Running gear
- Brake systems
- Technical data
- Brake allocation via PR No.
- Technical data
- Brake master cylinder and brake servo
- Front brakes
- Rear brakes
- Rear brakes (disc brakes)
- Rear brakes (disc brakes)
- Rear brakes (disc brakes)
- Rear brakes (disc brakes)
- Rear brakes (disc brakes)
- Rear brakes (drum brakes)
- Rear brakes (drum brakes)
- Brake test
- ABS, ADR, TCS, EDL, ESP
- General notes for anti-lock brake system (ABS)
- Notes for repairs on anti-lock brake system
- Connecting VAS 5051 and selecting functions
- Electrical/electronic components and fitting locations
- Faults displayed via warning lamps
- Assembly overview - hydraulic unit, brake servo/brake master cylinder
- Removing and installing parts of ABS system on front and rear axle
- Removing and installing parts of ABS system on front axle
- Removing and installing parts of ABS system on rear axle - Front-wheel drive
- Removing and installing speed sensor on rear axle (disc brakes - front-wheel drive)
- Removing and installing speed sensor on rear axle (drum brakes)
- Checking or removing and installing rotor on rear axle (disc and drum brakes - front-wheel drive)
- Removing and installing rear speed sensor wiring (front-wheel drive)
- Removing and installing parts of ABS system on rear axle - four-wheel drive
- Removing and installing parts of ESP system
- Brake, brake mechanics
- Repairing front brakes
- Repairing front brakes, FS III brake caliper
- Removing and installing brake pads
- Repairing front brakes, FN 3 brake caliper
- Removing and installing brake pads
- Removing
- Installing
- Brake pads with specified direction of rotation
- Repairing front brakes, 2FN brake caliper
- Removing and installing brake pads
- Removing
- Installing
- Repairing rear disc brakes - front-wheel drive
- Repairing rear disc brakes - four-wheel drive
- Repairing rear drum brakes
- Assembly overview - handbrake lever
- Assembly overview - brake pedal
- Repairing front brakes
- Brakes, hydraulics, regulator, servo
- Repairing front brake caliper
- Repairing FS III brake caliper
- Removing and installing front brake caliper piston
- Repairing FN 3 brake caliper
- Removing and installing front brake caliper piston
- Removing
- Installing
- Repairing brake caliper 2FN
- Removing and installing front brake caliper piston
- Removing
- Installing
- Repairing rear brake caliper
- Assembly overview - Brake pressure regulator
- Checking and adjusting brake pressure regulator
- Pressure leak test
- Bleeding brake system
- Assembly overview - brake servo/ brake master cylinder
- Assembly overview - brake servo /brake master cylinder for vehicles with ABS/EDL/TCS/ESP Mark 20 IE
- Assembly overview - brake servo /brake master cylinder for vehicles with ABS/EDL/TCS/ESP Mark 60
- Removing and installing brake master cylinder
- Removing and installing brake servo
- Repairing brake lines
- Repairing front brake caliper
- Technical data
- Running gear self-diagnosis for ABS
- Self diagnosis, V.A.G Inspection Service
- Running gear, axles, steering - front and four-wheel drive
- Technical data
- Front suspension, drive shafts
- Appraisal of accident vehicles
- Electrical/electronic components and fitting locations
- Repairing front suspension
- Overview - front axle
- I - Assembly overview, subframe, anti-roll bar and suspension link
- Modified attachment for anti-roll bar
- Checking swivel joint
- Removing and installing swivel joint
- Removing and installing suspension link
- Renewing bonded rubber bush for suspension link
- Removing and installing subframe
- Renewing bonded rubber bushes in subframe
- Repairing threads in longitudinal member
- II - Assembly overview - wheel bearing
- Pressing front wheel bearing out and in with wheel bearing housing installed
- III - Assembly overview - suspension strut
- Vehicle data sticker
- Removing and installing suspension strut
- Repairing front suspension strut
- Repairing front suspension, R32
- Overview - front axle
- I - Assembly overview, subframe, anti-roll bar and wishbone
- Checking swivel joint
- Removing and installing swivel joint
- Removing and installing suspension link
- Renewing bonded rubber bush for suspension link
- Removing and installing subframe
- Renewing bonded rubber bushes in subframe
- Repairing threads in longitudinal member
- II - Assembly overview - wheel bearing
- Pressing out and pressing in front wheel bearing
- III - Assembly overview - suspension strut
- Removing and installing suspension strut
- Repairing front suspension strut
- Servicing front drive shafts
- Overview - drive shafts
- Removing and installing drive shafts
- I - Repairing front drive shaft with constant velocity joint
- Checking outer constant velocity joint
- Checking inner constant velocity joint
- II - Repairing front drive shaft with constant velocity joint VL 3700
- III - Repairing front drive shaft with triple roller joint AAR 2000
- Dismantling and assembling triple roller joint
- IV - Repairing front drive shaft with triple roller joint AAR 2900
- Dismantling and assembling triple roller joint AAR 2900
- V - Repairing drive shaft with triple roller joint AAR 3300i
- Dismantling and assembling triple roller joint AAR 3300i
- Rear suspension, drive shaft
- Appraisal of accident vehicles
- Repairing rear axle
- Removing and installing rear axle
- Assembly overview - rear axle beam
- Removing and installing bonded rubber bush
- Removing left bonded rubber bush
- Installing right bonded rubber bush
- Removing right bonded rubber bush
- Installing right bonded rubber bush
- Continuation for both sides
- Removing and installing hydraulic bonded rubber bush
- Removing and installing spring and shock absorber
- Assembly overview - shock absorber on vehicle with front wheel drive
- Repairing wheel bearings
- Repairing rear axle (four-wheel drive vehicles)
- Assembly overview - trailing arm and transverse link
- Pressing rear wheel bearing out and in with trailing arm installed
- Removing and installing trailing arm bush
- Removing and installing upper ball joints or bonded rubber bushes
- Removing and installing lower ball joint or bonded rubber bush
- Removing and installing trailing arm
- Removing and installing transverse link
- Assembly overview - subframe with final drive
- Repairing rear drive shaft
- Wheels, tyres. axle align
- Appraisal of accident vehicles
- Torque settings for wheel bolts
- Wheel alignment
- Wheel alignment|General
- Test prerequisites:
- Test preparations
- Vehicle data sticker
- Wheel alignment specifications
- Adjusting camber on front axle
- Adjusting camber on rear axle, vehicles with front-wheel drive
- Adjusting camber on rear axle, vehicles with four-wheel drive
- Adjusting toe on rear axle, vehicles with front-wheel drive
- Adjusting toe on rear axle, vehicles with four-wheel drive
- Adjusting toe on front axle
- Checking left and right-hand wheel lock
- Wheels, tyres
- Instructions for changing or fitting wheels
- Protecting wheel centring seat against corrosion
- Rough running due to wheels/tyres - causes and rectification
- Causes of rough running
- Balancing wheels
- Conducting a road test before balancing wheels
- Balancing wheels on stationary wheel balancing machine
- Vibration control system VAS 6230
- Finish balancer
- Radial and lateral runout of wheels and tyres
- Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435
- Checking radial and lateral runout on wheel rim
- Matching
- Flat spots caused by storage or handling
- Steering
- Appraisal of accident vehicles
- Steering|Airbag
- Steering column
- Repairing power assisted steering
- Removing and installing power assisted steering box
- Assembly overview, power-assisted steering box (LHD)
- Assembly overview, power-assisted steering box (RHD)
- Assembly overview - power-assisted steering box with heat shield (vehicles with four-wheel drive)
- Removing and installing track rod
- Modified track rod ball joints
- Modified track rods
- Checking play, tightness and bellows of track rod ball joints
- Determining centre position of steering rack
- Adjusting steering box
- Vane pump, reservoir, hydraulic pipes
- Checking delivery pressure of power steering pump
- Removing and installing vane pump, vehicles with low-mounted vane pump
- Removing and installing vane pump, vehicles with high-mounted vane pump
- Assembly overview - vane pump with hydraulic lines
- Dismantling and assembling reservoir
- Attaching pressure line and suction hose for SDI with air conditioner
- Attaching pressure line and suction hose for vehicles with 1.4 ltr. or 1.6 ltr. engines with air conditioner
- Attaching pressure line and suction hose for vehicles with 1.4 ltr., 1.6 ltr or 1.9 ltr. SDI/TDI engines without air conditioner
- Attaching pressure line and suction hose for vehicles with TDI engine and air conditioner
- Attaching pressure line and suction hose for vehicles with TDI engine and no air conditioner
- Attaching pressure line to 5-speed manual gearbox 02J and 5-speed manual gearbox 02T
- Attaching pressure line to 5-speed manual gearbox 02K
- Attaching pressure line to 6-speed manual gearbox 02M
- Attaching pressure line to automatic gearbox 01 M
- Attaching pressure line to automatic gearbox 09A
- Assembly overview - low-mounted vane pump
- Assembly overview - high-mounted vane pump
- Definitions
- Guide for using trailers
- Technical data
- Technical data|Preface
- Technical prerequisites
- Notes on operation and driving
- Technical data|General
- Drawbar load details
- Legal requirements
- Bora 1999 ?, Bora Variant 1999 ?
- Golf 1998 ?, Golf Variant 1999 ?
