 Winter tyres for Jetta from model year 2006 5623
35 28 Winter tyres Touran from model year 2003 5624
35 29 Winter tyres for Passat model year 1994 to model year 1997 5624
35 30 Winter tyres for Passat model year 1997 to model year 2006 5624
35 31 Winter tyres for Passat W8 5625
35 32 Winter tyres for Passat Protect 5625
35 33 Winter tyres Passat from model year 2006 5625
35 34 Winter tyres Phaeton from model year 2003 5625
35 35 Winter tyres Sharan from model year 1996 5626
35 36 Winter tyres Touareg from model year 2003 5626
36 Approved makes of offroad tyres for initial fitting 5627
36 1 Offroad tyres for Touareg from model year 2003 5627
D4B807E3B5B Body Repairs General Body Repairs 5628
1 Safety instructions 5632
1 1 Part removal 5632
1 2 Battery and welding operation 5632
1 3 Electronic control unit 5632
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 5632
1 4 Paint, glass, soft pad and trim 5633
1 5 Fuel tank or fuel delivery pipeline 5633
1 6 Air conditioner 5633
1 6 1 Remedial measures: 5633
1 7 Airbag System 5634
1 8 Check the seat belts 5634
1 8 1 Belt body 5635
1 8 2 Automatic retractor (locking function) 5635
1 8 3 Visual inspection of the seat belt buckle 5636
1 8 4 Seat belt buckle function 5636
1 8 5 Seat belt guide member and tongue 5637
1 8 6 Fixing piece and fixing point 5637
1 9 Safety specifications for the seat belt tensioner 5637
1 10 Body repair on a vehicle equipped with the seat belt tensioners 5638
1 10 1 The following vehicles have been equipped with: 5638
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 5639
1 12 Remove the front seats with a side airbag 5639
2 Basic instruction 5640
2 1 Diagnosis of the accident vehicle 5640
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 5640
2 3 Correction 5640
2 4 Cutting 5640
2 5 Body-cut part and part section 5640
2 6 Original connection 5641
2 7 Galvanized body parts 5641
2 8 Remove the rest part 5641
2 9 New parts 5641
2 10 Parts 5641
2 11 Molded foam plastic pads 5642
3 Symbolic interpretation 5643
3 1 Symbolic interpretation for welding 5643
3 2 Symbolic interpretation for the operation method 5643
3 2 1 Grinding 5644
3 2 2 Thinning 5644
3 2 3 Punching 5644
3 2 4 Drilling 5645
3 2 5 Polishing 5645
3 2 6 Cavity corrosion protection 5645
3 2 7 Bonding 5646
3 2 8 Precise sealing 5646
4 Body repair tools 5647
4 1 Flaring tool -V A G 1317- 5647
4 2 Punching pliers -V A G 1329- 5647
4 3 Basic equipment -V A G 1366/3- 5647
4 4 Bottom protection layer spray gun -V A G 1379- 5648
4 5 Electric blower -V A G 1416- 5648
4 6 Door tensioner -V A G 1438- 5648
4 7 Body equipment component -V A G 1439- 5649
4 8 Pneumatic cutting knife -V A G 1523 A- 5649
4 9 Air chisel -V A G 1577- 5649
4 10 Edge closing iron block -V A G 1585- 5650
4 11 Welding fume ventilator -V A G 1586- 5650
4 12 Welding spot releasing device -V A G 1731- 5650
4 13 Pneumatic spray gun -V A G 1761/1- 5651
4 14 Pneumatic punching and thinning pliers -VAS 1996- 5651
4 15 Pneumatic adhesive spray gun -V A G 2005- 5651
4 16 Door hinge correction tool 5652
4 17 Hose kit 5023 for the inert gas protection welding 5652
4 18 Angle grinder -VAS 5174- 5652
4 19 Angle grinder -VAS 5175- 5653
4 20 Wire brush -VAS 5182- 5653
5 Body bonding 5654
5 1 Transporter 1991 → 5654
5 1 1 Separation process: 5654
5 1 2 Bonding process: 5654
5 2 Bonding types 5654
5 2 1 Bonding-strong 5654
5 2 2 Bonding-spot welding 5655
5 3 Repair method for replacing the parts 5655
5 3 1 Spot welding and bonding 5655
