Work descriptions - Attach sticker on drivers-side door beam (B
Contents
1. Windshield Wiper blades must be located at the markings a Marking for left hand drive vehicles b Marking for right hand drive vehicles Tightening torque wiper arms 20 Nm Rear window a 25mm Tightening torque wiper arm 15 Nm Windshield wiper blades checking pitch angle adjust if necessary Note Check the pitch angle only if the wiper blades are juddering or making noises Special tools testers and auxiliary items required Page 14 73 Work descriptions Page 15 73 a Windshield wiper adjustment device 3358 B V A G 1331 a Torque wrench V A G 1331 5 50 Nm a Open end spanner 24 mm Perform the following work procedure Bring windshield wiper arms in rest position Remove windshield wiper blade Insert windshield wiper arm 2 into windshield arm adjustment device 3358 B and secure using mounting Work descriptions Page 16 73 screw 3 Check pitch angle Pitch angle specified values for 1 Windshield wiper blade with plastic spoiler vehicles as of 11 94 If necessary adjust pitch angle to specified value as follows Place open end spanner 24 mm 1 onto adjustment device and set windshield wiper arm 2 to specified value arrows Remove windshield wiper arm 2 from adjustment device and secure again using mounting screw 3 Check adjusted value according to table If necessary repeat the setting and checking proc2. 40 C otherwise freeze protection will be reduced and cooling effect will also be reduced Checking freeze protection Special tools testers and auxiliary items required Work descriptions a Refractometer T10007 Note Read bright dark boundary to obtain an accurate reading for following tests Place a drop of water on glass to improve readability of bright dark boundary bright dark boundary can be clearly recognized on WATERLINE Check concentration of coolant additive using refractometer T10007 follow user manual Scale 1 of refractometer is designed for coolant additives G 12 G12 Plus and G11 Scale 2 is designed for coolant additive G 13 Note Freeze protection additives protect against freeze to about 13 F 25 C about 35 C in arctic climates If for climatic reasons greater freeze protection is required amount of G 12 Plus can be increased but only up to 60 freeze protection to about 40 F 40 C otherwise freeze protection and cooling effectiveness will be reduced Page 22 73 Work descriptions Page 23 73 NO2 0625 If freeze protection is insufficient drain off required quantity shown in freeze protection table and add coolant additive Note a Observe disposal regulations Freeze protection table Freeze protection to C F Quantity difference in Liters Specified value 4 cyl engines 6 cyl engine 70 ey Check coolant additive con
3. Automatic transmission ATF level checking Repair Manual Automatic Transmission Repair Group 37 ATF level checking and topping off Brake fluid changing Special tools testers and auxiliary items required V A G 1869 a Brake charger bleeder unit V A G 1869 V A G 1869 2 E aa an if z d w00 06793 Brake pedal actuator V A G 1869 2 Brake filling and bleeding tool VW 1238 V A G 1238 1 or V A G 1238 B Work descriptions Page 65 73 Brake pedal actuator V A G 1238 B a Bleeder bottle Use only new brake fluid with replacement part number B 000 700 A corresponds to US standard FMVSS 116 DOT 4 Warning NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids Oils containing minerals damage seals and sleeves on brake systems Brake fluid is poisonous Due to its caustic nature it must also never be brought into contact with paint Brake fluid is hygroscopic meaning that it absorbs moisture from the surrounding air and must therefore always be stored in air tight containers Rinse off any spilled brake fluid using plenty of water Observe disposal regulations Perform the following work procedure Using a bleeder bottle with integrated strainer extract as much brake fluid as possible from the brake fluid reservoir Warning Do not reuse used extracted brake fluid Observe operating instructions for V A G 1869 Con
4. 5 hole wheel mounting Tightening torque 120 Nm Clock setting Digital clock Two press buttons 1 are located below the tachometer at right for setting the clock The hour is set using the upper button h the minute is set with the lower min By pressing briefly best done using a ball point pen the time is set ahead by one hour or minute respectively Page 4 73 Work descriptions Page 5 73 Sustained pressing advances the hours minutes through the whole sequence The clock can be set accurately to the second using the minute button Press button until the clock displays one minute less than the time to be set Press the button at the instant when the second display of an accurate clock has reached a full minute or the time signal sounds from the radio Analog clock One button 2 is allocated below the clock at right for setting the time By pressing briefly best done using a ball point pen the time is set ahead by one minute Sustained pressing causes the minute hand to run through quickly whereby the hour is also set in this way The clock can be set accurately to the second using the button Press button until the clock displays one minute less than the time to be set Press the button at the instant when the second display of an accurate clock has reached a full minute or the time signal sounds from the radio Service Reminder Indicator SRI resetting For resetting Service
5. Noises Engine Hot starting behavior
6. Page 50 73 V A G 1332 Torque wrench V A G 1332 40 200 Nm a Electric flashlight and mirror Perform the following work procedure Wheel bolts The adapter to loosen tighten the anti theft wheel bolts is located in the vehicle tool kit Front disc brake pads For better judgement of remaining pad thickness remove the wheel on the passenger side wear higher than on drivers side Mark position of wheel in relation to brake disc Unbolt wheel securing bolts and remove wheel Measure inner and outer pad thickness a Pad thickness without backing plate Wear limit 2 mm With a pad thickness of 2 mm without backing plate the Work descriptions Page 51 73 brake pads have reached their wear limit and must be replaced repair measure Inform customer Note a When replacing brake pads it is absolutely necessary to check brake discs for wear Checking and if necessary replacing brake discs is a repair measure Check brake disc for wear Repair Manual Suspension Wheels Brakes Steering Repair Group 46 Front brakes servicing Install wheel to marked position Tighten wheel securing bolts using diagonal sequence to following tightening torque 4 hole wheel mounting Tightening torque 110 Nm 5 hole wheel mounting Tightening torque 120 Nm Place adapter with vehicle tool kit after completing work Reinstall wheel bolt covers if necessary Rear drum brake pads Rear d