- Technical data
- Wheels and Tyres Guide - Archive
- Wheels, tyres. axle align
- General notes on wheels and tyres (passenger cars)
- Legislative and technical conditions for converting wheel and tyre combinations
- Documents and codes/designations
- Useful information regarding tyres
- Identification markings on the tyre sidewall
- Explanation of tyre markings
- Speed ratings for tyres
- Undulations
- Tyre storage
- Tyre ageing
- Winter tyres
- Winter tyres with speed symbol "V"
- Extra Load (XL) V winter tyres
- Maximum speeds for V and Extra Load (XL) winter tyres
- Reinforced and Extra Load (XL) tyres
- Snow chains
- Tyre wear/ mileage for passenger car tyres
- Tyre wear/ mileage for passenger car tyres|General
- Requirements to be met by tyres
- Wear behaviour of high-speed tyres
- Factors influencing the service life of a tyre
- Driving style
- Tyre maintenance
- Evenly worn tyres
- Measuring tread depth
- One-sided wear
- Outer shoulder wear
- Wear in middle of tyre
- Diagonal washout
- Tyre noise
- Rough running caused by wheels/tyres
- Causes of rough running
- Balancing wheels
- Conducting a road test before balancing wheels
- Balancing wheels on stationary wheel balancing machine
- Vibration control systemVAS 6230
- Finish balancer
- Radial and lateral runout of wheels and tyres
- Checking radial and lateral runout on wheels and tyres with tyre gaugeV.A.G 1435
- Checking radial and lateral runout on wheel rim
- Matching
- Flat spots caused by storage or handling
- Vehicle pulls to one side
- Tyre damage
- General information
- Construction of a radial belted tyre
- Impact damage
- Tyre damage|Cuts
- Damage caused by foreign bodies
- Loss of air from tyre
- Tyre pressure
- Tyre damage due to insufficient tyre pressure
- Rising tyre temperature caused by insufficient inflation pressure
- Tyre damage due to fitting error (fitting damage)
- Tyres with run-flat properties
- Rolling resistance optimised tyres
- Facts about disc-type wheels (passenger cars)
- Fitting and removing wheels
- Breakdown set for VW Vehicles
- Temporary spare tyres and wheels for VW vehicles
- Recommended summer tyres
- Summer tyres for Golf, Golf 4Motion model year 1998 to model year 2004
- Summer tyres for Bora, Bora 4Motion model year 1999 to model year 2005
- Summer tyres for Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model
- Summer tyres for Golf R32
- Summer tyres for Golf Anniversary GTI
- Recommended all-season tyres
- Recommended winter tyres
- Winter tyres Golf, Golf 4Motion model year 1998 to model year 2004
- Winter tyres Bora, Bora 4Motion model year 1999 to model year 2005
- Winter tyres Golf Variant, Golf Variant 4Motion model year 1999 to model year 2006, Bora Variant, Bora Variant 4Motion model yea
- Winter tyres for Golf 32
- Winter tyres for Golf Anniversary GTI
- Wheels, tyres. axle align
- Body
- General body repairs, exterior
- Body front
- Bonnet, flaps, cab, central locking
- Front door, central locking
- Front door
- Front door|Tools
- Assembly overview
- Removing and installing door
- Adjusting door
- Assembly overview - door handle and door lock
- Removing and installing lock cylinder housing
- Removing and installing door handle
- Removing and installing door lock
- Removing and installing locking button for locking rod
- Removing
- Installing
- Removing
- Installing
- Door seals
- Removing and installing additional seal
- Central locking
- Assembly overview for central locking and convenience system
- Removing and installing batteries for key with remote control (non folding type) ? 04.01
- Removing and installing batteries for key with remote control (folding type) ? 04.01
- Removing and installing batteries for key with remote control (folding type) 05.01 ?
- Adapting keys with remote control
- Front door
- Rear door,sliding door,wing doors,central locking
- Sliding roof
- Sliding/tilting sunroof
- Sliding/tilting sunroof with glass panel (Webasto)
- Assembly overview - sliding/tilting sunroof with glass panel
- Removing sliding/tilting sunroof glass panel
- Installing glass panel for sliding/tilting sunroof
- Adjusting glass panel for sliding/tilting sunroof (height adjustment)
- Renewing panel seal
- Removing wind deflector
- Removing sliding headlining
- Removing drive mechanism for sliding/tilting sunroof
- Adjusting drive mechanism for sliding/tilting sunroof (zero position)
- Removing pre-selector control for sliding/tilting sunroof
- Checking parallel running
- Adjusting parallel running
- Removing and installing carrier unit
- Removing coulisse guide rail
- Cleaning water drain hoses
- Sliding/tilting sunroof with glass panel (Meritor)
- Assembly overview - sliding/tilting sunroof with glass panel
- Removing sliding/tilting sunroof glass panel
- Installing glass panel for sliding/tilting sunroof
- Adjusting glass panel for sliding/tilting sunroof (height adjustment)
- Adjusting panel seal
- Renewing panel seal
- Removing wind deflector
- Removing sliding headlining
- Removing drive mechanism for sliding/tilting sunroof
- Adjusting drive mechanism for sliding/tilting sunroof (zero position)
- Removing pre-selector control for sliding/tilting sunroof
- Checking parallel running
- Adjusting parallel running
- Removing and installing carrier unit
- Removing coulisse guide rail
- Cleaning water drain hoses
- Bumper
- Front bumper
- Assembly overview - bumper cover
- Removing and installing bumper cover
- Removing release lever
- Assembly overview - bumper carrier
- Assembly overview - bumper cover, Golf R32
- Removing and installing bumper cover, Golf R32
- Removing and installing adapter, Golf R32
- Assembly overview - centre air intake and air guide, Golf R32
- Assembly overview - bumper carrier, Golf R32
- Rear bumper
- Assembly overview - bumper cover
- Removing and installing bumper cover
- Assembly overview - bumper carrier
- Assembly overview - towing bracket
- Removing and installing towing bracket
- Assembly overview - bumper cover, Golf R32
- Removing and installing bumper cover, Golf R32
- Removing and installing adapter, Golf R32
- Assembly overview - bumper carrier, R32
- Front bumper
- Glazing/window mechanism
- Flush bonded windows
- Flush bonded windows|Tools
- Materials
- Assembly overview - windscreen
- Removing and installing plenum chamber cover
- Removing windscreen
- Installing windscreen
- Assembly overview - side window, Golf
- Removing undamaged side window
- Removing damaged side window
- Installing side window
- Assembly overview - side window, estate
- Removing undamaged side window
- Removing damaged side window
- Installing side window
- Assembly overview - rear window, Golf
- Removing undamaged rear window
- Removing damaged rear window
- Installing rear window
- Assembly overview - rear window, Bora
- Removing undamaged rear window
- Removing damaged rear window
- Installing rear window
- Preparing undamaged window for glazing
- Preparing new window for glazing
- Preparing new window without precoating for glazing
- Preparing body flange for glazing
- Installation instructions
- Minimum curing time
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- Door window
- Door window|Tools
- Assembly overview - front door window
- Removing front door window
- Adjusting door window
- Removing and installing assembly carrier
- Assembly overview - rear door window
- Removing and installing assembly carrier, rear door window and quarter light window
- Fitting door window to window regulator
- Electric window regulator with convenience function (automatic opening and closing) and force limitation mechanism
- Overriding resistance in event of force limitation intervention
- Removing and installing window regulator motor or assembly carrier with window regulator
- Assembly overview - assembly carrier with window regulator
- Repairing window regulator
- Flush bonded windows
- Exterior equipment
- Removing and installing wheel housing liner
- Exterior mirror
- Roof mouldings
- Roof rail
- Exterior equipment|Trim
- Bump strips
- Special body parts, Golf GTI (132 kW) and Golf R32
- Safety requirements
- Special body parts, Golf GTI (132 kW) and Golf R32|Tools
- Materials
- Assembly overview
- Front and rear spoiler (Golf GTI)
- Side skirt (Golf GTI, Golf R32)
- Roof spoiler (Golf GTI, Golf R32)
- Preparing body kit component for bonding
- Installation instructions
- Minimum curing time
- Touching up paint damage
- Cleaning off excess adhesive sealing material
- General body repairs, interior
- Interior equipment
- Interior mirror
- Compartments, covers and trims
- Assembly overview - centre console
- Removing and installing centre console
- Assembly overview - centre console extension
- Removing and installing centre console extension
- Removing and installing front ashtray
- Assembly overview - rear ashtray
- Removing and installing rear ashtray
- Removing and installing front can holder
- Removing and installing rear can holder
- Removing and installing glove box
- Removing and installing glove box locking cylinder
- Removing and installing trim below steering column
- Removing and installing front centre armrest
- Removing and installing sun visor
- Removing and installing middle sun visor
- Grab handles
- Sill panel trims
- Assembly overview - Sill panel trim
- Removing and installing sill panel moulding
- Assembly overview - Sill panel trim
- Removing and installing sill panel trim
- Passenger protection
- Seat belts
- Safety regulations for belt tensioners
- Disposal of belt tensioner units
- Assembly overview - front seat belts
- Removing and installing front seat belts
- Assembly overview - rear outer seat belts
- Removing and installing rear outer seat belts
- Assembly overview - centre rear seat belt
- Removing and installing centre rear seat belt
- Inspecting seat belts
- Checking child seat anchors after an accident
- Passenger protection|Airbag
- Passenger protection|Tools
- Overview - installation locations
- Overview - installation locations
- Safety precautions when working on the airbag
- Disposal of airbag units
- Deactivating the airbag
- Renewing airbag units following an accident
- Assembly overview - driver airbag unit
- Removing and installing driver airbag unit
- Assembly overview - driver airbag unit
- Removing and installing driver airbag unit
- Removing
- Installing
- Assembly overview - steering wheel
- Removing and installing steering wheel
- Removing and installing return ring with slip ring
- Assembly overview - front passenger airbag unit
- Removing and installing front passenger airbag unit
- Assembly overview - front passenger airbag unit
- Removing and installing front passenger airbag unit
- Removing
- Installing
- Removing and installing airbag control unit (J 234)
- Assembly overview - driver/front passenger curtain airbag
- Removing and installing curtain airbag on driver and passenger side
- Assembly overview - driver/front passenger curtain airbag
- Removing and installing curtain airbag on driver and passenger side
- Removing
- Installing
- Assembly overview - driver/front passenger curtain airbag
- Removing and installing curtain airbag on driver and passenger side
- Removing
- Installing
- Assembly overview - driver/front passenger side airbag
- Removing and installing driver and front passenger side airbag
- Adapting components
- Crash sensors
- Seat belts
- Trim, noise insulation
- dash panel
- Door trims
- Door trims|Tools
- Assembly overview - front door trim on driver side
- Removing and installing front door trim on driver side
- Assembly overview - front door trim on passenger side
- Removing and installing front door trim on passenger side
- Assembly overview - rear door trim
- Removing and installing rear door trim