5 3 2 Plug welding and bonding (if spot welding is impossible) 5655
5 3 3 Welding fume ventilator 5656
5 3 4 Preparations 5656
5 3 5 Trimming 5656
6 Corrosion protection measures 5657
6 1 Corrosion protection 5657
7 Waste disposal instructions 5658
7 1 Waste disposal 5658
7 2 Air pressure tappet exhaust 5658
7 3 Airbag 5659
7 3 1 Waste disposal 5659
8 Contact corrosion protection 5660
8 1 Connection of aluminum alloy/magnesium alloy with steel 5660
9 Steel plate repair 5661
9 1 High-strength body plate 5661
9 2 Galvanized body parts 5661
9 2 1 Preparations 5661
9 2 2 Part cutting 5662
9 2 3 Connection process 5662
9 3 Welding on the galvanized body steel plate 5662
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 5662
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 5663
9 3 3 Welding transformer 5663
9 3 4 Welding clamp 5663
9 4 Tearing test 5663
10 Aluminum repair 5664
10 1 Painting 5664
10 2 Surface treatment 5664
10 3 Leveling 5665
10 4 Temperature control for heating 5665
11 Plastic repair method 5666
11 1 Material 5666
11 2 Repairing the pit 5667
11 3 Repairing the scratch 5668
11 4 Repair the crack 5670
11 5 Repairing the small hole (the diameter is more than 30 mm) 5671
11 6 Plastic repair (glass fibre material) 5672
11 7 Repair process 5673
11 7 1 Repairing the breakage position 5673
11 7 2 Repairing the surface damage 5675
12 Glass repair 5676
12 1 Repairing the windshield 5676
12 1 1 Premises 5676
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 5677
12 1 3 Repair description 5678
D4B8038DB0A 4 cylinder injection engine (crossflow cylinder head) mechanics 5682
00 – Technical data 5686
1 Technical data 5686
1 1 Engine number 5686
1 2 Engine data 5686
10 – Removing and installing engine 5688
1 Removing and installing engine 5688
1 1 Notes on removing 5688
1 2 Notes on installing 5690
1 3 Specified torques 5691
1 4 Assembly mountings 5692
1 5 Renewing engine carrier rubber mounting 5693
13 – Crankshaft group 5696
1 Dismantling and assembling engine 5696
1 1 Assembly overview 5696
1 1 1 Part I 5697
1 1 2 Part II – engine codes AEK, ATU, AWF, AWG 5699
1 1 3 Part Il – engine codes AFT, AKS 5700
1 1 4 Part III 5701
1 2 Removing and installing poly V-belt 5703
1 3 Removing, installing and tensioning toothed belt 5705
2 Removing and installing sealing flange and pressure plate/drive plate 5709
2 1 Assembly overview – sealing flanges 5709
2 2 Renewing crankshaft oil seal – pulley end 5711
2 3 Removing and installing drive plate 5713
3 Crankshaft 5715
3 1 Assembly overview – crankshaft 5715
3 2 Crankshaft dimensions 5716
4 Dismantling and assembling pistons and conrods 5717
4 1 Assembly overview – pistons and conrods 5717
4 2 Checking pistons, piston rings and cylinder bores 5718
4 3 Piston and cylinder dimensions 5720
15 – Cylinder head, valve gear 5721
1 Cylinder head 5721
1 1 Assembly overview – cylinder head 5721
1 1 1 Engine codes AEK, ATU, AWF, AWG 5721
1 1 2 Engine codes AFT, AKS 5724
1 2 Removing and installing cylinder head 5725
1 3 Checking compression 5727
2 Valve gear 5729
2 1 Assembly overview – valve gear 5729
2 2 Reworking valve seats 5733
2 3 Removing and installing camshaft oil seal 5734
2 4 Removing and installing camshaft 5736
2 5 Checking hydraulic bucket tappets 5738
2 6 Checking valve guides 5739
2 7 Renewing valve guides 5739
2 7 1 Vehicles ► 10 94 5739
2 7 2 Vehicles 11 94 ► 5740
2 8 Renewing valve stem seals 5741
17 – Lubrication 5744
1 Parts of lubrication system 5744