7. Reminder Indicator SRI refer to Repair Manual Electrical Equipment Repair Group 90 Service Reminder Indicator SRI resetting Climatronic setting temperature to 72 F 22 C Note Work descriptions Page 6 73 a A comfortable climate in the vehicle is reached most quickly at a temperature setting of 72 F 22 C Therefore this setting should only be changed if required for personal comfort Perform the following work procedure Switch on ignition 1 n T t ROTO 54 x i Check whether 72 F 22 C has been set 1 in the display If necessary please perform temperature adjustment as follows Press button 5 for automatic operation AUTO appears in the display 2 Set temperature to 72 F 22 C by pressing button 4 for colder or button 3 for warmer Radio activating Anti theft coding For activating Anti theft coding refer to Repair Manual Electrical Equipment Repair Group 91 Radio anti theft coding Sound System activating Engine oil level checking engine oil topping off if necessary Note Observe disposal regulations Work descriptions Page 7 73 After switching the engine off wait a few minutes at least 3 minutes to allow the oil to flow back into the oil pan Pull out oil dipstick wipe off with a clean cloth and re insert dipstick again up to stop NO2 0067 Withdraw dipstick again and read oi
8. beam headlights 12 cm a Fog lights 20 cm On vehicles with headlight range control a sticker with the inclination measure specifications in can be found on the lock carrier Headlights must be adjusted according to this information The percentage information on the sticker is based on a projection distance of 10 meters For example inclination of 1 2 converts to approx 12 cm a For vehicles with headlight range control the thumbwheel on instrument cluster must be in the base position Checking headlight setting with new test screen without 15 setting line Headlights Check the following With the low beam switched on check whether the horizontal light dark border contacts the hyphenated line 1 of the test surface and whether the break away point 2 between the left horizontal part and the rising part on the right of the light dark border runs vertically through the central point 3 The bright core of the light beam must be on the right of the vertical line Note To make it easier to find break away point 2 cover and uncover left half of headlight as viewed when looking forward a few times Then check dipped beam again Work descriptions Page 70 73 After correct adjustment of low beams the center point of the light beam of high beams must lie on the central mark 3 a For the previous test screen with 15 setting line adjust as for new test screen But to
9. upward Note a Observe disposal regulations Also the filter housing 3 and the seal 4 is to Page 29 73 Work descriptions be removed and the dust and pollen filter is to be installed for vehicles of of Vehicle Identification Number VIN 1H R 000 001 Install rubber seal and cover Vehicles as of Vehicle Identification Number VIN 1H R 000 001 1 Frame 2 Filter element 3 Plastic nut 4 Filter housing with seal Press retainers of filter housing 4 in direction of arrow B and remove filter element with frame upward Note Observe disposal regulations Installing Guide in frame 1 at left and right into the first pleat arrow A of new filter element 2 Insert retainers located on frame into holes on filter housing 4 and press frame with filter element downward Install rubber seal and cover Page 30 73 Work descriptions Page 31 73 Ribbed belt adjust tension Vehicles with gasoline engine as of 06 95 with A C system without automatic tensioning roller for ribbed belt engine codes AAM ADY ADZ AEK ANN ANP Special tools testers and auxiliary items required Gauge belt tensioner VW 210 V A G 1332 Wo0 426 Torque wrench V A G 1332 40 200 Nm with socket insert 18 mm Open end wrench 17 mm Work descriptions Position gauge belt tensioner VW 210 pre set to ribbed belt between compressor and generator Pr
10. 0 Nm a Data sheets for exhaust emission test Note Page 41 73 Work descriptions Page 42 73 f the oil is drained and not extracted using the oil extractor V A G 1307 or the oil extractor V A G 1358 A replace gasket for oil drain plug Observe disposal regulations TDl engines After the engine oil and the oil filter are replaced the following must be considered after the first engine start As long as the oil pressure warning light in the instrument panel is lit the engine may run only at idle Do not accelerate Throttle bursts can damage the turbocharger or cause it to fail completely Only when the warning light goes out the full oil pressure is reached and driver may accelerate Capacities with filter change refer to Fluis Capacity Charts for appropriate model and year Tightening torques of oil drain plug Note Remember that the following torque specifications must not be exceeded A higher torque can lead to leaks in the area of the drain plug or even to damage 4 cyl engines Sheet metal oil pan 30 Nm aluminum oil pan 20 Nm 6 cyl engines 30 Nm Due to the positive properties of the oils 01 6 Properties of the oils use only the following approved engine oils Oil specification Work descriptions Page 43 73 TRNA SNE SAE 20NAN2IwW S z z s D SAE ON JC1IWA9 SAE 10W O10W50 f SAE Sw 53 SAE Gasoline engines A Multi range ligh
11. 1 9 Liter 4 Cyl 2V Eco Diesel Fuel Injection Glow Plug Engine Code s AAZ Repair Group Work descriptions Page 68 73 23 Idle speed idle speed boost maximum engine speed RPM and residual fuel delivery checking and adjusting Headlight setting checking adjusting headlights if necessary Special tools testers and auxiliary items required a Headlight adjuster The following test and adjustment instructions are applicable to all countries But national legislation and regulations of the respective country is to be adhered to Test and adjustment requirements Tire pressure OK a Lenses must not be damaged or dirty Reflectors and bulbs OK a Vehicle load must be established Load With one person or 75 kg on the drivers seat with otherwise unloaded vehicle curb weight The curb weight is the weight of the vehicle ready for operation with completely filled fuel tank at least 90 including the weight of all equipment items carried for operation e g spare wheel tool vehicle jack fire extinguisher etc Vehicle must be rolled for several meters or the front and rear suspension must be bounced several times so that the springs settle Vehicle and headlight adjuster must be on a level surface operating instructions for headlight adjuster Vehicle and headlight adjuster must be aligned a Inclination measure must be set Inclination measure Work descriptions Page 69 73 a Main and high