- Removing and installing loudspeaker
- Pillar and side trims
- Pillar and side trims|Tools
- Removing and installing upper A-pillar trim
- Assembly overview - upper A-pillar trim
- Removing and installing upper A-pillar trim
- Removing
- Installing
- Removing and installing lower A-pillar trim
- Assembly overview - upper B-pillar trim
- Removing and installing upper B-pillar trim
- Assembly overview - upper B-pillar trim
- Removing and installing upper B-pillar trim
- Removing
- Installing
- Assembly overview - upper B-pillar trim
- Removing and installing upper B-pillar trim
- Removing
- Installing
- Assembly overview - lower B-pillar trim
- Removing and installing lower B-pillar trim
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Assembly overview - upper C-pillar trim
- Removing and installing upper C-pillar trim
- Removing
- Installing
- Assembly overview - upper D-pillar trim
- Removing and installing upper D-pillar trim
- Removing and installing wheel housing trim
- Removing and installing wheel housing trim
- Removing
- Installing
- Removing and installing wheel housing trim
- Removing
- Installing
- Removing and installing rear shelf
- Assembly overview - side trims
- Removing and installing side trim
- Luggage compartment trims
- Assembly overview - support for luggage compartment cover
- Removing and installing support for luggage compartment cover
- Removing and installing retractor for luggage compartment cover
- Assembly overview - right side luggage compartment trim
- Removing and installing right side luggage compartment trim
- Assembly overview - right side luggage compartment trim
- Removing and installing right side luggage compartment trim
- Removing
- Installing
- Assembly overview - right side luggage compartment trim
- Removing and installing right side luggage compartment trim
- Removing
- Installing
- Removing and installing right-hand stowage compartment
- Removing luggage compartment floor covering
- Removing and installing rear lock carrier cover
- Removing and installing rear lock carrier cover
- Removing
- Installing
- Removing and installing rear lock carrier cover
- Removing
- Installing
- Rear lid trims
- Rear lid trims|Tools
- Assembly overview - rear lid lower trim
- Removing and installing rear lid lower trim
- Assembly overview - rear lid upper trim
- Removing and installing rear lid upper trim
- Removing and installing rear lid trim
- Assembly overview - rear lid trims
- Removing and installing rear lid trim
- Removing
- Installing
- Roof trims
- Roof trims|Tools
- Removing and installing roof frame trim
- Removing and installing roof frame trim
- Removing
- Installing
- Removing and installing moulded headlining
- Removing and installing moulded headlining
- Removing
- Installing
- Seat frames
- Front seats
- Front seats|Tools
- Removing and installing front seat
- Assembly overview - front seat
- Assembly overview - front seat
- Removing and installing front backrest
- Removing and installing lumber support
- Removing and installing seat height adjustment element
- Assembly overview - backrest lock cable
- Removing and installing backrest lock cable
- Removing and installing head restraint guides
- Removing and installing trim, 8-way seat
- Removing and installing control unit, 8-way seat
- Removing and installing operating unit, 8-way seat
- Removing and installing seat fore and aft adjustment, 8-way seat
- Removing front height adjustment drive, 8-way seat
- Removing rear height adjustment drive, 8-way seat
- Removing backrest adjustment drive, 8-way seat
- Rear seats
- Removing and installing rear bench seat
- Removing and installing bench seat with integrated child seat
- Assembly overview - bench seat
- Removing and installing rear bench seat
- Removing
- Installing
- Removing and installing backrest
- Removing and installing centre armrest
- Removing and installing right backrest lock
- Front seats
- Seat padding, covers
- Front seat covers and padding
- Front seat covers and padding|Tools
- Removing and installing front seat cover and padding
- Removing and installing front seat cover and padding
- Removing
- Installing
- Removing and installing front backrest cover and padding
- Removing and installing front backrest cover and padding
- Removing
- Installing
- Seat heater elements
- Rear seat covers and padding
- Front seat covers and padding
- Interior equipment
- Body self-diagnosis
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis
- Self-diagnosis of airbag system
- Self-diagnosis for convenience system
- Functional description
- Determining which source has possibly triggered the anti-theft alarm
- Description of the interior monitoring system
- System active indicator
- Initiating self-diagnosis for the convenience system
- Overview of the selectable functions
- Interrogating control unit version
- Coding convenience system control unit using fault reader V.A.G 1551
- Interrogating fault memory
- Erasing fault memory
- Ending output
- Fault table
- Final control diagnosis
- Reading measured value block
- Display group overview
- Matching ignition keys to radio wave remote control
- Matching a new additional key
- Radio wave remote control function variations >05.98
- Radio wave remote control functional variations 06.98 >
- Removing and installing batteries for the main key with radio wave remote control
- Removing and installing batteries for the main key (folding) with radio wave remote control
- Self-diagnosis for central locking
- Functional description
- System active indicator
- Initiating convenience system self-diagnosis
- Overview of the selectable functions
- Interrogating control unit version
- Coding central locking control unit using fault reader V.A.G 1551
- Interrogating fault memory
- Erasing fault memory
- Ending output
- Fault table
- Final control diagnosis
- Read measured value block
- Display group overview
- Matching ignition keys to radio wave remote control
- Radio wave remote control functional variants
- Removing and installing batteries for the main key with radio wave remote control
- Removing and installing batteries for the main key (folding) with radio wave remote control
- Self-diagnosis for the driver's side seat adjustment
- Functional description for the seat adjustment
- Functional description for the self-diagnosis
- Initialising the memory system
- Storing seat and mirror settings for normal driving
- Storing mirror setting for reversing
- Allocating the radio wave remote control key to the memory buttons
- Activating seat and mirror settings for normal driving
- Activating the mirror setting for reversing
- Initiating self-diagnosis for the seat adjustment
- Overview of the selectable functions
- Interrogating control unit version
- Interrogating fault memory
- Erasing fault memory
- Ending output
- Fault table
- Read measured value block
- Display group overview
- Self diagnosis, V.A.G Inspection Service
- General body repairs, exterior
- Engine
- 4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Removing and installing fuel tank with its attachments and fuel filter
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel filter
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleed fuel system
- Accelerator mechanism
- Activated charcoal canister system
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Servicing injection system
- Fitting locations overview
- General notes on injection
- Dismantling and assembling intake manifold upper part
- Dismantling and assembling intake manifold lower part
- Dismantling and assembling air cleaner
- Safety precautions
- Rules for cleanliness
- Removing and installing intake manifold upper part
- Technical data
- Checking components
- Engine control unit
- Servicing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Removing and installing parts of lubrication system
- Engine oil
- Assembly overview - parts of lubrication system
- Dismantling and assembling oil filler bracket
- Dismantling and assembling oil pump with balancer shaft gear assembly
- Removing and installing oil pump with balancer shaft gear assembly
- Removing and installing oil sump
- Checking oil pressure and oil pressure switch
- Removing and installing parts of lubrication system
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of lubrication system
- Removing and installing fuel tank with attachments and fuel filter
- Removing, installing and checking suction jet pump: vehicles with all-wheel drive
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Power control
- Activated charcoal filter system
- Removing and installing parts of lubrication system
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- Overview of installation locations
- General notes on injection
- Dismantling and assembling top part of intake manifold
- Dismantling and assembling bottom part of intake manifold
- Dismantling and assembling fuel rail with injectors .
- Dismantling and assembling air filter
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 5-cyl. injection engine (4-valve)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Assembly overview - thermostat housing
- Draining and filling coolant
- Removing and installing radiator and fan
- Removing and installing coolant pump
- Checking continued coolant circulation pump V51
- Checking radiator fan
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing, installing and checking suction jet pump: vehicles with four-wheel drive
- Crash fuel shut-off
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Checking fuel pump
- Checking electronic power control (EPC)
- Activated charcoal filter system
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Removing and installing parts of exhaust system
- Assembly overview - Exhaust manifold, front exhaust pipe with catalytic converter and attachments: vehicles with front-wheel dri
- Assembly overview - Exhaust manifold, front exhaust pipe with catalytic converter and attachments: vehicles with four-wheel driv
- Assembly overview - silencer with mountings: vehicles with front-wheel drive
- Assembly overview - silencer with mountings: vehicles with four-wheel drive
- Secondary air system
- Removing and installing parts of exhaust system
- Ignition system, glow plug system
- 4-cyl. injection engine (2.0 ltr.), mechanics
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Removing and installing fuel tank with attachments and fuel filter
- Removing, installing and checking suction jet pump: vehicles with four-wheel drive
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump G23
- Activated charcoal filter system
- Checking electronic power control (EPC)
- Accelerator mechanism
- Removing and installing parts of fuel supply system
- Exhaust system
- 4-cylinder injection engine (1.6 l engine) Mechanics
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Parts of cooling system - body side
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Electronically regulated cooling system
- Checking electronically regulated cooling system
- Dismantling and assembling coolant distribution housing
- Checking map-controlled engine cooling thermostat
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Accelerator mechanism
- Checking electronic power control (EPC)
- Activated charcoal filter system
- Exhaust system
- 4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)
- Vehicle electrics
- Electrical system
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Checking battery
- Charging battery
- Disconnecting and reconnecting batteries
- Removing and installing battery
- Specified torques: battery
- Starter-current supply-CC|Starter
- Specified torques: starter
- Alternator
- Checking alternator C
- Alternator ? 04.99
- Alternator 05.99 ?