1 1 Engine oil 5744
1 2 Assembly overview – parts of lubrication system 5744
1 3 Checking oil pressure and oil pressure switch 5747
19 – Cooling 5749
1 Removing and installing parts of cooling system 5749
1 1 Parts of cooling system, body side 5749
1 1 1 Engine codes AEK, AFT, AKS 5749
1 1 2 Engine codes ATU, AWF, AWG 5751
1 2 Parts of cooling system – engine side 5752
1 2 1 Engine codes AEK, AFT, AKS 5753
1 2 2 Engine codes ATU, AWF, AWG 5754
1 3 Dismantling and assembling coolant pump 5756
1 4 Draining and filling coolant 5756
1 5 Removing and installing radiator and fan 5759
20 – Fuel supply system 5761
1 Removing and installing parts of fuel supply system 5761
1 1 Safety precautions when working on fuel supply system 5761
1 2 Rules for cleanliness 5762
1 3 Assembly overview – fuel tank with attachments and fuel filter 5762
1 4 Adjusting accelerator cable 5765
1 4 1 Vehicles with manual gearbox 5765
1 4 2 Vehicles with automatic gearbox 5766
1 5 Removing and installing fuel delivery unit 5767
1 6 Checking fuel pump 5769
1 6 1 Checking function and voltage supply 5771
1 6 2 Checking fuel delivery rate 5771
1 6 3 Checking non-return valve for fuel pump 5773
1 7 Crash fuel shut-off 5773
2 Activated charcoal filter system 5774
2 1 Function 5774
2 2 Assembly overview – activated charcoal filter system 5775
2 2 1 Engine code AEK 5775
2 2 2 Engine codes AFT, AKS 5776
2 2 3 Engine codes ATU, AWF, AWG 5777
2 3 Test solenoid valve 1 for activated charcoal filter 5777
2 4 Checking fuel tank breather 5779
26 – Exhaust system 5781
1 Removing and installing parts of exhaust system 5781
1 1 Exhaust manifold, front exhaust pipe with catalytic converter and add-on parts 5781
1 2 Silencer with mountings 5784
1 3 Checking catalytic converter 5785
2 Secondary air system 5788
2 1 Function 5788
2 2 Removing and installing components of secondary air system 5788
2 3 Checking combination valve 5790
2 3 1 Vehicles ► 05 00 5790
2 3 2 Vehicles 05 00 ► 5791
2 4 Checking secondary air pump motor 5791
2 5 Checking secondary air inlet valve 5792
D4B8027068B Air conditioning systems with refrigerant R134a General information 5794
00 – Technical data 5800
1 Safety information 5800
1 1 Safety precautions when working on air conditioning systems 5800
1 2 Safety precautions when working on high-voltage system 5801
1 3 Safety precautions when working in the vicinity of high-voltage components 5801
1 4 Safety precautions when tow-starting or towing 5802
2 Repair instructions 5803
2 1 Rules for cleanliness when working on high-voltage system 5803
3 General information on air conditioning 5804
3 1 Other reference material 5804
3 2 Basics of air conditioning technology 5804
3 2 1 Physical principles: 5804
3 2 2 Heat always flows from a warmer to a colder substance 5805
3 2 3 Pressure and boiling point 5805
3 3 Vapour pressure table for refrigerant R134a 5806
3 4 Refrigerant R134a 5807
3 4 1 Physical data of refrigerant R134a 5807
3 4 2 Critical point 5807
3 4 3 Environmental aspects of refrigerant R134a 5808
3 5 Properties of refrigerant R134a 5808
3 5 1 Trade names and designations 5808
3 5 2 Colour 5808
3 5 3 Vapour pressure 5808
3 5 4 Physical properties of R134a 5809
3 5 5 Effects on metal 5809
3 5 6 Critical temperature and critical pressure 5809
3 5 7 Union 5809
3 5 8 Charge factor 5809
3 5 9 Detecting leaks 5809
3 6 Refrigerant oil 5810
3 6 1 Properties of refrigerant oil 5810
3 7 Comfort 5811
3 7 1 Environmental aspects 5811
3 8 How air conditioning works 5812