12. 15 2 5 140 kW with tires 205 50 R 15 2 4 215 40 R 16 24 half load full load Work descriptions Page 59 73 front rear front rear Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Golf wagon half load full load vehicles with gasoline engine 40 44 kW with tires 195 50 R 15 195 60 R 14 74 85 kW with tires 195 50 R 15 195 60 R 14 half load full load KK T oo with tires 185 60 R 14 195 50 R 15 195 60 R 14 Work descriptions Page 60 73 55 kW with tires 185 60 R 14 195 50 R 15 195 60 R 14 195 50 R 15 2 6 3 2 195 60 R 14 2 0 2 2 0 2 2 8 Spare wheel gasoline and diesel 66 kW with tires 81 kW with tires Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Golf wagon syncro half load full load vehicles with gasoline engine 66 kW 85 kW with tires 140 kW with tires half load full load Vehicles with Diesel engine 66 kW with tires Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Jetta Work descriptions Page 61 73 a vehicles with gasoline engine with tires o with tires 74 kW fies 4 hole wheel mounting 85 kW with tires 205 50 R 15 1 9 5 hole wheel mounting 85 kW with tires C ee ee with tires I ce eee ses ee Vehicle
13. 159 arrow until specified value is obtained Tighten mounting nut for tensioning roller to 45 Nm Install toothed belt cover Toothed belt for camshaft drive checking 4 cyl gasoline engine 1996 gt Check condition of toothed belt Open fasteners of upper toothed belt cover and remove cover Check condition of toothed belt for a Cracks cross sectional breaks Layer separation toothed belt carcass cord strands Breaks on toothed belt carcass a Fraying of cord strands a Surface cracks plastic sheathing Traces of oil and grease Work descriptions Page 40 73 Note tis essential to replace toothed belt if malfunctions are found This will avoid possible break downs or operating problems replacement of a toothed belt is a repair measure When checking condition it is especially important to note following damage A Cracks cover side B Lateral scouring C Fraying D Tears in tooth base Toothed belt and toothed belt tensioning roller Replacing SDI TDI engines Repair Manual Engine Mechanical Repair Group 13 Engine disassembling and assembling Toothed belt removing and installing tensioning Engine oil drain or extract and fill replace oil filter Special tools testers and auxiliary items required Work descriptions V A G 1307 A a Oil extractor V A G 1307 A a Oil extractor V A G 1358 A V A G 1331 Torque wrench V A G 1331 5 5
14. NEVER bring brake fluid into contact with fluids containing mineral oil oil gasoline cleaning fluids Oils containing minerals damage seals and sleeves on brake systems Brake fluid is poisonous Due to its caustic nature it must also never be brought into Work descriptions Page 67 73 contact with paint Brake fluid is hygroscopic meaning that it absorbs moisture from the surrounding air and must therefore always be stored in air tight containers Rinse off any spilled brake fluid using plenty of water Observe disposal regulations Note the following Delivery Inspection For the delivery inspection the fluid level must lie at the max marking Note To ensure that the brake fluid will not overflow the reservoir the max marking must not be exceeded Inspection Service The fluid level must always be judged in conjunction with brake pad wear When vehicle is in use the fluid level tends to drop slightly due to brake pad wear and automatic adjustment When fluid level is at min marking or just above it is not necessary to top up if brake pad wear limit is almost reached If brake pads are new or well above wear limit then fluid level must be between min and max markings If fluid level is below min marking brake system must be checked repair measure before brake fluid is added Checking idle speed adjusting if necessary diesel engine engine code AAZ Repair Manual
15. Use the spark plug connector tool 3277 A to pull off and press on the spark plug connectors Power assisted steering fluid level checking Page 25 73 Work descriptions Page 26 73 Perform the following work procedure Check fluid level engine must not be running and front wheels must be in straight ahead position Fluid level must be between min and max marking If necessary top off with the following fluid G 002 000 Note f fluid level has sunk to the min marking power assisted steering must be checked repair measure It is not enough to simply top off with fluid Fuel filter replacing diesel engine Note a Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Perform the following work procedure Removing Work descriptions Page 27 73 gt sore Remove retaining clamp 5 Remove regulating valve with attached fuel lines Disconnect the fuel hoses from the hose connections 1 and 2 Installing Fill new filter with clean diesel fuel Thus the engine can be started faster Install new O ring Install regulating valve with attached fuel lines gt Camas Install retaining clamp 5 Slide the fuel hoses across the hose connections 1 and 2 and secure the hoses using hose clamps Note Direction of flow is indicated by arrows do not int
16. Volkswagen Golf IN Work descriptions Work descriptions Affix service sticker Apply sticker Your first service during delivery inspection Attach sticker on drivers side door beam B pillar the sticker is found as an instruction contained in the very front of the owner information packet Cross out the instruction after attaching the sticker Attach sticker Your next service event NO2 1061 Service sticker Your next service event Mark Oil change service or Inspection service whichever is the case next with a cross and enter date mile kilometer reading if necessary also mark with a cross additional work to be performed e g replace toothed belt and brake fluid service and enter date mile kilometer reading service interval 01 4 Inspection Service Attach sticker Page 1 73 69 Work descriptions on drivers side door beam B pillar Battery check battery terminals for secure seating Special tools testers and auxiliary items required V A G 1331 Torque wrench V A G 1331 5 50 Nm Note a Tight fitting battery terminals guarantee proper function and a long battery service life Open cover cap if installed 1 of battery positive pole Check battery terminal clamps are seated securely on the battery terminals by moving the battery positive wire 1 and the battery Ground GND wire 2 back and forth by hand Warning If battery cl