- Alternator 05.00 ? (Hitachi)
- Checking poly V-belt
- Alternator, 4-cylinder 16V 1.4 l and 1.6 l fuel-injection engine
- Alternator, 4-cylinder 1.6 l, 1.8l and 2.0 l fuel injection engine
- Alternator, 5-cylinder 2.3 l fuel injection engine
- Alternator, 6-cylinder fuel injection engine
- Alternator, 4-cyl. SDI/TDI engine
- Assembly overview - vehicles ? 04.99 with power steering
- Assembly overview - vehicles ? 04.99 with power steering and air conditioner compressor
- Assembly overview - vehicles 05.99 ? with power steering
- Assembly overview - vehicles 05.99 ? with power steering and air conditioner compressor
- Removing and installing poly-V-belt
- Belt routing - vehicles with power steering vane pump
- Belt routing - vehicles with power steering vane pump and air conditioner compressor
- Alternator, 4-cyl. unit-injector diesel engine
- Renewing poly-V-belt pulley on alternator
- Installing poly-V-belt pulley with freewheel
- Torque settings: Alternator
- General torque settings for all vehicles
- Torque settings for vehicles with 4-cyl. 16V 1.4 l and 1.6 l fuel-injection engine
- Torque settings for vehicles with 4-cyl. 1.6 l, 1.8 l and 2.0 l fuel-injection engine
- Torque settings for vehicles with 5-cyl. 2.3 l fuel-injection engine
- Torque settings for vehicles with 6-cyl. fuel-injection engine
- Torque settings for vehicles with 4-cyl. SDI/TDI engine
- Torque settings for vehicles with 4-cyl. unit-injector diesel engine
- Cruise control system (CCS)
- Instruments, GCI
- Dash panel insert
- General description
- Renewing dash panel insert
- Removing and installing dash panel insert
- Dash panel insert, rear view
- Pin assignment of connections on dash panel insert ? 04.99
- Pin assignment of connections on dash panel insert 05.99 ?
- Pin assignment of connections on dash panel insert 05.02 ?
- Warning lamp symbols in dash panel insert
- Service interval display
- Dash panel insert
- Windscreen wipe/wash system
- Windscreen wiper system
- Removing and installing windscreen wiper system
- Removing and installing wiper arms
- Adjusting wiper blade park position
- Removing and installing wiper rubber blade
- Removing and installing aerodynamic wipers
- Removing and installing wiper rubber blade, aerodynamic wiper
- Removing and installing rain sensor G213
- Fitting a new adhesive pad to the rain sensor (Valeo)
- Windscreen washer system
- Assembly overview - windscreen washer system, Golf/Bora
- Removing and installing reservoir for windscreen and headlight washer system
- Removing and installing windscreen and rear window washer pump V59
- Removing and installing windscreen washer fluid level sender G33
- Removing and installing windscreen washer jets
- Adjusting windscreen washer system washer jets
- Rear window wiper system
- Rear window washer system
- Headlight washer system
- Washer fluid line hose couplings
- Hose repair
- Torque settings: window wash/wipe system
- Windscreen wiper system
- Lights, lamps, switches outside
- Headlights - Golf
- Assembly overview - headlight
- Removing and installing headlight
- Renewing headlight bulbs
- Renewing left dipped beam bulb L123 and right dipped beam bulb L124
- Renewing left main beam bulb L125 and right main beam bulb L126
- Renewing left side light bulb M1 and right side light bulb M3
- Renewing front left turn signal bulb M5 and front right turn signal bulb M7
- Renewing left fog light bulb L22 and right fog light bulb L23
- Repairing upper headlight retaining tabs
- Removing and installing left headlight range control motor V48 and right headlight range control motor V49
- Converting headlights for driving on the left or right
- Converting left-hand drive headlights for driving on the right
- Adjusting headlights
- Headlights - Bora
- Assembly overview - headlight
- Removing and installing headlight
- Renewing headlight bulbs
- Renewing left twin filament bulb/sealed beam insert L1 and right twin filament bulb/sealed beam insert L2
- Renewing left side light bulb M1 and right side light bulb M3
- Renewing front left turn signal bulb M5 and front right turn signal bulb M7
- Renewing left fog light bulb L22 and right fog light bulb L23
- Repairing upper headlight retaining tabs
- Removing and installing left headlight range control motor V48 and right headlight range control motor V49
- Converting headlights designed for driving on the right to driving on the left
- Converting left-hand drive headlights for driving on the right
- Adjusting headlights
- Headlights with gas discharge bulbs
- Fault finding
- Assembly overview - headlights with gas discharge bulbs, Golf/Bora ? 04.02
- Procedure and safety notes for gas discharge bulbs
- Renewing bulbs in gas discharge headlight, Golf/Bora ? 04.02
- Removing and installing left headlight starter J426 and right headlight starter J427 , vehicles ? 04.02
- Removing and installing headlight range control unit J431 , vehicles ? 04.02
- Assembly overview - headlights with gas discharge bulbs, Golf 05.02 ?
- Assembly overview - headlights with gas discharge bulbs, Bora 05.02 ?
- Renewing bulbs in gas discharge headlight, Golf/Bora 05.02 ?
- Removing and installing headlight range control unit , Golf 05.02 ?
- Removing and installing headlight range control unit , Bora 05.02 ?
- Removing and installing gas discharge light starter unit N195 , Golf
- Removing and installing gas discharge light starter unit N195 , Bora
- Removing and installing left headlight range control motor V48 and right headlight range control motor V49 , Golf
- Removing and installing left headlight range control motor V48 and right headlight range control motor V49 , Bora
- Removing and installing headlight
- Repairing upper headlight retaining tabs
- Adjusting headlights with gas discharge bulb
- Headlight conversion for left-hand/right-hand traffic
- Removing and installing front left vehicle level sender G78 and front right vehicle level sender G289
- Checking and, if necessary, adjusting setting of front left vehicle level sender G78 and front right vehicle level sender G28
- Removing and installing rear left vehicle level sender G76 and rear right vehicle level sender G77
- Checking setting of rear left vehicle level sender G76 and rear right vehicle level sender G77
- Coding headlight range control unit J431
- Side mounted repeater turn signals
- Tail lights
- Assembly overview - tail lights, Golf
- Assembly overview - tail lights, Bora
- Assembly overview - tail lights, Golf Variant/Bora Variant
- Removing and installing tail light, Golf
- Removing and installing tail light, Bora
- Removing and installing tail light, Golf Variant/Bora Variant
- Removing and installing tail light bulb carrier, Golf/Bora
- Removing and installing tail light bulb carrier, Golf Variant/Bora Variant
- Torque settings: tail light
- Number plate lights
- Additional brake lights
- Steering column switch
- Ignition switch and lock cylinder
- Parking aid
- Headlights - Golf
- Lights, lamps, switches inside, anti-theft system
- Interior lights and switches
- Removing and installing light switch E1
- Removing and installing headlight range control regulator E102 with switches and instruments illumination regulator E20
- Removing and installing sliding sunroof adjustment regulator E139
- Removing and installing front interior light W1
- Removing and installing window regulator switch
- Removing and installing mirror adjustment switch E43 with mirror adjustment change-over switch E48
- Removing and installing switches in centre of dash panel
- Removing and installing door contact switch
- Removing and installing bonnet contact switch F266
- Removing and installing anti-theft alarm and vermin repellent system contact switch F120
- Removing and installing luggage compartment light switch F5
- Removing and installing glove compartment light W6
- Removing and installing rear left reading light W11 and rear right reading light W12
- Removing and installing rear reading light with interior monitoring sensor G273
- Removing and installing luggage compartment light W3 , Golf/Bora
- Removing and installing luggage compartment light W3 , Golf Variant/Bora Variant
- Removing and installing remote fuel tank flap release switch E204
- Removing and installing rear lid handle release button E234 , Bora
- Removing and installing rear lid handle release button E234 , Golf Variant/Bora Variant
- Removing and installing interior monitoring deactivation switch E267
- Removing and installing operating mode change-over switch (petrol or gas) E382
- Immobilizer
- Anti-theft alarm system (ATA)
- Activating and deactivating anti-theft alarm
- Removing and installing interior monitoring deactivation switch E267
- Removing and installing interior monitoring sensor G273
- Removing and installing bonnet contact switch F266
- Central locking and anti-theft alarm system aerial R47
- Removing and installing anti-theft alarm H8
- Torque settings: lights, bulbs, switches - interior
- Interior lights and switches
- Wiring
- Vehicle diagnosis, testing and information systems
- Removing and installing fuse holder and relay carrier
- Removing and installing fuse holder
- Removing and installing relay plate and 13-position relay carrier
- A-pillar coupling station
- Removing and installing fuse holder on battery
- Removing and installing protective housing for relays in engine compartment
- Removing and installing cable duct in engine compartment
- Removing and installing protective housing in plenum chamber
- Torque settings: fuse holder and relay carrier
- Repairing wiring harness and connectors
- Starter-current supply-CC
- Communication
- Infotainment
- Communication Systems
- Radio "ALPHA” ? 04.98
- Radio "BETA” ? 04.98
- Radio "GAMMA” ? 04.98
- Radio "ALPHA” 5.98 ?
- Radio "BETA” 05.98 ?
- Radio "GAMMA” 05.98 ?
- Radio "DELTA”
- Radio system "RCD 200”
- Radio "Volkswagen Individual”
- Radio navigation system (RNS) with multifunction display and TV tuner
- Radio navigation system (RNS) with monochrome display
- CD changer/CD player
- Telematics system
- Telematics system (USA only, Model Year 2004 ?)