3 9 General work safety 5812
3 9 1 Product characteristics 5812
3 9 2 Handling refrigerants 5813
3 9 3 Wear safety goggles 5813
3 9 4 Wear protective gloves and apron 5813
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 5813
3 9 6 Do not breath in refrigerant vapour 5813
3 9 7 Absolutely NO SMOKING 5813
3 9 8 Welding and soldering on refrigeration systems 5813
3 9 9 Pungent smell 5814
3 9 10 First aid 5814
3 9 11 Handling pressure vessels 5814
3 9 12 Do not heat up above 50°C 5814
3 9 13 Do not expose to uncontrolled heat 5814
3 9 14 Seal empty tanks/containers 5814
3 9 15 Safety instructions for using extraction and charging equipment 5815
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 5815
3 11 Basics for working on refrigerant circuit 5816
3 11 1 O-ring 5817
3 11 2 Before operating the air conditioning system after recharging with refrigerant 5818
4 General information on refrigerant circuit 5819
4 1 Components of refrigerant circuit 5819
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 5819
4 1 2 Air conditioning system compressor with magnetic clutch: 5819
4 1 3 Air conditioner compressor without magnetic clutch 5820
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 5821
4 1 5 Electrical air conditioner compressor for high-voltage system 5822
4 1 6 Condenser 5823
4 1 7 evaporator 5823
4 1 8 Reservoir 5824
4 1 9 Restrictor 5824
4 1 10 Receiver 5825
4 1 11 Expansion valve 5826
4 1 12 O-ring 5827
4 1 13 Pipes and hoses of refrigerant circuit 5827
4 1 14 High-pressure safety valve 5827
4 2 Design of refrigerant circuit 5830
4 2 1 Refrigerant circuit with expansion valve and evaporator 5830
4 2 2 Refrigerant circuit with restrictor and reservoir 5830
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 5831
4 3 1 Evacuation and charging valve with Schrader valve 5831
4 3 2 Extraction and charging valve, high-pressure side 5832
4 3 3 Extraction and charging valve, low-pressure side 5833
4 4 Switches and senders in refrigerant circuit and related connections 5833
4 4 1 High-pressure switch for air conditioning system -F23- 5833
4 4 2 High-pressure switch for magnetic clutch -F118- 5834
4 4 3 Low-pressure switch for air conditioning system -F73- 5834
4 4 4 Connections with valve for switches in refrigerant circuit 5835
4 4 5 Air conditioning system pressure switch -F129- 5835
4 4 6 High-pressure sender -G65- 5836
4 4 7 Refrigerant pressure and temperature sender -G395- 5837
4 4 8 Air conditioner compressor regulating valve -N280- 5837
4 5 Electrical components not installed in refrigerant circuit 5838
4 5 1 Control and regulating unit for air conditioning system -J127- 5838
4 5 2 Radiator fan control unit -J293- 5838
4 5 3 Radiator fan control unit -J293- 5839
4 5 4 Temperature switch for evaporator -E33- 5840
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 5840
4 6 Pressures and temperatures in refrigerant circuit 5841
4 7 Refrigerant circuit with expansion valve 5841
4 8 Refrigerant circuit with restrictor and reservoir 5843
4 9 Test and measurement work that can be performed using a pressure gauge 5845
4 9 1 Pressure gauges enable the following test and measurement work 5845
4 10 Air conditioner service and recycling equipment 5846
4 10 1 Classification of extraction and charging devices in groups 5846
4 10 2 Charging devices that do not require a permit 5846
4 11 Notes to repairs on refrigerant circuit 5847
5 Laws and regulations 5848
5 1 Laws and regulations 5848
5 2 Recycling and refuse law 5853