17. amp is not seated securely on positive terminal disconnect battery Ground GND strap on battery negative terminal first to prevent possible accidents Page 2 73 Work descriptions Page 3 73 If the battery clamp on positive terminal is not seated securely Disconnect battery Ground GND wire at battery negative terminal first 2 Tighten battery clamp on battery positive terminal to 5 Nm Close cover cap on battery positive pole Re connect battery Ground GND wire to battery negative pole 2 and also tighten to 5 Nm If the battery clamp on negative terminal is not seated securely Tighten battery clamp 2 on battery negative terminal to 5 Nm Battery checking Delivery Inspection Perform visual check Repair Manual Electrical Equipment Repair Group 27 Checking battery visual check electrolyte level no load voltage load test Inspection Service Perform visual check and electrolyte level check Repair Manual Electrical Equipment Repair Group 27 Checking battery visual check electrolyte level no load voltage load test Wheel securing bolts tighten to correct torque setting Work descriptions Special tools testers and auxiliary items required V A G 1332 Torque wrench V A G 1332 40 200 Nm Note Make sure that wheel bolts are tightened alternately to the following tightening torque 4 hole wheel mounting Tightening torque 110 Nm
18. are not indicated on the display User manual for VAS 5051 tester Indicated on display Select vehicle system Press 00 Check DTC memory complete system on the display arrow The VAS 5051 sends all known address words one after the other When a control module responds with its identification the display indicates the number of stored errors or indicates no malfunction recognized Any system malfunctions that are stored will be displayed one after the other Then the VAS 5051 sends the next Page 18 73 Work descriptions Page 19 73 address word The automatic test sequence is over when the following indication appears on the display Press the Print button 1 on the display and then press Screen in the print menu The VAS 5051 prints out all malfunctions or 0 malfunctions detected If malfunctions are stored then a repair measure is required Pass malfunction protocol on for repair Press the Go to button 2 on the display NO2 0458 Indicated on display Press the End button arrow on the display Press the End button in the exit menu Note a The Vehicle Diagnosis Testing and Information System VAS 5051 must remain connected if service interval display is to be reset Door arrester and securing bolts lubricating Work descriptions Page 20 73 Lubricate door arrester arrow A using lubricant G 000 150 Lubricate securing b
19. avoid incorrect settings ignore 15 setting line Fog lights Check whether the upper light dark border touches the setting line and runs across the complete test screen width horizontally Auxiliary lights Later inserted auxiliary headlights of other systems must be checked and adjusted according to the guidelines valid for them Headlights adjusting Adjusting headlights for Golf Cabrio 04 98 gt 01 6 Adjusting headlights for Golf Cabriolet 04 98 Work descriptions a m ta RR inte a 7 ARAD l Headlight right A Vertical adjustment B Lateral adjustment Both adjustment wheels on left headlight are allocated symmetrically Insert a Phillips head screwdriver into the hole A to lower the headlight and turn the white hand wheel behind it to the right Note f hand wheel is accessible in the engine compartment the adjustment may also be performed directly using the hand wheel Then turn it to the left to lower the headlight Also the lateral adjustment can be performed through the hole B using the hand wheel if there is access in the engine compartment Right fog light Remove cap for towing eyelet Turn adjusting screw 1 toward left to lower beam height Horizontal adjustment is not possible Page 71 73 Work descriptions Page 72 73 Adjusting screw on left headlight is allocated symmetrically Adjusting headlights for Golf Cabriolet 04 98
20. centration after test drive again Checking coolant level Check coolant level in expansion tank with engine cold Work descriptions Page 24 73 a Delivery inspection Coolant level at max marking a Inspection service Coolant level between min and max marking If coolant is too low add required amount according to mixture ratio Mixture ratio Freeze protection to C F Coolant additive G 12 Plus 25 C 13 approx 40 35 C 31 approx 50 40 C 40 approx 60 Note Coolant additive G 12 Plus prevents freeze and corrosion damage scaling and also raises boiling point of coolant Therefore cooling system must be filled year round with freeze and corrosion protection additives A higher boiling point improves engine reliability under heavy load particularly in countries with tropical climates Coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries coolant additive portion must be at least 40 Spark plugs replacing Special tools testers and auxiliary items required Work descriptions w00 0060 Spark plug removal tool 3122 B Assembly tool 3277 A V A G 1331 Torque wrench V A G 1331 5 50 Nm Note Spark plug specification Repair Manual Fuel injection Ignition Repair Group 28 Ignition Glow plug system Observe disposal regulations For vehicles with 6 cyl engine
21. e set 15 scale values Remove bolt 3 Using open end wrench 2 press tensioning roller 1 downward until marking on plunger matches pre set value 15 scale values on gauge belt tensioner VW 210 simultaneously tighten bolt 3 using torque wrench pre set to 85 Nm Ribbed belt replace V belt drives and sizes Repair Manual Electrical Equipment Repair Group 27 Ribbed belts and V belts routing and sizes Checking condition and tension of V belt tensioning V belt if necessary vane pump power assisted steering V belt drives and sizes Repair Manual Electrical Equipment Repair Group 27 Ribbed belts and V belts routing and sizes Special tools testers and auxiliary items required Work descriptions V A G 1410 SS Torque wrench V A G 1410 V A G 1410 2 a Ring insertion tool 22 mm V A G 1410 2 Checking v belt condition Checking Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base break up a Fraying of cord strands a Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks Page 33 73 Work descriptions Page 34 73 Traces of oil and grease Note tis essential to replace V belt if malfunctions are found This will avoid possible break downs or operating problems The replacement of the ribbed belt is a repair measure Tensio