- Loudspeaker systems
- Digital Sound System (DSP)
- Telephone systems
- Aerial systems
- Multifunction steering wheel
- Notes on operating mobile telephones and two-way radios
- Suppression
- Infotainment
- Electrical System, General Information
- Starter-current supply-CC
- Starter-current supply-CC|Battery
- Checking battery
- Charging battery
- Battery chargerVAS 5095 A
- Battery chargerVAS 5900
- Description of battery chargerVAS 5900
- Charging battery with battery chargerVAS 5900
- Charging battery in service mode with battery chargerVAS 5900
- Charging totally discharged batteries with battery chargerVAS 5900
- Charging battery in support mode with battery chargerVAS 5900
- Charging battery in maintenance mode with battery chargerVAS 5900
- Battery chargerVAS 5903
- Description of battery chargerVAS 5903
- Charging battery with battery chargerVAS 5903
- Charging battery in refresh charge mode with battery chargerVAS 5903
- Charging totally discharged battery with battery chargerVAS 5903
- Charging battery in support mode with battery chargerVAS 5903
- Charging battery in maintenance mode with battery chargerVAS 5903
- Battery chargerVAS 5906
- MidtronicsINC 940 battery charger only for USA/Canada
- Solar panelVAS 6102A
- Totally discharged batteries
- Cruise control system (CCS)
- Windscreen wipe/wash system
- Lights, lamps, switches outside
- Lights, lamps, switches inside, anti-theft system
- Wiring
- Vehicle diagnostic, testing and information systems
- Wiring harness and connector repairs
- Contact surface cleaning setVAS 6410
- Renewing Lambda probe
- Starter-current supply-CC
- Electrical system
- Power transmission
- Automatic gearbox 01M
- Technical data
- Suggestions and criticism of this workshop manual
- Further information on "automatic gearbox 01M”
- Gearbox identification
- Identification codes, engine allocation, ratios, equipment
- Capacities
- Repair instructions
- Repair instructions|Tools
- Volkswagen testers
- Repair instructions|Gearbox
- Repair instructions|ATF
- Changing ATF
- Seals and sealing rings
- Nuts and bolts
- Locking devices
- Bearings
- Piston rings
- Inner plates
- Repair instructions|Shims
- Clutches
- Valve body
- Electrical components
- Guided fault finding, vehicle self-diagnosis and testing
- Repair with an exchange component
- Fault finding for the automatic 4-speed gearbox
- Vehicle cannot drive forwards or backwards
- Vehicle will not drive forwards
- Vehicle will not reverse
- Gearbox oily
- Oil or ATF leaks around torque converter
- Visible fouling of ATF and/or engine coolant
- ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
- Gearbox oily only near breather - no other external leaks in gearbox
- ATF escaping from breather (only for longitudinally installed gearbox 01N)
- Selector mechanism does not move freely
- Not all selector lever positions can be selected; selected drive ranges do not function
- Parking lock does not engage
- Parking lock disengages "with a jolt” (selector lever sometimes difficult to move from "P” to "R”)
- Final drive noisy
- Performance - jolting in neutral or during certain engine and gearbox movements
- Engine speed drops when driving range is selected
- Vehicle does not start at all or also starts in "R-D-3-2-1”
- Vehicle does not start or engine stalls after a short time
- Selector lever can be moved from "N” or "P” without brake being operated
- Selector lever cannot be moved from "N” or "P” although brake is operated
- Shifts occur sporadically or not at all
- All shifts are "hard or jolting”
- One particular shift is "hard or jolting”
- Shift from 3rd to 4th gear takes "too long” in vehicles through 12.92 having economy/sport switch
- Shifts take "too long”
- Hard shifts immediately after repair
- Gearbox downshifts at constant vehicle speed without apparent reason
- Gearbox does not downshift for kickdown
- Gearbox does not shift until it warms up
- Gearbox switches to emergency running
- Selector lever position "1”, gearbox does not shift to 1st gear (no power transfer in 1st gear)
- Selector lever position "D”, "3” or "2”, gearbox does not shift to 1st gear
- Selector lever position "D”, "3” or "2”, automatic gearbox does not shift to 2nd gear (no power transfer)
- Selector lever position "D” or "3” does not shift to 3rd gear, hydraulic (3H)
- Selector lever position "D” or "3” does not shift to 3rd gear, mechanical (3M)
- Selector lever position "D” or "3” does not shift to 3rd gear (not gearbox 001)
- Selector lever position "D” does not shift to 4th gear
- Selector lever position "D” does not shift to 4th gear, mechanical (4M)
- Selector lever position "R”, automatic gearbox does not shift to reverse gear
- Torque converter
- Automatic gearbox, control, assembly, housing
- Connecting Volkswagen tester and selecting functions
- Carry out basic setting
- Electrical and electronic components and their locations
- Repairing selector mechanism
- Checking selector mechanism
- Checking operation of the ignition key withdrawal lock
- Removing and installing selector lever cable
- Checking and adjusting selector lever cable
- Dismantling and assembling shift mechanism
- Removing and installing selector lever handle
- Removing and installing selector lever
- Removing and installing selector lever lock solenoid N110 and wiring for selector lever illumination
- Removing, installing and adjusting locking cable for ignition key withdrawal lock
- Measuring main pressure
- Removing and installing gearbox - required tools
- Dismantling and assembling gearbox
- Removing and installing ATF cooler and ATF filler tube
- Overview - dismantling and assembling planetary gearbox
- I - Removing and installing ATF pump to support tube
- II - Removing and installing reverse clutch -K2- to large sun gear
- III - Removing and installing freewheel and reverse gear brake -B1-
- IV - Planet carrier and gearbox housing with input gear and cover
- Dismantling planetary gearbox
- Assembling planetary gearbox
- Installing exchange component
- Overview - all planetary gearbox adjustments
- Adjusting planet carrier
- Adjusting reverse gear brake -B1-
- Adjusting clutch play between -K1- and -K2-
- Adjusting 2nd and 4th gear brake -B2-
- Adjusting 2nd and 4th gear brake -B2-
- Adjusting 2nd and 4th gear brake -B2-
- Automatic gearbox, gears, control
- Dismantling and assembling ATF pump
- Dismantling and assembling freewheel with -B1- piston
- Dismantling and assembling 1st to 3rd gear clutch -K1-
- Dismantling and assembling reverse gear clutch -K2-
- Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
- Removing and installing oil pan
- Removing and installing ATF strainer
- Removing and installing gearbox oil temperature sender G93
- Removing and installing valve body
- Dismantling and assembling parking lock
- Final drive, differential, differential lock
- Technical data
- 5-speed manual gearbox 02J
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Servicing gear selector mechanism up to 05.99
- Servicing gear selector mechanism from 05.99
- Removing and installing gearbox
- Checking gear oil
- Dismantling and assembling gearbox
- Servicing gearbox housing and clutch housing
- Dismantling and assembling gearbox selector mechanism up to 05.99
- Dismantling and assembling gearbox selector mechanism from 05.99
- Dismantling and assembling selector forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5-speed automatic gearbox 09A
- Technical data
- Torque converter
- Automatic gearbox, control, assembly, housing
- Connecting Volkswagen tester and selecting functions
- Electrical and electronic components and their locations
- Repairing selector mechanism
- Checking selector mechanism
- Checking and adjusting selector lever cable
- Checking operation of the ignition key withdrawal lock
- Removing and installing selector mechanism
- Dismantling and assembling shift mechanism
- Removing and installing selector lever lock solenoid N110
- Removing and installing selector lever cable
- Removing and installing locking cable
- Adjusting locking cable
- Checking gearbox
- Removing and installing gearbox
- Checking ATF level and topping up
- Gearbox repair
- Position of selector elements
- Dismantling and assembling gearbox
- Assembling gearbox
- Removing and installing ATF cooler
- Automatic gearbox, gears, control
- Housing cover for planetary gearbox
- 1st through 3rd gear clutch "K1”
- Reverse gear clutch "K2” and 3rd through 5th gear clutch "K3”
- 5th gear clutch "K4”
- Valve body
- Removing and installing sender in gearbox
- Renewing oil seal for selector shaft
- Removing, installing and adjusting multifunction switch F125
- Final drive, differential, differential lock
- 5-speed automatic gearbox 09A self-diagnosis
- Automatic gearbox 01M self-diagnosis
- Self diagnosis, V.A.G Inspection Service
- 5-speed manual gearbox 02K
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switches F36
- Removing and installing clutch pedal switch F36 with rectangular housing
- Removing and installing clutch pedal switch F36 with round housing
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Assembly overview - hydraulic system
- Removing and installing master cylinder
- Bleeding clutch system
- Repairing clutch
- Repairing clutch mechanism
- Gearbox mechanics,operation, construction,diff.
- Repairing selector mechanism
- Installation position of selector mechanism
- Assembly overview - selector lever housing and selector lever
- Removing and installing selector lever and selector rod
- Removing selector lever from and installing in selector lever housing
- Assembly overview - gear selector relay points on gearbox
- Adjusting selector mechanism
- Removing and installing gearbox
- Checking gearbox oil
- Dismantling and assembling gearbox
- Repairing gearbox housing and selector shaft
- Repairing clutch housing
- Repairing gearbox housing cover
- Repairing selector mechanism
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5 and 6-speed manual gearbox 02M
- Technical data
- Clutch, control
- Fault finding, power transmission
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switchesF36
- Removing and installing clutch pedal switchF36 with rectangular housing
- Removing and installing clutch pedal switchF36 with round housing
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Assembly overview - hydraulic system
- Removing and installing master cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Gearbox mechanics,operation, construction,diff.
- Fault finding, power transmission
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Separating gaiter from gear lever and assembling with gear knob
- Repairing gear lever and selector housing
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)
- Adjusting selector mechanism, gearbox with angled rod from gearbox date 19 05 3)
- Functional check
- Removing and installing gearbox
- Checking gear oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Removing and installing gearbox housing and selector mechanism through gearbox date 18 05 3
- Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3
- Removing and installing input shaft, output shafts, differential and selector rods
- Installing to engine and gearbox support
- Dismantling and assembling procedure for gearboxes through gearbox date 18 05 3
- Dismantling and assembling procedure for gearboxes from gearbox date 19 05 3
- Repairing gearbox housing
- Repairing clutch housing
- Dismantling and assembling selector mechanism on gearbox side
- Repairing selector forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5-speed manual gearbox 02T
- Technical data
- Clutch, control
- Gearbox mechanics,operation, construction,diff.
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- 5-speed manual gearbox 02C, four-wheel drive
- Technical data
- Clutch, control
- Repairing clutch mechanism
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switches F36
- Removing and installing clutch pedal switch F36 with rectangular housing
- Removing and installing clutch pedal switch F36 with round housing
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Assembly overview - hydraulic system
- Removing and installing master cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Repairing clutch mechanism
- Gearbox mechanics,operation, construction,diff.