5 2 1 Disposal of refrigerant and refrigerant machine oil 5853
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 5854
5 4 Maintaining records on refrigerant 5854
6 Refrigerant circuit 5855
6 1 Important repair notes on air conditioning 5855
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 5855
7 Working with the air conditioner service station 5856
7 1 Important instructions for working with the air conditioner service station 5856
7 2 Connecting a air conditioner service station for measuring and testing 5857
7 3 Drain the refrigerant circuit using the air conditioner service station 5858
7 4 Evacuating refrigerant circuit using air conditioner service station 5858
7 5 Filling refrigerant circuit with air conditioner service station 5860
7 6 Bringing air conditioning system into service after charging 5861
7 7 Charging the container in the air conditioning service station with refrigerant 5861
7 8 Emptying air conditioner service station 5862
8 Detecting leaks in refrigerant circuit 5863
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 5864
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 5865
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 5866
9 Clearing refrigerant circuit of contaminants 5874
9 1 Vehicles with high-voltage system (hybrid vehicles) 5874
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 5875
9 2 1 Flushing refrigerant circuit 5877
9 3 Flushing refrigerant circuit with refrigerant R134a 5877
9 3 1 Principle circuit diagrams for various purging circuits 5885
9 3 2 Purging electrical air conditioner compressor 5891
9 3 3 Adapters for setting up flushing circuits 5895
10 Clearing refrigerant circuit of contaminants, commercial vehicles 5909
10 1 Vehicles with high-voltage system 5909
10 2 Flushing refrigerant circuit with refrigerant R134a 5910
10 3 Adapters for setting up flushing circuits 5910
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 5914
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 5914
10 5 1 Connection diagram for flushing circuit 5914
10 5 2 Procedure for setting up and flushing refrigerant circuit 5915
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 5920
10 6 1 Connection diagram for flushing circuit 5920
10 6 2 Procedure for setting up and flushing refrigerant circuit 5921
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 5927
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 5927
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 5928
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5929
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5936
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 5944
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 5945
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 5946
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5947
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5952
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 5961
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 5961
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 5962
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 5963
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 5968
11 Complaints 5977
11 1 Possible complaints about refrigerant circuit 5977
11 1 1 Conditions for testing: 5977
11 1 2 Possible complaints 5977
11 2 Odours from heater and air conditioning unit 5978
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 5978
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 5979