22. edure until the specified value is reached Remove adjustment device and install windshield wiper blade Tightening torque wiper arms 20 Nm Check to ensure that windshield wiper system is not juddering On Board Diagnostic OBD checking DTC memory of all systems using Vehicle Diagnostic Testing and Information Work descriptions Page 17 73 System VAS 5051 01 6 Checking DTC memory of all systems using Vehicle Diagnosis Testing and Information System VAS 5051 Checking DTC memory of all systems using Vehicle Diagnosis Testing and Information System VAS 5051 Special tools testers and auxiliary items required Vehicle Diagnosis Testing and Information System VAS 5051 Diagnostic cable VAS 5051 6A Connecting Vehicle Diagnosis Testing and Information System VAS 5051 Engage parking brake Automatic transmission Shift selector lever into position pe or N Manual transmission Gear stick in neutral Open ashtray remove if necessary and slide cover for diagnostic connection toward left Connect Vehicle Diagnosis Testing and Information System VAS 5051 using the diagnostic cable VAS 5051 6A with ignition switched off Switch ignition on Work descriptions Indicated on display Select operating mode Press the button for vehicle On Board Diagnostic OBD on the display arrow Note f the indications shown in the work procedure
23. er dampened rag Windshield wiper washer system and headlight cleaning system check function adjust spray jets if necessary Note If during the function test it is determined that the wiper blades are juddering or making noises then check the pitch angle of the wiper blades 01 6 Windshield wiper blades checking park position adjusting if necessary for juddering wiper blades check pitch angle adjust if necessary Filling with fluid The windshield wash wipe system fluid reservoir must be filled up to edge If fluid must be topped off always add windshield cleanser in summer or frost protection in winter to the water Windshield washer system check jet setting adjust jets if necessary Special tools testers and auxiliary items required a Windshield wiper adjustment tool 3125 A Windshield Note Work descriptions Page 10 73 Never use a needle or a similar object since it may damage the water hoses in the spray nozzle Check jet setting adjust if necessary using adjustment tools for windshield wiper nozzle 3125A Tolerance 20 mm Rear window Jet setting dimension for the rear window Spray jet center wiper area Note Ifthe spray jet is uneven or cannot be adjusted to the specified dimensions the spray nozzle must be replaced repair measure Headlight cleaning system check jet setting adjust jets if necessary Special tools testers and auxiliary items
24. erchange the connections Check fuel system for proper seal visual check Accelerate several times afterwards fuel must flow Work descriptions without bubbles through the transparent hose at idle Fuel filter drain water diesel engine Note a Make sure that diesel does not come in contact with the coolant hoses Clean hoses immediately if necessary Observe disposal regulations Perform the following work procedure Remove retaining clamp A and regulating valve B with fuel hoses attached Let approx 100 cm of fluid drain from drainage bolt C Install regulating valve and attach retaining clamp Tighten drainage bolt Check fuel system for proper seal visual check Accelerate several times Afterwards fuel must flow without bubbles through the transparent hose at idle Dust and pollen filter replace filter element The filter is located beneath the fresh air plenum cover on the right side Perform the following work procedure Removing Loosen and remove plastic screws for securing the cover Page 28 73 Work descriptions Remove rubber seal 1 up to center of vehicle Press front cover upward Vehicles up to and including Vehicle Identification Number VIN 1H P 990 000 1 Filter element 2 Plastic nut 3 Filter housing 4 Gasket Press retainers arrows of filter element 1 in direction of arrow and remove filter element
25. f a ribbed belt is a repair measure Tensioning ribbed belt V belt drives and sizes Repair Manual Electrical Equipment Repair Group 27 Ribbed belts and V belts routing and sizes Toothed belt for camshaft drive diesel engine checking condition and tension tensioning toothed belt if necessary Special tools testers and auxiliary items required Work descriptions Gauge belt tensioner VW 210 V A G 1331 Torque wrench V A G 1331 5 50 Nm V 159 a V159 Pin wrench Condition of toothed belt checking Checking a Cracks cross sectional breaks Layer separation toothed belt carcass cord strands a Breaks on toothed belt carcass Fraying of cord strands a Surface cracks plastic sheathing Traces of oil and grease Page 36 73 Work descriptions Page 37 73 Note tis essential to replace toothed belt if malfunctions are found This will avoid possible break downs or operating problems The replacement of a toothed belt is a repair measure When checking the condition it is especially important to note the following damage A Cracks cover side B Lateral scouring C Fraying D Tears in tooth base Engine code AAZ up to engine number 292066 For these engines if damage to toothed belt due to lateral scouring at toothed belt guard is detected especially damage illustrated in figures B and or C perform the following repair meas
26. g to VW standard 502 00 This oil which is suitable for gasoline engines corresponds to the VW norms 501 01 as well as 500 00 and additionally exhibits further advantages It is particularly suitable for the application with more strenuous operating conditions e g difficult road conditions predominant use of trailer high portion of uphill driving and driving in hot climate zones Note a Single range oils are generally not all year round usable because of their limited viscosity range These oils should be used therefore only in extreme climate zones a When using the multi range oil SAE 5 W 30 continuously high engine speeds and constant strong load must be avoided This restriction does not apply to multi range light duty oils Replacing oil filter Work descriptions Page 45 73 Special tools testers and auxiliary items required V A G 1331 Torque wrench V A G 1331 5 50 Nm a Oil filter wrench a Oil filter strap wrench 4 cyl engine Perform the following work procedure Loosen oil filter using tension strap e g Hazet 2171 1 and remove oil filter Note Observe disposal regulations Clean engine sealing surface Lubricate rubber seal lightly with oil Screw in new filter and tighten hand tight 6 cyl engine Work descriptions Page 46 73 There are two different versions of the oil filter A and B The following work description applies to both versions D