- Connecting VAS 5051 and selecting functions
- Electrical and electronic components and their locations
- Electrical check of Haldex coupling
- Repairing selector mechanism
- Removing and installing gearbox
- Removing and installing bevel box
- Checking gear oil in manual gearbox with bevel box
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Removing and installing cover for gearbox housing and 5th gear
- Removing and installing gearbox housing and selector mechanism
- Removing and installing input shaft, output shaft, differential and selector forks
- Procedure for removing and installing gearbox housing cover, gearbox housing, selector mechanism, input shaft, output shaft, dif
- Assembly overview - Repairing gearbox housing and clutch housing
- Dismantling and assembling selector mechanism on gearbox side
- Dismantling and assembling selector forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Propshaft
- Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed)
- Haldex coupling
- Renewing bevel box output flange oil seal (bevel box removed)
- Modifying gearbox support VW 353
- Adjustment overview
- Checking gear oil in rear final drive and topping up
- Adjusting differential
- Removing and installing rear final drive
- Renewing propshaft flange oil seal on rear final drive (final drive removed)
- Dismantling and assembling bevel box
- Renewing flange shaft oil seals (final drive installed)
- Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft
- Renewing O-ring between Haldex coupling and pinion housing (final drive removed)
- Renewing O-rings for rear final drive housing cover (final drive installed)
- Dismantling and assembling rear final drive
- Assembly overviews - rear final drive
- Removing and installing cover for Haldex coupling and plates
- Removing and installing pinion housing
- Removing and installing differential and bevel gear with stub shaft
- Removing and installing cover for Haldex coupling from plate housing
- Assembly overview - Removing and installing Haldex coupling cover with plate housing, set of plates, pinion housing with shaft b
- Dismantling and assembling differential
- Repair shaft bevel gear mounting
- Repairing bearings for bevel gear with stub shaft
- Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set)
- 6-speed manual gearbox 02M, 02Y, all-wheel drive
- Technical data
- Clutch, control
- Fault finding, power transmission
- Repairing clutch mechanism
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switchesF36
- Removing and installing clutch pedal switchF36 with rectangular housing
- Removing and installing clutch pedal switchF36 with round housing
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Assembly overview - hydraulic system
- Removing and installing master cylinder
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
- Gearbox mechanics,operation, construction,diff.
- Vehicle diagnosis, testing and information systemVAS 5051
- Electrical and electronic components and their locations
- Checking Haldex coupling
- Fault finding, power transmission
- Repairing selector mechanism
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Separating gaiter from gear lever and assembling with gear knob
- Repairing gear lever and selector housing
- Assembly overview - removing and installing selector cables
- Removing and installing selector mechanism
- Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)
- Adjusting selector mechanism, gearbox with angled rod from gearbox date 19 05 3)
- Functional check
- Removing and installing gearbox
- Removing and installing bevel box
- Checking gear oil
- Dismantling and assembling gearbox
- Overview - gearbox
- Assembly overview
- Removing and installing gearbox housing and selector mechanism through gearbox date 18 05 3
- Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3
- Removing and installing input shaft, output shafts, differential, bevel box and selector rods
- Installing to engine and gearbox support
- Dismantling and assembling procedure for gearboxes through gearbox date 18 5 3
- Dismantling and assembling procedure for gearboxes from gearbox date 19 05 3
- Repairing gearbox housing
- Repairing clutch housing
- Dismantling and assembling selector mechanism on gearbox side
- Repairing selector forks
- Gearbox,mechanics,gears,shafts,internal operation
- Final drive, differential, differential lock
- Propshaft
- Renewing flange shaft oil seals with gearbox and bevel box installed
- Checking function of Haldex coupling
- Renewing bevel box output flange oil seal (bevel box removed)
- Oil seals
- Differential for manual gearbox
- Renew O-rings
- Adjustment overview - manual gearbox
- Bevel box
- Removing and installing rear final drive
- Check gear oil in rear final drive
- Renewing needle bearing
- Checking oil level or changing oil in Haldex coupling
- Dismantling and assembling rear final drive
- Dismantling and assembling rear final drive
- Removing and installing cover for Haldex coupling and plates
- Removing and installing pinion housing
- Removing and installing differential and bevel gear with stub shaft
- Removing and installing cover for Haldex coupling from plate housing
- Dismantling and assembling procedure
- Differential for rear final drive
- Repairing shaft bevel gear bearing
- Repairing bearing for bevel gear with stub shaft
- Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set)
- General notes
- Adjustment and marking of final drive gear sets
- Position of shims
- Adjustment overview - rear final drive
- Recommended sequence for new adjustment of final drive gear set
- Adjusting shaft bevel gear
- Adjusting bevel gear (with stub shaft)
- Adjusting preload of tapered roller bearing for bevel gear (with stub shaft)
- Example:
- Determining thickness of shim S1*
- Example:
- Measuring backlash
- Example:
- Determining thickness of shim S2
- Example:
- Available shims for S2
- Determining thickness of shim S1
- Available shims for S1
- Carrying out control measurement - measuring backlash
- Automatic gearbox 01M
- Heating, ventilation, air conditioning
- Heating, air conditioning
- Heating
- Heating, air conditioning|Heating
- Repairing heating system
- Removing vents
- Removing central and side vents from the Golf 1998 ?
- Removing side vents on passenger side of Bora 1999 ?
- Removing side vents on passenger side of Bora 1999 ?
- Removing centre vents in Bora 1999 ?
- Removing side window vent
- Removing and installing rear duct
- Removing and installing controls for fresh and heated air
- Checking ventilation
- Notes on mapped cooling, engine code BAD
- Heater unit
- Dismantling and assembling heated air and fresh air controls
- Warm air and fresh air control cables
- Heating, air conditioning|Heating
- Aux. heater/heater booster
- Air conditioner
- Notes on repair work to vehicles with air conditioning and on handling refrigerant
- Air conditioning system with manual controls
- Air conditioning and heating system - passenger compartment
- Removing and installing heating and air conditioning controls
- Dismantling and assembling heating and air conditioning controls
- Installing and adjusting heating and air conditioning cables
- Air conditioning and heating system - Engine compartment
- Removing and installing air conditioner compressor bracket, engine codes AHW, AKQ, APE, AUS, ATN, AXP, AZD, BCA und BCB
- Removing and installing air conditioner compressor bracket, engine codes AEG, AEH, AGN, AGU, AKL, ALN, APF, APK, AQA, AQY, ARX,
- Removing and installing compressor bracket, engine codes: AGP, AGR, AHF, AQM, ASV and ALH
- Removing and installing bracket for air conditioner compressor, engine codes AJM, ARL, ASZ, ATD, AUY, AXR, AXS and BEW
- Removing and installing air conditioner compressor bracket, engine code BAD
- Removing and installing air conditioner compressor bracket, engine code AGZ and AQN
- Removing and installing air conditioner compressor bracket, engine codes AFP, AQP, AUE, BDE and BFH
- Repairing Sanden air conditioning system magnetic coupling N25
- Repairing Zexel air conditioner magnetic coupling N25
- Climatronic air conditioning system with automatic regulation
- Before beginning repair work, perform the following steps:
- Procedure for checking and adjusting components
- Function of operating and display unit for Climatronic control unit E87 with Climatronic control unit J255
- Climatronic - passenger compartment
- Removing and installing operating and display unit for Climatronic air conditioning system E87 with Climatronic control unit
- Renewing control motors for air conditioning regulation
- Climatronic - engine compartment
- Repair work on refrigerant circuit which may be performed only in workshops with specially trained mechanics
- Repairing refrigerant circuit components
- Removing extraction and charging valve, low pressure side
- Removing extraction and charging valve, high pressure side
- Checking pressure release valve on air conditioner compressor (Sanden and Zexel)
- Checking pressure relief valve on air conditioner compressor (Denso)
- Tasks of receiver with dryer bag
- Checking air conditioning system pressure switch F129
- Notes on installing air conditioner compressor, engine code BAD
- Checking high pressure sensor G65
- Removing expansion valve
- Removing and installing condenser
- Removing and installing evaporator housing
- Dismantling and assembling distribution box and evaporator housing
- Repairing refrigerant circuit components
- Capacities
- Heating
- Heating, air conditioning
- Power unit
- Simos injection and ignition system
- Self diagnosis, V.A.G Inspection Service
- General to self-diagnosis
- Fault memory
- Fault table, fault codes 00282...00530
- Fault table: SAE P0 and P2 codes
- Fault table, fault codes 00533...17978
- Fault table: SAE P1 and P3 codes
- Final control diagnosis
- Measured value blocks
- READINESS code
- Evaluating measured value blocks, display groups 0...9 -Basic functions-
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Evaluating measured value blocks, display groups 30...49, 99 -Lambda regulation-
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...89 -Reducing emissions-
- Evaluating measured value blocks, display group 100 -Readiness code-
- Evaluating measured value blocks, display groups 120...129 -Communication-
- Mixture preparation system, electronic inj.,Gas
- Servicing injection system
- Checking components
- Checking Lambda probe heating
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake air temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
- Checking functions
- Engine control unit
- Checking additional signals
- Checking signal from/to air conditioning system
- Checking data bus
- Checking driving range signal
- Testing speed signal
- Checking engine speed signal
- Checking signal from power steering pressure switch
- Checking signal from clutch pedal switch
- Checking signal from brake light switch and brake pedal switch
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- Motronic injection and ignition system (5-cyl. engine)
- Self diagnosis, V.A.G Inspection Service
- General to self-diagnosis
- Fault memory
- Fault table: Fault codes 00281 ... 00527
- Fault table: Fault codes 00530 ... 00578
- Fault table: Fault codes 00579 ... 01177
- Fault table: Fault codes 01235 ... 18259
- Measured value blocks
- Final control diagnosis
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Mixture preparation system, electronic inj.,Gas
- Servicing injection system
- Checking components
- Checking Lambda probe heating
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake manifold temperature sender
- Checking engine speed sender
- Removing and installing injectors
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake manifold change-over
- Checking intake air system for leaks (unmetered air)
- Checking functions
- Replacing, coding and matching engine control unit
- Replacing engine control unit
- Coding engine control unit
- Coding variations of engine control unit
- Matching engine control unit to throttle valve control part
- Matching engine control unit to electronic immobilizer
- Checking engine control unit voltage supply
- Procedure after voltage supply open circuit
- Checking additional signals
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- Motronic injection and ignition system (2.0 ltr. engine)
- Self diagnosis, V.A.G Inspection Service
- General to self-diagnosis
- Fault memory
- Fault table: V.A.G codes and SAE P0 codes
- Fault table: SAE P0 and P2 codes
- Fault table: Fault code P1176...P1851
- Fault table: SAE P1 and P3 codes
- Final control diagnosis
- READINESS code
- Measured value blocks
- Evaluating measured value blocks, display groups 0...9 -Basic functions-
- Evaluating measured value blocks, display groups 10...29 -Ignition-