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 5980
12 Connecting the air conditioning service station 5981
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 5981
12 1 1 Connecting a air conditioner service station for measuring and testing 5981
13 Checking pressures on vehicles 5982
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 5982
13 1 1 Conditions for testing 5982
13 1 2 Checking pressures 5983
13 1 3 Continuation of checking pressures 5985
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 5986
13 2 1 Specifications: 5986
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 5990
13 3 1 Specifications: 5990
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 5995
13 4 1 Conditions for testing 5995
13 4 2 Check 5995
13 4 3 Specified values 5995
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 5996
13 5 1 Specifications: 5996
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 6001
13 6 1 Specifications: 6001
13 7 With expansion valve, receiver and electrical air conditioner compressor 6012
14 Renewing components 6013
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 6014
14 1 1 If the refrigerant circuit was completely empty 6014
14 1 2 If there is still refrigerant in the refrigerant circuit 6016
14 2 Renew the air conditioner compressor 6016
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 6016
14 2 2 Leaks or internal damage (e g noises or lack of power) 6018
14 3 Replace receiver or reservoir and restrictor 6018
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 6018
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 6020
15 Testing equipment and tools 6021
15 1 List of test equipment, tools and materials 6021
15 1 1 Tools and materials available from regional sales centre or importer 6021
15 1 2 Tools and materials commercially available 6022
15 1 3 Tools and materials available from regional sales centre or importer 6023
15 1 4 Tools and materials commercially available 6029
GOL53201020 Body Repairs 6032
00 – Technical data 6038
1 Vehicle identification data 6038
1 1 Identification plate 6038
1 2 Vehicle data plate 6038
1 3 Vehicle identification number 6038
2 Body dimensions 6039
2 1 Floor group, front 6039
2 2 Floor group, centre 6041
2 3 Floor group, rear (Golf) 6042
2 4 Floor group, rear (Vento) 6043
2 5 Floor group, rear (Variant) 6044
2 6 Body – front 6047
2 7 Body, centre (2-door) 6050
2 8 Body, centre (4-door) 6051
2 9 Body, rear (Golf) 6055
2 10 Body, rear (Vento) 6057
2 11 Body, rear (Variant) 6059
3 Straightening jig 6062
3 1 Overview, Golf 6062
3 2 Overview, Vento 6069
3 3 Overview, Golf syncro 6071
3 4 Overview, Golf Variant 6074
3 5 Overview, Golf Variant syncro 6077
4 Galvanized body parts 6083
50 – Body – front 6084
1 Renewing support for suspension link 6084
1 1 Removing 6084
1 1 1 Cutting locations 6084
1 1 2 Replacement part 6085
2 Renewing front wheel housing 6086
2 1 Removing 6086
2 1 1 Cutting locations 6086
2 1 2 Replacement parts 6087
2 1 3 Welding in 6087
3 Renewing front wheel housing – partial renewal 6089
3 1 Removing 6089
3 1 1 Cutting locations 6089
3 1 2 Replacement parts 6090
3 1 3 Welding in 6090
4 Front longitudinal member – partial renewal in front of auxiliary link mounting 6091
4 1 Removing 6091
4 1 1 Cutting locations 6091
4 1 2 Replacement part 6092
4 1 3 Welding in 6092
5 Front longitudinal member – partial renewal behind auxiliary link mounting 6093
5 1 Removing 6093
5 1 1 Cutting locations 6093