27. gt CAA Headlight left Both adjustment screws on right hand headlight are similar A Vertical adjustment B Lateral adjustment Use a Phillips head screwdriver on the adjustment screw arrow A for height adjustment and on the adjustment screw arrow B for horizontal adjustment Road test vehicle To what extent the following can be checked is dependent upon the vehicle equipment and local conditions urban country The following should be checked by means of a road test Engine Output misfiring idling speed acceleration Clutch Pulling away pedal pressure odors Gear selection Ease of operation shift lever position Automatic transmission Selector lever position shift lock ignition key removal lock shift behavior Foot operated and hand operated parking brake Function free travel and effectiveness pulling to one side juddering squeal ABS function A pulsing at the brake pedal must be felt when performing ABS controlled braking Steering Function steering free play steering wheel centralized when wheels are in straight ahead position Work descriptions Page 73 73 Sunroof Function Cruise Control System CCS Function Radio Reception SVC interference Multifunction indicator MFI Functions A C system Function Vehicle Moving off line when travelling straight anead level road Imbalance Wheels drive axles prop shafts Wheel bearings
28. isc brake pads 01 6 Rear disc brake pads Check thickness of the brake pads through inspection holes in the brake carrier metal sheets arrow Wear limit 2 5 mm only pad thickness Work descriptions Page 52 73 At a pad thickness of 2 5 mm the brake pads have reached their wear limit and must be replaced repair measure Inform customer Note Pay attention to pads smeared with brake fluid or grease Rear disc brake pads Illuminate area behind hole in wheel using an electric flashlight Determine thickness of outer pad by checking visually Illuminate inner pad using an electric flashlight and mirror Determine thickness of inner pad by checking visually a Pad thickness without backing plate Wear limit 2 mm With a pad thickness of 2 mm without backing plate the brake pads have reached their wear limit and must be replaced repair measure Inform customer Note a When replacing brake pads it is absolutely necessary to check brake discs for wear Checking and if necessary replacing brake discs is a repair measure Check brake disc for wear Work descriptions Page 53 73 Repair Manual Suspension Wheels Brakes Steering Repair Group 46 Rear brakes servicing Underbody sealant perform visual check for damage During visual check observe floor pan wheel housings and sills Note a Malfunctions found must be repaired repair measure This inhibits cor
29. l level Area a Oil must be topped off Afterward it is sufficient if the oil level is somewhere in the area b Areab Oil need not be topped off Area c Oil must not be topped off Note At an oil level above the area c there is a danger of damage to the catalytic converter Airbag for driver and passenger visually checking airbag units Driver side airbag Identification for airbag is the writing AIRBAG on the cushion plate of steering wheel Work descriptions Page 8 73 Perform a visual check of the cushion plate 1 for external damage Warning Pad panel of steering wheel must neither be glued nor coated or processed in any other way So that also in future function of airbag is ensured refer customer again expressly to it The pad panel of the steering wheel may be cleaned only with a dry or with water dampened rag Passenger side airbag Identification for airbag is the writing AIRBAG on the right side of instrument cluster Perform a visual check of the surface of the airbag module 2 for external damage Warning The foamed surface of the airbag module on the passenger side must not have been pasted up or coated or processed in any manner So that also Work descriptions Page 9 73 in the future the function of the airbag is ensured refer the customer again expressly to it The surface of the airbag module may be cleaned only with a dry or with wat
30. n the wheel disk do not need to be removed The filler valve must be reached through the opening The pressures listed in the table are valid for cold tires Do not reduce increased pressures on warm tires Important information concerning winter tires recommended by Volkswagen is found in Repair Manual Wheels and Tires Guide Repair Group 44 Wheels tires vehicle alignment Tires pressures for the relevant model are on a sticker attached to the inside of fuel tank flap Tire filling pressure table for normal tires for all factory installed tire sizes Inflation pressure values in bar for the following vehicles Golf Golf vehicles with gasoline engine 40 44 kW with tires Work descriptions Page 57 73 175 70 R 13 1 2 2 8 1 8 2 0 ser TTT with tires 74 kW mines E a 4 hole wheel mounting 85 kW 5 hole wheel mounting 85 kW with tires 110 kW with tires Ty with tires Co Vehicles with Diesel engine 47 kW with tires 175 70 R 13 Work descriptions Page 58 73 2 6 185 60 R 14 2 1 1 9 2 4 S J L with tires sem J C 81 kW with tires 5 hole wheel mounting 81 kW with tires Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Golf syncro half load full load vehicles with gasoline engine 66 kW with tires 195 50 R 15 2 3 2 5 85 kW with tires 185 60 R 14 2 5 195 50 R
31. nails and glass splinters if necessary Inspection Service Check tires tread and side walls for damage and remove foreign objects for example nails and glass splinters if necessary Check tires for scuffing one sided wear porous side walls cuts and fractures Work descriptions Page 55 73 Note a The customer must be informed of malfunctions found Checking tire wear pattern The wear pattern of the front wheels can be used to assess whether a check of the tie and camber is necessary a Feathering on tread indicates incorrect toe setting One sided tread wear is mainly attributed to incorrect camber When wear of this nature is noticed determine cause by performing an alignment repair measure Depth of tire tread including spare wheel checking Checking tread depth Minimum depth 1 6 mm Note a This figure may vary for individual countries according to legislation The minimum tread depth is reached when the tires have worn down level with the 1 6 mm high tread wear indicators positioned at intervals around the tire f the tread depth is approaching the legal minimum permissible depth the customer must be informed Tire inflation pressure including spare wheel checking correcting inflation pressures if necessary Special tools testers and auxiliary items required Tire pressure gauge Note Work descriptions Page 56 73 a Spare wheels with a rectangular opening i