- Evaluating measured value blocks, display groups 30...49 -Lambda regulation-
- Evaluating measured value blocks, display groups 30...49, 107 -Lambda regulation-
- Evaluating measured value blocks, display groups 50...69 -Speed regulation-
- Evaluating measured value blocks, display groups 70...79 -Reducing emissions-
- Evaluating measured value blocks, display groups 80...100 -Readiness code-
- Evaluating measured value blocks, display groups 70...89 -Reducing emissions-
- Evaluating measured value blocks, display groups 120...129 -Communication-
- Mixture preparation system, electronic inj.,Gas
- Servicing injection system
- Checking components
- Checking Lambda probe heating for Lambda probe before catalyst
- Checking Lambda probe heating for Lambda probe after catalyst
- Checking air mass meter
- Checking throttle valve control part
- Checking coolant temperature sender
- Checking intake air temperature sender
- Checking engine speed sender
- Checking injectors
- Checking fuel pressure regulator and holding pressure
- Checking intake air system for leaks (unmetered air)
- Checking functions
- Engine control unit
- Checking additional signals
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 6-cylinder injection engine
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Parts I and II - engine codes AQP and AUE - assembly overview
- Parts I and II - engine codes BDE, BFH, BJS and BML - assembly overview
- Part I: chain drive - engine codes AQP and AUE - assembly overview
- Part I: chain drive - engine codes BDE, BFH, BJS and BML - assembly overview
- Part II: Assembly overview - crankshaft drive
- Removing and installing poly V-belt
- Removing and installing sealing flanges and dual-mass flywheel
- Removing and installing crankshaft
- Dismantling and assembling pistons and conrods
- Dismantling and assembling engine
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Assembly overview - thermostat housing
- Removing and installing thermostat housing
- Draining and filling coolant
- Removing and installing radiator
- Checking continued coolant circulation pump
- Checking radiator fan
- Removing and installing coolant pump
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing suction-jet pump
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Activated charcoal filter system (vehicles with engine codes AQP, AUE, BDE, BFH and BML)
- Activated charcoal filter system (vehicles with engine code BJS)
- Electronic power control (EPC)
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- Overview of fitting locations
- General notes on injection
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Removing and installing intake manifold
- Assembly overview - fuel rail for engine codes AQP, AUE and BDE
- Assembly overview - fuel rail for engine codes BFH, BJS und BML
- Assembly overview - air filter
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (direct injection)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Dismantling and assembling cylinder block, crankshaft and flywheel
- Assembly overview
- Removing and installing engine speed senderG28
- Crankshaft dimensions
- Renewing crankshaft oil seal - belt pulley end
- Tightening procedure for poly V-belt pulley securing bolt
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Dismantling and assembling pistons and conrods
- Engine cylinder head, valve gear
- Cylinder head
- Repairing valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel gauge senderG
- Removing and installing fuel delivery unit
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Removing and installing high-pressure pump
- Checking electronic power control (EPC)
- Activated charcoal filter system
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- Assembly overview - parts of injection system
- Assembly overview - intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - fuel pressure regulator and fuel metering valve
- Assembly overview - air filter
- Cleaning throttle valve moduleJ338
- Removing and installing injectors
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cyl. injection engine (natural gas)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Removing and installing parts of lubrication system
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system (petrol)
- Accelerator mechanism
- Activated charcoal filter system
- Removing and installing parts of fuel supply system (natural gas)
- Safety precautions when working on natural gas system
- Rules for cleanliness
- Natural gas system components
- Fuel line connecting points
- Assembly overview - fuel tank mounting and securing straps
- Assembly overview - fuel tank with attachments
- Removing and installing fuel tank
- Removing and installing tank shut-off valve
- Removing and installing thermal fuse
- Assembly overview - filling connection
- Removing and installing filling connection
- Leak test
- Evacuating fuel tank (natural gas)
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- Assembly overview - intake manifold upper part
- Assembly overview - intake manifold lower part
- Assembly overview - fuel rail with injectors (petrol operation)
- Assembly overview - gas rail with gas injection valves
- Assembly overview - gas pressure regulator
- Removing and installing gas pressure regulator
- Assembly overview - air filter
- Cleaning throttle valve module J338
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Engine control unit
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- 4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Removing and installing fuel tank with its attachments and fuel filter
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel filter
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Bleed fuel system
- Accelerator mechanism
- Activated charcoal canister system
- Removing and installing parts of fuel supply system
- Mixture preparation system, electronic inj.,Gas
- Servicing injection system
- Fitting locations overview
- General notes on injection
- Dismantling and assembling intake manifold upper part
- Dismantling and assembling intake manifold lower part
- Dismantling and assembling air cleaner
- Safety precautions
- Rules for cleanliness
- Removing and installing intake manifold upper part
- Technical data
- Checking components
- Engine control unit
- Servicing injection system
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.6 l roller rocker finger)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Electronically regulated cooling system
- Parts of cooling system, body side
- Parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Dismantling and assembling coolant distribution housing
- Checking map-controlled engine cooling thermostat
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Accelerator mechanism
- Activated charcoal filter system
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- 4-cylinder injection engine (1.6 l engine, roller rocker fingers), Mechanics
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Parts of cooling system - body side
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Electronically controlled cooling system
- Dismantling and assembling coolant distribution housing
- Checking map-controlled engine cooling thermostat F265
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Removing and installing fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Checking electronic power control (EPC)
- Activated charcoal filter system
- Removing and installing parts of fuel supply system
- Exhaust system
- 4-cylinder injection engine (5-valve)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Removing and installing fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Accelerator mechanism
- Checking electronic power control (EPC)
- Active charcoal filter system
- Removing and installing parts of fuel supply system
- Exhaust turbocharger, G-charger
- Mixture preparation system, electronic inj.,Gas
- Repairing injection system
- Engine codes overview ARZ, AUM and AUQ
- Fitting locations overview AGN
- Fitting locations overview AGU
- Fitting locations overview AQA
- General notes on injection
- Removing and installing parts of injection system for ARZ, AUM, AUQ engines
- Removing and installing parts of the injection system for AGN engine
- Removing and installing parts of the injection system for AGU engine
- Removing and installing parts of the injection system for AQA engine
- Dismantling and assembling intake manifold upper part for AGN engine
- Dismantling and assembling intake manifold lower part for AGN engine
- Dismantling and assembling air cleaner
- Dismantling and assembling fuel rail with injectors
- Safety precautions
- Rules for cleanliness
- Technical data
- Checking components
- Repairing injection system
- Exhaust system
- Ignition system, glow plug system
- Repairing ignition system
- General notes on ignition system
- Removing and installing parts of ignition system
- Removing and installing parts of ignition system
- Removing and installing parts of ignition system
- Removing and installing parts of ignition system
- Safety precautions
- Test data, spark plugs
- Repairing ignition system
- 4-cylinder diesel engine with unit injector
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Parts of cooling system - body side
- Parts of cooling system - engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments
- Assembly overview - fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing fuel cooler
- Removing and installing fuel tank
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel pump
- Checking fuel pump
- Removing, installing and checking suction jet pump
- Assembly overview - accelerator mechanism
- Checking tandem pump
- Removing and installing tandem pump
- Removing and installing parts of fuel supply system
- Exhaust turbocharger, G-charger
- Fuel preparation system Diesel injection
- Exhaust system
- Ignition system, glow plug system
- Direct injection and preglow system with distributor-type pump to 04.99
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis
- Fault memory
- Final control diagnosis
- Measured value blocks
- Safety precautions
- Read measured value block
- Evaluating measured value blocks
- Display group 000 at idling speed (engine warm, coolant temperature not below 80 °C)
- Display group 001 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Injected quantity display
- Evaluation: Voltage display from modulating piston travel sender G149
- Display group 002 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Accelerator pedal position display
- Evaluation: Operating condition display
- Display group 003 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in (specified) display
- Evaluation: Air mass drawn in (actual) display
- Display group 004 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (specified) display
- Evaluation: Commencement of injection (actual) display
- Display group 005
- Display group 006 with ignition on
- Evaluation: Brake pedal monitor display
- Evaluation: Cruise control system display
- Display group 007 with ignition switched on (engine cold and not running)
- Evaluation: Fuel temperature display
- Evaluation: Intake manifold temperature or intake air temperature display
- Evaluation: Coolant temperature display
- Display group 009
- Display group 012
- Display group 013 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Idling speed smooth running control display
- Display group 015
- Display group 016 at idling
- Evaluation: Additional heater display
- Evaluation: Heater element activation display
- Display group 19 with ignition on
- Evaluation: Voltage from modulating piston travel sender G149 display (stop and start limit stops)
- Display group 000 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Display group 004 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (actual) display
- Evaluation: Display of duty cycle from commencement of injection valve
- Display group 008 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Injected quantity (driver's requirement) display
- Evaluation: Injected quantity limitation via revs. (torque limitation) display
- Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
- Engine codes AGR, AHF, ALH
- Engine codes AGP, AQM
- Display group 010 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in display
- Evaluation: Intake manifold pressure (charge pressure) display
- Evaluation: Accelerator pedal position display
- Display group 011 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Charge pressure display (actual)
- Fuel preparation system Diesel injection
- Repairing diesel direct injection system
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Repairing injection pump
- Repairing intake manifold flap
- Removing and installing intake manifold flap motor
- Removing and installing injection pump