5 1 2 Replacement part 6094
5 1 3 Welding in 6094
6 Renewing front part of longitudinal member 6095
6 1 Removing 6095
6 1 1 Cutting locations 6095
6 1 2 Replacement parts 6096
6 1 3 Welding in 6096
51 – Body – centre 6098
1 Renewing roof 6098
1 1 Removing 6098
1 1 1 Cutting locations 6098
1 1 2 Replacement parts 6099
2 Renewing roof (Vento) 6100
2 1 Removing 6100
2 1 1 Cutting locations 6100
2 1 2 Replacement parts 6101
3 Renewing roof (Variant) 6102
3 1 Removing 6102
3 1 1 Cutting locations 6102
3 1 2 Replacement part 6103
4 Renewing T-pins for roof strip 6105
4 1 T-pin position dimensions (Golf, 2-door) 6105
4 2 Welding in T-pins (Golf, 2-door) 6106
4 2 1 Replacement part 6106
4 3 T-pin position dimensions (Golf, 4-door) 6107
4 4 Welding in T-pins (Golf, 4-door) 6108
4 4 1 Replacement part 6108
4 5 T-pin position dimensions (Vento) 6109
4 6 Welding in T-pins (Vento) 6110
4 6 1 Replacement part 6110
5 Renewing inner side panel (Variant) 6111
5 1 Removing 6111
5 1 1 Cutting locations 6111
5 1 2 Replacement parts 6112
5 1 3 Welding in 6113
6 Renewing inner side panel – partial renewal (Variant) 6115
6 1 Removing 6115
6 1 1 Cutting locations 6115
6 1 2 Replacement part 6116
6 1 3 Welding in 6116
7 Renewing lower A-pillar- partial renewal 6118
7 1 Removing 6118
7 1 1 Cutting locations 6118
7 1 2 Replacement part 6119
7 1 3 Welding in 6119
8 Renewing upper A-pillar- partial renewal 6120
8 1 Removing 6120
8 1 1 Cutting locations 6120
8 1 2 Upper parting cut 6121
8 1 3 Lower parting cut 6121
8 1 4 Replacement parts 6121
8 1 5 Welding in 6121
9 Renewing B-pillar- partial renewal 6122
9 1 Removing 6122
9 1 1 Cutting locations 6122
9 1 2 Replacement part 6123
9 1 3 Welding in 6123
10 Renewing outer side member 6124
10 1 Removing 6124
10 1 1 Cutting locations 6124
10 1 2 Replacement part 6125
10 1 3 Welding in 6125
11 Renewing floor panel – partial renewal 6126
11 1 Removing 6126
11 1 1 Cutting locations 6126
11 1 2 Replacement parts 6127
53 – Body – rear 6128
1 Renewing rear cross panel 6128
2 Renewing rear cross panel 6129
2 1 Removing 6129
2 1 1 Cutting locations 6129
2 1 2 Replacement parts 6130
2 1 3 Welding in 6130
3 Renewing rear cross panel – partial renewal 6132
3 1 Removing 6132
3 1 1 Cutting locations 6132
3 1 2 Replacement parts 6133
4 Renewing rear cross panel (syncro) 6134
4 1 Removing 6134
4 1 1 Cutting locations 6134
4 1 2 Replacement parts 6135
4 1 3 Welding in 6135
5 Renewing rear cross panel (Vento) 6137
5 1 Removing 6137
5 1 1 Cutting locations 6137
5 1 2 Replacement part 6138
6 Renewing rear cross panel (Variant) 6139
6 1 Removing 6139
6 1 1 Cutting locations 6140
6 1 2 Replacement parts 6140
6 1 4 Foam insulation 6141
7 Renewing rear cross panel (Variant) 6142
7 1 Includes: Lock carrier 6142
7 1 1 Cutting locations 6142
7 1 2 Replacement parts 6143
7 1 3 Welding in 6143
7 1 4 Foam insulation 6144
8 Renewing rear cross panel (Variant syncro) 6146
8 1 Includes: Lock carrier 6146
8 1 1 Cutting locations 6146
8 1 2 Replacement parts 6147
8 1 4 Foam insulation 6149
9 Renewing tail light mounting (Variant) 6150
9 1 Removing 6150
9 1 1 Cutting locations 6150
9 1 2 Replacement part 6151
9 1 3 Welding in 6151
10 Renewing intermediate piece (Vento) 6152
10 1 Removing 6152
10 1 1 Cutting locations 6152
10 1 2 Replacement parts 6153
11 Renewing luggage compartment floor, part section 6154
11 1 Removing 6154
11 1 1 Cutting locations 6154
11 1 2 Replacement parts 6155
12 Renewing luggage compartment floor (syncro) 6156