32. nect brake filling and bleeding tool V A G 1869 to brake fluid reservoir however do not switch on yet Insert brake pedal depressor V A G 1869 2 between drivers seat and brake pedal and pre tension Pull hose off clutch slave cylinder Work descriptions Page 66 73 Connect bleeder hose of reservoir on to bleeder screw of clutch slave cylinder Switch on brake filling and bleeding tool V A G 1869 Open bleeder screw of clutch slave cylinder and allow approx 100 cm of brake fluid to drain out Close bleeder screw Pull off bleeder hose of reservoir and connect hose to clutch slave cylinder Open bleeder screws of the respective brake calipers and let the corresponding amount of brake fluid see table below flow out The action of pumping in new brake fluid flushes used brake fluid out of the system Sequence Brake fluid quantity which must flow out of wheel brake cylinders or brake wheel brake calipers cylinder brake calipers 0 4 to 0 5 liters 0 4 to 0 5 liters Right front 0 4 to 0 5 liters 0 4 to 0 5 liters Total quantity 2 Liter Remove connection on brake fluid reservoir and remove brake pedal depressor Check pedal pressure and brake pedal free play Free play Max of pedal travel Brake fluid level depending on brake pad wear checking Use only new brake fluid with replacement part number B 000 700 A corresponds to US standard FMVSS 116 DOT 4 Warning
33. ning V belt Check V belt tension by strong thumb pressure depth of impression approx 5 mm and adjust if necessary For the following adjustment the torque wrench V A G 1410 in connection with the ring insertion tool 22 mm V A G 1410 2 A is particularly suitable Loosen fixing bolts 1 and 2 clamping screw 3 and mounting nut 4 for clamps if available at least one turn Tension the V belt to 4 Nm by turning the tension nut using the torque wrench run in belt and tighten the clamping screw 3 of the tension nut to 25 Nm Tighten mounting bolt 1 for vane pump to 45 Nm Tighten mounting bolt 2 for vane pump and mounting nut 4 for clamps if available to 25 Nm Checking condition of ribbed belt and tensioning ribbed belt generator not vehicles as of 06 95 with A C system without automatic tensioning roller for ribbed belt engine codes AAM ADY ADZ AEK ANN ANP Checking condition of ribbed belt Work descriptions Page 35 73 Checking Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base break up Fraying of cord strands a Flank wear material wear frayed flanks flank brittleness glassy flanks surface cracks Traces of oil and grease Note tis essential to replace ribbed belt if malfunctions are found This will avoid possible break downs or operating problems The replacement o
34. olts arrow B using lock cylinder grease spray G 000 400 01 Sunroof checking function cleaning and greasing guide rails Perform the following work procedure Check function of sunroof ee ce Clean guide rails arrows and spray on grease spray G 000 450 02 Engine from top and bottom visual check for leaks and damage Perform visual check as follows Check engine for leaks and damage Check hoses pipes and connections of Fuel system a Cooling and heating system Work descriptions Page 21 73 and brake system Check for leaks abrasions porosity and brittleness Note Ensure that all malfunctions detected are repaired within repair measures Cooling system checking freeze protection and coolant level Note All engines are filled with freeze and corrosion protection additives G 12 Plus according to TL VW 774 F color lilac Make sure that only G 12 Plus is used for topping off G 12 Plus color lilac can be mixed with previous coolant additive G 12 color red Note G 12 Plus is suitable as a filled for life filling for cast iron and all aluminum engines and gives optimum protection against freeze corrosion damage scaling and over heating G 12 Plus increases boiling point to 135 C and ensures for a better heat dissipation Coolant concentration must be at least 40 freeze protection to 25 C and should never exceed 60 freeze protection to
35. rain oil at drain plug 1 Remove filter lower part 3 using tool Note Observe disposal regulations Install new filter element 5 and new O ring 4 coated with oil Tighten filter lower part with 25 Nm and drain plug with new sealing ring 2 to 10 Nm Toothed belt wear checking SDI TDI engines Special tools testers and auxiliary items required Caliper gauge commercially available Perform the following work procedure Open clips 1 of upper toothed belt guard Work descriptions Page 47 73 Unhook toothed belt guard 2 and pull to the side Measure the width of the toothed belt using a caliper Wear limit 22 mm Note With a toothed belt width of 22 mm the toothed belt has reached its wear limit and must be replaced repair measure Inform customer CV boots visual check Perform the following work procedure Check outer CV joint boots 2 and inner CV joint boots 1 for leaks and damage Manual transmission final drive check oil level for vehicles with All Wheel Drive AWD also check transmission oil in rear final drive 5 speed manual transmission 020 Work descriptions Page 48 73 Repair Manual Manual Transmission Repair Group 34 Gear oil checking 5 speed manual transmission 02A Repair Manual Manual Transmission Repair Group 34 Gear oil in manual transmission with bevel gear transfer case checking Repair Manual Man
36. required Work descriptions Page 11 73 Adjustment fixture 3019 A Check jet setting adjust if necessary using adjustment tool 3019A The following jet setting dimensions apply for the left headlight right headlight symmetrical b ul see _ Li Se T TiL 2 At typ w AN wy N a Y _ Golf and Golf Cabriolet gt 03 98 a 130 mm C 65 mm b 60 mm d 125 mm Golf Cabriolet 04 98 gt Work descriptions a 100 mm b 75mm c 55 mm d 125 mm If necessary adjust nozzles as follows Pull out spray nozzle arrow up to stop and align to the respective spray points using adjustment tool 3019 Bis NO2 0243 Nozzle setting dimensions for left headlight right headlight is similar Adjust the inner spray nozzle to the following dimension a 100mm b 75mm Page 12 73 Work descriptions Adjust the outer spray nozzle to the following dimension c 55mm d 125mm Note Ifthe spray jet is uneven or cannot be adjusted to the specified dimensions the spray nozzle must then be replaced Windshield wiper blades checking park position adjusting if necessary for juddering wiper blades check pitch angle adjust if necessary Windshield wiper blades checking rest position adjusting if necessary Special tools testers and auxiliary items required V A G 1331 Torque wrench V A G 1331 5 50 Nm Page 13 73 Work descriptions