- Dynamically checking and adjusting commencement of injection
- Removing and installing injectors
- Repairing injectors
- Sealing injection pump
- Checking components and functions
- Checking voltage supply for diesel direct injection system
- Checking engine speed sender G28
- Checking intake manifold pressure sender G71 and altitude sender F96
- Checking coolant temperature sender G62
- Checking brake light switch F and brake pedal switch F47
- Checking clutch pedal switch F36
- Checking intake manifold temperature sender G72
- Checking fuel temperature sender G81
- Checking modulating piston travel sender G149 and quantity adjuster N146
- Check needle lift sender G80
- Checking injection timing control range
- Checking air mass meter G70
- Checking intake manifold flap change-over
- Checking intake manifold flap motor V157
- Checking additional signals
- Renewing, coding and matching engine control unit
- Repairing diesel direct injection system
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- Direct injection and glow plug system with distributor pump as of 05.99
- Self diagnosis, V.A.G Inspection Service
- Self-diagnosis
- Fault table
- Final control diagnosis
- Measured value blocks
- Safety precautions
- Read measured value block
- Evaluating measured value blocks
- Display group 000 at idling speed (engine warm, coolant temperature not below 80°C)
- Display group 001 at idling speed (engine warm, coolant temperature not below 80°C)
- Evaluation: Injected quantity display
- Evaluation: Modulating piston movement sender G149 voltage display
- Display group 002 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Accelerator pedal position display
- Evaluation: Operating condition display
- Display group 003 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in (specified) display
- Evaluation: Air mass drawn in (actual) display
- Display group 004 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (specified) display
- Evaluation: Commencement of injection (actual) display
- Display group 005
- Display group 006 with ignition switched on
- Evaluation: Brake pedal monitor display
- Evaluation: Cruise control system display
- Display group 007 with ignition switched on (engine cold and not running)
- Evaluation: Fuel temperature display
- Evaluation: Intake manifold temperature or intake air temperature display
- Evaluation: Coolant temperature display
- Display group 009
- Display group 012
- Display group 013 at idling speed (engine warm, coolant temperature not below 80 °C)
- Evaluation: Idling speed smooth running control display
- Display group 015
- Display group 016 at idling
- Evaluation: Additional heater display
- Evaluation: Heater element activation display
- Display group 19 with ignition on
- Evaluation: Modulating piston movement sender G149 voltage display (start and stop position stops)
- Display group 000 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Display group 004 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Commencement of injection (actual) display
- Evaluation: Commencement of injection valve duty cycle display
- Display group 008 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Injected quantity (driver's requirement) display
- Evaluation: Injected quantity limitation via revs. (torque limitation) display
- Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
- Engine codes AGR, AHF, ALH, ASV
- Engine codes AGP, AQM
- Display group 010 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Air mass drawn in display
- Evaluation: Intake manifold pressure (charge pressure) display
- Evaluation: Accelerator pedal position display
- Display group 011 at full throttle (road test in 3rd gear, coolant temperature not below 80 °C)
- Evaluation: Charge pressure display (actual)
- Fuel preparation system Diesel injection
- Repairing diesel direct injection system
- Safety precautions
- Rules for cleanliness
- Fitting locations overview
- Repairing injection pump
- Repairing intake manifold flap
- Removing and installing intake manifold flap motor V157
- Removing and installing injection pump
- Dynamically checking and adjusting commencement of injection
- Removing and installing injectors
- Repairing injectors
- Sealing injection pump
- Checking components and functions
- Checking voltage supply for diesel direct injection system
- Checking engine speed sender G28
- Checking intake manifold pressure sender G71 and altitude sender F96
- Checking coolant temperature sender G62
- Checking intake manifold temperature sender G72
- Checking fuel temperature sender G81
- Checking modulating piston movement sender G149 and metering adjuster N146
- Checking needle lift sender G80
- Checking injection timing control range
- Checking air mass meter G70
- Checking intake manifold flap change-over
- Checking intake manifold flap motor V157
- Checking additional signals
- Renewing, coding and matching engine control unit
- Repairing diesel direct injection system
- Ignition system, glow plug system
- Self diagnosis, V.A.G Inspection Service
- 5-cylinder injection engine, mechanics
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Removing and installing parts of cooling system
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Assembly overview - thermostat housing
- Draining and filling coolant
- Removing and installing radiator
- Checking continued coolant circulation pump V51
- Checking radiator fan V7 and radiator fan, right V35
- Removing and installing coolant pump
- Removing and installing parts of cooling system
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Assembly overview - fuel tank with attachments and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Removing and installing suction jet pump
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
- Removing and installing fuel tank
- Crash fuel shut-off
- Checking fuel pump
- Accelerator mechanism
- Activated charcoal filter system
- Removing and installing parts of fuel supply system
- Exhaust system
- 4-cylinder diesel engine, mechanics
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Removing and installing parts of fuel supply system
- Safety precautions when working on fuel supply system
- Rules for cleanliness
- Assembly overview - fuel tank with attachments
- Assembly overview - fuel filter
- Removing and installing fuel tank
- Removing and installing fuel pump
- Checking fuel pump
- Removing and installing suction jet pump
- Assembly overview - accelerator mechanism
- Checking accelerator pedal position sender
- Adjusting accelerator pedal position sender
- Removing and installing parts of fuel supply system
- Exhaust turbocharger, G-charger
- Exhaust system
- Removing and installing parts of exhaust system
- Front exhaust pipe and catalytic converter with attachments, engine codes AGR, AHF, ALH, ASV
- Exhaust manifold, front exhaust pipe and catalytic converter with attachments, engine codes AGP, AQM
- Front exhaust pipe and catalytic converter with attachments for vehicles with four-wheel drive
- Silencer with attachments, engine codes AGR, AHF, ALH, ASV
- Silencer with mountings, engine codes AGP, AQM
- Silencer with mountings for vehicles with four-wheel drive
- Exhaust gas recirculation system
- Removing and installing parts of exhaust system
- 4-cylinder injection engine (1.4 l and 1.6 l engine)
- Technical data
- Engine assy,cylinder block,crankcase
- Enginecrankshaft group, pistons
- Dismantling and assembling engine
- Cylinder block, sealing flange
- Assembly overview - aluminium cylinder block
- Assembly overview - cast-iron cylinder block
- Crankshaft dimensions
- Renewing crankshaft oil seal - belt pulley end
- Tightening procedure for poly V-belt pulley securing bolt
- Removing and installing pressure plate/drive plate
- Renewing crankshaft sealing flange - flywheel end
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Pistons and conrods
- Engine cylinder head, valve gear
- Engine lubrication
- Engine cooling
- Fuel supply, gas operation
- Parts of fuel supply system
- Accelerator mechanism
- Electronic power control (EPC)
- Activated charcoal filter system
- Mixture preparation system, electronic inj.,Gas
- Exhaust system
- Ignition system, glow plug system
- Simos injection and ignition system
- Heating, ventilation, air conditioning system
- Air conditioning system with refrigerant R134a
- Technical data
- General notes on air conditioning systems
- Introduction
- Additional information
- Basics of air conditioning
- Vapour pressure table for refrigerant R134a
- Refrigerant R134a
- Characteristics of refrigerant R134a
- Refrigerant machine oil
- General notes on air conditioning systems|Comfort
- How air conditioning works
- General safety
- Product characteristics
- Handling refrigerants
- Wear protective glasses
- Wear protective gloves and apron
- Do not allow liquid refrigerant to come in contact with the skin
- Do not breath in refrigerant vapour
- Absolutely NO SMOKING
- Welding and soldering on refrigeration systems
- Pungent smell
- First aid
- Handling pressure vessels
- Do not heat above 50° C
- Do not apply uncontrolled heat
- Seal empty containers
- Safety instructions for using extraction and charging equipment
- Safety precautions for when working on vehicles with air conditioning and when handling refrigerant R134a
- Basics for working on refrigerant circuit
- General information on refrigerant circuit
- Refrigerant circuit components
- Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides
- Air conditioning system compressor with magnetic clutch:
- Air conditioner compressor without magnetic clutch
- Air conditioner compressor without magnetic clutch, with elastic drive coupling
- Electric compressor for hybrid vehicles
- Condenser
- Evaporator
- Reservoir
- Restrictor
- Receiver
- Expansion valve
- Refrigerant circuit components|O-ring
- Pipes and hoses in refrigerant circuit
- High-pressure safety valve
- Design of refrigerant circuit
- Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit
- Switch and sender in refrigerant circuit and related connections
- High-pressure switch for air conditioning systemF23
- High-pressure switch for magnetic clutchF118
- Low-pressure switch for air conditioning systemF73
- Connections to valves for switches in the refrigerant circuit
- Air conditioning system pressure switchF129
- High-pressure senderG65
- Refrigerant pressure and temperature senderG395
- Air conditioner compressor regulating valveN280
- Electrical components not installed in refrigerant circuit
- Pressures and temperatures in the refrigerant circuit
- Refrigerant circuit with expansion valve
- Refrigerant circuit with restrictor and reservoir
- Test and measurement work that can be performed using a pressure gauge
- Air conditioner service and recycling equipment
- Notes to repairs on refrigerant circuit
- Refrigerant circuit components
- Statutory texts and instructions
- Refrigerant circuit
- Working with the air conditioner service station
- Important notes for working with the air conditioner service station
- Connecting air conditioner service station for measuring and checking
- Draining refrigerant circuit using air conditioner service station
- Evacuating refrigerant circuit using air conditioner service station
- Charging refrigerant circuit using air conditioner service station
- Bringing air conditioning system into service after charging
- Charging container in air conditioner service station with refrigerant
- Draining air conditioner service station
- Detecting leaks in refrigerant circuit
- Clearing refrigerant circuit of contaminants
- Complaints
- Connecting air conditioner service station
- Checking pressures on vehicles
- Checking pressures in refrigerant circuit (using air conditioner service station)
- Checking systems with a restrictor and collector (with internally regulated air conditioner compressor)
- Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor)
- Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor)
- Checking systems with a restrictor and reservoir and air conditioner compressor regulating valveN280 (with externally regulated
- Checking systems with an expansion valve, receiver and air conditioner compressor regulating valveN280 (with externally regulate
- With expansion valve, receiver and electric compressor for hybrid vehicles
- Renewing components
- Testing equipment and tools
- List of test equipment, tools and materials
- Tools and materials available from distribution centre or importer
- Tools and materials commercially available
- Tools to be made locally
- Tools and materials available from distribution centre or importer
- Tools and materials commercially available
- Tools to be made locally
- List of test equipment, tools and materials
- General notes on air conditioning systems
- Technical data
- Air conditioning system with refrigerant R134a