12 1 Removing 6156
12 1 1 Right luggage compartment floor cutting locations 6156
12 1 2 Left luggage compartment floor cutting locations 6157
12 1 4 Replacement part 6157
12 1 5 Welding in 6158
13 Renewing rear luggage compartment floor (Variant) 6159
13 1 Removing 6159
13 1 1 Cutting locations 6159
13 1 2 Replacement part 6160
13 1 3 Welding in 6160
13 2 Part section 6160
13 2 1 Cutting locations 6161
13 2 2 Replacement part 6161
13 2 3 Welding in 6161
14 Renewing rear pillar, partial renewal (Variant) 6163
14 1 Removing 6163
14 1 1 Cutting locations 6163
14 1 2 Replacement part 6164
14 1 3 Welding in 6164
15 Renewing cover plate (Vento) 6165
15 1 Removing 6165
15 1 1 Cutting locations 6165
15 1 2 Replacement part 6166
16 Rear longitudinal member – part section 6167
16 1 Removing 6167
16 1 1 Cutting locations 6167
16 1 2 Replacement part 6168
16 1 3 Welding in 6168
17 Rear longitudinal member – part section (syncro) 6169
17 1 Removing 6169
17 1 1 Cutting locations 6169
17 1 2 Replacement part 6170
17 1 3 Welding in 6171
18 Renewing rear longitudinal member – partial renewal (Variant) 6172
18 1 Removing 6172
18 1 1 Cutting locations 6172
18 1 2 Replacement part 6173
18 1 3 Welding in 6173
19 Renewing rear longitudinal member (Vento) 6175
19 1 Removing 6175
19 1 1 Cutting locations 6175
19 1 2 Replacement part 6176
20 Renewing rear longitudinal member – partial renewal (Variant syncro) 6177
20 1 Removing 6177
20 1 1 Cutting locations 6177
20 1 2 Replacement parts 6178
21 Renewing side panel – partial renewal (2-door) 6181
21 1 Removing 6181
21 1 1 Cutting locations 6181
21 1 2 Upper parting cut 6181
21 1 3 Lower parting cut 6182
21 1 4 Replacement part 6182
21 1 5 Welding in 6182
22 Renewing side panel – partial renewal (4-door) 6183
22 1 Removing 6183
22 1 1 Cutting locations 6183
22 1 2 Upper parting cut 6184
22 1 3 Lower parting cut 6184
22 1 4 Replacement parts 6184
23 Renewing side panel (Vento) 6185
23 1 Removing 6185
23 1 1 Cutting locations 6185
23 1 2 Replacement parts 6186
23 1 3 Welding in 6186
24 Renewing side panel (Variant) 6188
24 1 Removing 6188
24 1 1 Cutting locations 6188
24 1 2 Replacement parts 6189
24 1 3 Welding in 6189
25 Renewing lower part of side panel (4-door) 6190
25 1 Removing 6190
25 1 1 Cutting locations 6190
25 1 2 Replacement part 6191
25 1 3 Welding in 6191
26 Renewing side panel, partial renewal (Variant) 6192
26 1 Removing 6192
26 1 1 Cutting locations 6192
26 1 2 Replacement part 6193
26 1 3 Welding in 6193
27 Renewing side panel, partial renewal (2-door) 6194
27 1 Removing 6194
27 1 1 Cutting locations 6194
27 1 2 Replacement part 6195
27 1 3 Welding in 6195
28 Renewing rear wheel housing 6196
28 1 Removing 6196
28 1 1 Cutting locations 6196
28 1 2 Replacement part 6197
29 Renewing rear wheel housing (Variant) 6199
29 1 Removing 6199
29 1 1 Cutting locations 6199
29 1 2 Replacement part 6200
30 Renewing outer wheel housing liner 6201
30 1 Removing 6201
30 1 1 Cutting locations 6201
30 1 2 Replacement part 6202
31 Renewing wheel housing liner (Variant) 6203
31 1 Removing 6203
31 1 1 Cutting locations 6203
31 1 2 Replacement parts 6204
31 1 3 Welding in 6204
32 Renewing rear cross member (Variant) 6205
32 1 Removing 6205
32 1 1 Cutting locations 6205
32 1 2 Replacement part 6206
32 1 3 Welding in 6206
33 Renewing rear cross member (Variant syncro) 6207
33 1 Includes: Left and right cross members and cover plate 6207
33 1 1 Cutting locations 6207
33 1 2 Replacement parts 6208

S.V 27/01/2025