37. rosion and rusting through Tie rod ends check play security and joint boots Perform the following work procedure With vehicle raised wheels hanging free check play by moving tie rods and wheels arrow Play zero play Check mountings Check joint boots for damage and proper seating Ball joints visual check Work descriptions Page 54 73 Check joint boots arrow of ball joints for leaks and damage Tires including spare wheel check condition and wear pattern Note For reasons of safety only tires of same type and tread pattern should be installed on a vehicle Additional notes for syncro vehicles a The vehicle must be equipped with tires of the same make Otherwise the viscous clutch would unnecessarily increase the ratio of the rear final drive due to the arising RPM difference of both axles This can cause damage a However different tread depths of front axle and rear axle tires e g due to wearout is harmless It is recommended however to mount the tires with the greater tread depth in the front If the front wheels are more strongly worn out than the rear wheels they have a smaller rolling circumference and turn therefore faster a Thus tensions in the drive train arise and the tires wear faster Checking condition Perform the following work procedure Delivery Inspection Check tires tread and side walls for damage and remove foreign objects for example
38. s with Diesel engine 47 kW with tires Work descriptions Page 62 73 175 70 R 13 2 1 1 9 2 4 2 8 185 60 R 14 195 50 R 15 55 kW 66 kW 175 70 R 13 2 6 3 0 185 60 R 14 2 6 3 0 195 50 R 15 2 3 l 3 81 kW with tires 0 Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Golf Cabriolet 03 98 half load full load vehicles with gasoline engine 55 kW 66 kW with tires 195 50 R 15 74 kW 85 kW with tires 185 60 R 14 195 50 RAS half load full load Vehicles with Diesel engine 66 kW with tires Work descriptions Page 63 73 195 50 R 15 2 9 2 3 2 7 3 0 Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Golf Cabriolet 04 98 gt half load full load vehicles with gasoline engine oe OE R with tires 205 45 R 16 74 kW 85 kW with tires half load full load rear Vehicles with Diesel engine 66 kW with tires 185 60 R 14 195 50 R 15 205 45 R 16 ge Sw sZ DN 185 60 R 14 195 50 R 15 205 45 R 16 Spare wheel gasoline and diesel Spare wheel 4 2 Regular wheel Meet highest intended inflation pressure for vehicle Automatic transmission changing ATF Work descriptions Page 64 73 Repair Manual Automatic Transmission Repair Group 37 ATF level checking and topping off ATF replacing
39. t duty oils specification VW 500 00 B Multi range oils specification VW 501 01 or Multi range oils specification API SF or API SG Only when approved engine oil is not available SYS W AD IRNAN SNE SAE 20 4024 SAE OWI 1IW49 9 amp 2 w i 9 2 f z v SAE SW Diesel engines A Multi range light duty oils specification VW 500 00 for turbo diesel engines only in conjunction with specification VW 505 00 B Multi range oils specification VW 505 00 suitable for all Diesel engines without restrictions or Multi range oils specification API CD only to be added in case of emergency for turbo diesel engines Multi range oils specification VW 501 01 for turbo diesel engines only in conjunction with specification VW 505 00 Properties of the oils Work descriptions Page 44 73 Multi range oils according to VW standard 501 01 and 505 00 are oils with the following properties All season usability in moderate climate zones Excellent cleanability a Secure lubrication properties at all engine temperature and load conditions High resistance to aging Multi range light duty oils according to VW standard 500 00 exhibit beyond that the following advantages All season usability at almost all occurring outside temperatures a Smaller friction losses of the engine Optimum cold starting ability also at very low temperatures Multi range light duty oils accordin
40. ual Transmission Repair Group 39 Gear oil in rear final drive checking Automatic transmission checking oil level of final drive Note Observe disposal regulations Remove drive for speedometer wipe off with a cloth and install drive again Remove drive and check oil level Oil level must be between min and max marking Note Oil capacity between min and max marking is 0 1L If oil level is too low top off axle oil Oil specifications Work descriptions Page 49 73 Repair Manual Automatic Transmission Repair Group 00 Capacities If oil level is too high extract oil using oil siphoning unit V A G 1358 A Install drive for speedometer Brake system visual check for leaks and damage Check the following components for leaks and damage a Master brake cylinder Brake booster with Anti lock Brake System ABS Hydraulic unit Brake pressure regulator Brake calipers Ensure that brake hoses are not twisted Ensure that brake hoses do not touch any vehicle components when steering is at full lock Check brake hoses are not porous or brittle Check brake hoses and lines for chafing Check brake connections and methods of securing for correct seating leaks and corrosion Warning Malfunctions found must be repaired repair measure Brake pads front and rear checking thickness Special tools testers and auxiliary items required Work descriptions
41. ure Remove injection pump Work descriptions Page 38 73 Repair Manual Fuel Injection Ignition Repair Group 23 Diesel injection pump removing and installing Slightly loosen three mounting bolts C of pump console Press pump console downward at point A and lift at point B Re tighten the three mounting bolts to 20 Nm in this position 2 mechanic required Note After installation and adjustment work let engine run approx 5 minutes without toothed belt guard and observe the running behavior of the toothed belt during this Toothed belt must run in center on the drive wheels If toothed belt still runs toward the outside pump console must be replaced and installed as described above Checking tension of toothed belt and tensioning toothed belt if necessary Information about tightening torques and work procedures Repair Manual Engine Mechanical Repair Group 13 Engine disassembling and assembling Toothed belt removing and installing tensioning A Remove upper toothed belt cover Work descriptions Page 39 73 Using the gauge belt tensioner VW 210 measure toothed belt tension between camshaft gear and injection pump sprocket Specified value Scale value 12 13 If current value is outside the specified range toothed belt must be tensioned as follows Loosen mounting nut for tensioning roller Turn tensioning roller toward right using e g Pin wrench V
Download Pdf Manuals
Related Search